Diagnostics from smart valve actuators using HART communication can save maintenance costs and improve plant reliability when used in a comprehensive maintenance management program, says Herman Storey, chief technology officer of Herman Storey Consulting. 

 

While most smart devices are field instruments, smart valve actuators have the same capabilities, and users often launch a valve maintenance program for ahead of instruments. HART Plant of the Year recipients bear this out: Dow, Monsanto, and MOL all used HART diagnostics to improve plant reliability and save money on valve maintenance. Valves are far more maintenance intensive than instrumentation and have more wear-prone moving parts than a typical flowmeter or pressure sensor.

 

The ability of a given valve to function can have a huge impact on a process unit's operation, depending on where it's located. Its ability to move as expected and control as needed makes all the difference, so diagnostic information is a huge advantage for reliability. HART Communication can also supply real-time valve position feedback to operators, confirming that a valve is in the position that the control system says it is. 

 

When a valve maintenance program in a large facility is thought out well, implemented with care, and with the right individuals at the helm, a full-time valve engineer can easily be worth $1 million or more when the costs of repair and replacement are combined with improved operations and plant availability.