Valves project saves $40k at Chinese chemicals site
30 Jan 2013
Shanghai, China – Shanghai Ethylene Cracker Complex (SECCO) has reported improved control, production efficiency, and uptime, and a $40,000 saving in annual maintenance costs, through replacing valve positioners.
The SECCO complex – the largest integrated chemical facility in China – includes a naptha-fed ethylene cracker and ten downstream derivative plants with thousands of control valves of different brands, types and sizes.
Temperature fluctuations in the process had caused high variability in the end product which, combined with vibration of the pipeline, often led to damage and replacement of the positioners on these valves.
After SECCO engineers and Fisher valve specialists from Emerson discussed ways to address this problem, SECCO decided to replace the facility’s positioners with Emerson’s Fisher Fieldvvue DVC6200f digital valve positioner.
The DVC6200f is designed to offer linkage-less, non-contact position feedback to reduce vibration-induced problems as well as diagnostics and FOUNDATION fieldbus communication to promptly alert operators of potential valve problems.
Another selling point, said Emerson, was the DVC6200f’s diagnostic capability to predict problems before they occur, allowing operators to take pre-emptive action to minimise process variability or avoid a plant shutdown.The instrument is easily mountable onto any valve, which was also important for SECCO.
After installation, operations in the facility were enhanced with better stability and control. Production efficiency improved, while waste and rework were reduced, according to Emerson
SECCO has saved an estimated $40,000 annually by eliminating the frequent replacements of positioners as well as maintenance, labour and potential production loss, the supplier said.
