Baker Hughes Masoneilan SVI3, Instruction Manual

Page 1: ...Masoneilan SVI 3 Digital Positioner Advanced Performance Instruction Manual Rev B Baker Hughes Data Classification Public...

Page 2: ...CAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS THEREFORE THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE...

Page 3: ...Hughes Company All rights reserved Document Changes Version Date Changes 03 2021 Original Release A 03 2021 Added Online Valve Diagnostics Section Added Russia and China Regional Contents Added Handli...

Page 4: ...ware 20 2 4 1 ValVue and SVI3 DTM Software 20 2 4 2 Masoneilan Software Download 20 2 5 Advanced and Online Diagnostics 20 3 SVI3 Installation and Set Up 21 3 1 Physical Dimension and Weights 21 3 1 1...

Page 5: ...4 3 6 NORMAL Operating Mode and MANUAL Mode Menus 56 4 3 7 VIEW DATA Menu 57 4 3 8 VIEW ERR Diagnostics Messages 58 4 3 9 Configure Menu 59 4 3 10 Calibration Menu 63 4 3 11 Adjust Input Signal Range...

Page 6: ...4 Critical Service Cavitation Control Trim 111 7 4 5 Diagnostic Valve Tests 111 7 5 Determining an SVI Positioner Compliance Voltage in a Control System 111 7 5 1 Compliance Test Setup 112 7 6 HART Ph...

Page 7: ...SVI3 digital valve positioner is intended for use with industrial compressed air or natural gas systems only see Installing an SVI3 in a Natural Gas Environment on page 35 Ensure that an adequate pres...

Page 8: ...e or pipe sealent in order to meet the highest level of ingress protection Ensure that dust levels are accounted for during installation Wiring and conduit must conform to all local and national codes...

Page 9: ...uch changes affect the function and performance of the product Refer to Product Safety manual ES817 for detailed safety instructions WARNING Before using these products with fluids compressed gases ot...

Page 10: ...I3 is a critical component for safety in Hazardous Areas To ensure safe operation and proper seal fully engage the cover threads within the housing and cover flange area makes contact with the housing...

Page 11: ...s area without ensuring compliance with local and plant regulations CAUTION A control circuit must be HART compatible or have a HART filter installed Contact the manufacturers of the controller or DCS...

Page 12: ...ware operation the convention is to spell mode is all uppercase letters MODE Italics is used for emphasis on important items Fields where data is entered or user entered data is italicized Actions per...

Page 13: ...ous software such as PACTware however it is designed to work best with our ValVue3 software See the ValVue3 help or Masoneilan ValVue3 Software Instruction Manual BHMN31426 Masoneilan SVI3 Digital Pos...

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Page 15: ...enables the unit to fulfill the broadest range of applications The optional pushbutton and LCD display enables local operations of calibration and configuration functions Remote operations can be per...

Page 16: ...Fully Potted Electronics Uniform Hazardous Area Approvals for ATEX IEC USA and Canada with Other Approvals Available Upon Request Local Online Diagnostic Condition Moni tor Total Stem Travel Number of...

Page 17: ...e position feedback sensor 2 Uses the difference between the position setpoint and position feedback is analyzed by the position control algorithm to set a servo signal for the I P converter 3 Process...

Page 18: ...3 2 2 Temperature Sensor A temperature sensor is located in the electronics module and measures temperature within the enclosure This measurement is used to provide temperature compensation for the po...

Page 19: ...perating in conjunction with the display permit reading and modification of the instrument operating parameters without a PC or HART hand held communicator These switches perform generic functions Inc...

Page 20: ...SVI3 DTM Software manual to download and install the software 2 5 Advanced and Online Diagnostics The SVI3 offers various levels of control valve diagnostics Up to five pressure sensors plus circuitr...

Page 21: ...reserved 3 SVI3 Installation and Set Up 3 1 Physical Dimension and Weights Figure 4 SVI3 Components 3 1 1 SVI3 Dimensions Figure 5 illustrates the dimensions and weight of the SVI3 single acting Pneum...

Page 22: ...22 Baker Hughes 2021 Baker Hughes Company All rights reserved Figure 5 SVI3 Single Acting Dimensions SVI3 Single acting Model with Aluminum Housing 3 100 Kg...

Page 23: ...SVI3 on Reciprocating Valves on page 30 for instructions Install the SVI3 magnetic assembly rotary valves only See 3 4 2 Mounting the SVI3 on Rotary Valves on page 25 for instructions Assemble the SV...

Page 24: ...otary installation Figure 6 Sample Rotary Installation Figure 7 shows an 87 88 with an SVI3 mounted as an example of a reciprocating installation Figure 7 Sample Reciprocating Installation Output to A...

Page 25: ...tary control valves that have less than 60 rotation such as a Camflex or a Varimax For valves that have rotation greater than 60 refer to Special Cases on page 30 Verify that the mounting has not been...

Page 26: ...with two 5 16 18 UNC flat head cap screws and tighten using 3 16 Hex Key as shown in Figure 8 Figure 8 Camflex ATO and ATC Mounting 3 16 Hex Key with tee handle 5 32 1 2 Hex Key 3 mm 4 mm 5 mm Hex Ke...

Page 27: ...the imaginary line through the center of both magnets See Figure 9 Figure 9 Magnet Axis NOTE Upon internal valve pressure the thrust shaft is pushed out to the mechanical stops usually a thrust beari...

Page 28: ...he magnet Table 2 Travel Sensor Alignment Rotary Mounting System Stroke Direction Magnet Orientation Valve Position Sensor Counts Rotary 60 Rotation Clockwise or counter clockwise rotation 0 Closed 0...

Page 29: ...3 onto the mounting bracket with four M6 x 20 mm socket head cap screws using 6mm Hex Key 9 Ensure that No interference exists with the position sensor protrusion Ensure that the V Seal makes contact...

Page 30: ...88 Multi Spring actuators as an example Verify that the mounting has not been damaged in shipment for a pre mounted SVI3 physically inspect the actuator linkage Record the following information for t...

Page 31: ...slot 3 Install the second 5 16 18 UNC 2A HEX Head Screw in correct mounting hole according to the actuator size and travel distance Refer Table 3 on page 31 and Figure 11 Then tighten both fasteners...

Page 32: ...d thread the take off rod to the actuator stem connector Figure 13 Ensure that the travel pointer located on the coupling is correctly positioned 7 Attach the right hand threaded rod end to the lever...

Page 33: ...4 20 UNC nut and thread the left hand lock nut onto the rod end 11 Thread the turnbuckle onto the left hand threaded rod end Refer to Figure 13 12 Adjust the turnbuckle until the hole in the SVI3 leve...

Page 34: ...op tables in valve specification sheets to determine the correct positioner supply pressure Minimum supply pressure should be 5 psi to 10 psi 345 bar 69 bar 34 485 68 97 kPa above maximum spring range...

Page 35: ...an SVI3 in a Natural Gas Environment Approximately 2 8 SLPM 5 9 SCFH 30psi of natural gas exhausts from the SVI3 Positioner and vented For indoor applications take this into consideration and provide...

Page 36: ...uit Cabling must be shielded to prevent electrical noise that would interfere with the HART tones with the shield grounded Shield must be properly grounded in only one place For details and calculatio...

Page 37: ...sitioner may not operate properly Connect the wires as follows wire size 12 to 22 AWG 4 mm2 to 34 mm2 1 Strip approximately 1 4 in 6 35 mm of the insulation at the end of wires 2 Unscrew the end cover...

Page 38: ...us alert status bits and open close states 4 20 mA OUT to support position retransmit functions Digital Input DI connection REMOTE connection to wire a Masoneilan remote position sensor Process Variab...

Page 39: ...18 4 Unscrew the required connector insert the wire with correct polarity and tighten the connector screw 5 Tighten the gland and Reinstall the cover DI Connections Follow the procedure for Wiring an...

Page 40: ...source the current will be limited only by the capacity of the power source and the switch can be damaged Without a load when the switch is on closed the external voltage would be dropped across the...

Page 41: ...50 Resistor to limit the current to less than 1A Please consult qualified electrical personnel to calculate the value of resistor to be used Since the relay coils is a Inductive load The back EMF when...

Page 42: ...rt Guide Quick Start Guide which is downloadable at https valves bakerhughes com resource center Figure 22 Remote Position Sensor Input Connections Retransmit Connections Follow the procedure for Wiri...

Page 43: ...p Document Number HCF SPEC 11 and the references The SVI3 is a HART compliant device of type Actuator It is therefore a receiver of 4 20 mA and cannot have a voltage source applied to its input termin...

Page 44: ...fety barrier be placed between the process control system and the SVI3 If the SVI3 is located in a hazardous area with Intrinsically Safe protection a barrier is not required for a flameproof installa...

Page 45: ...the control system Recheck all wiring connections and ground points 3 6 5 3 Compliance Voltage in Single Drop Current Mode The SVI3 requires 9 0 V at 20 mA and 11 0 V at 4 mA Typical smart devices re...

Page 46: ...age across SVI3 Control Terminals with 20mA Signal 9 0 V Drop in single channel Zener barrier with 342 Ohms end to end resistance 6 84 V Drop in 22 AWG cable 3000 long 30 Ohms per 1000 1 8 V Drop in p...

Page 47: ...h linear and percentage characteristics Some hysteresis is shown for the actuator pressure signal that is caused by friction in typical actuators The scales are chosen to emphasize the relationships b...

Page 48: ...48 Baker Hughes 2021 Baker Hughes Company All rights reserved Figure 27 ATO and ATC Action with Linear Positioner Characteristics...

Page 49: ...Masoneilan SVI3 Installation and Maintenance Manual 49 2021 Baker Hughes Company All rights reserved Figure 28 ATO and ATC Action in Percentage of Positioner Characteristics...

Page 50: ...mode and is operational in the default factory configuration The following values appear POS Position in percentage PRES Pressure unit of measurement and value SIGNAL Current input in mA An exclamatio...

Page 51: ...peration and full access to all data ValVue is downloaded from the website https valves bakerhughes com resource center and is recommended for set up service and maintenance where a PC or laptop is pe...

Page 52: ...s that are described later in this section ValVue is used to perform all diagnostics functions The pushbuttons do not support diagnostics functions The SVI3 has two operational modes Normal normal ope...

Page 53: ...hrough Figure 32 on page 58 When using these diagrams as a map you can move through the menus to the function you needed 4 3 2 NAMUR Status The SVI3 uses the industry standard NAMUR NE 107 status sign...

Page 54: ...hough the output signal is valid the wear reserve is nearly exhausted or a function will soon be restricted due to operational conditions 4 3 3 Pushbutton Locks and Configuration Lock Jumper Before pe...

Page 55: ...nus in section 4 3 3 Calibration Menu 1 Ensure you are on the Main screen for MANUAL or NORMAL mode 2 Press and hold the SMART CAL pushbutton It must be held for a minimum of three seconds and a maxim...

Page 56: ...ate mode menu the valve is still in NORMAL mode and still responds to the 4 20 mA signal Figure 31 NORMAL Operation and MANUAL Menu Structures Normal Mode Main Screen NORMAL MANUAL VIEW DATA VIEW ERR...

Page 57: ...esponds to changes in set point input signal and the values displayed change in accordance with changes in input signal MANUAL mode the valve is locked in position 4 3 7 1 Viewing Configuration and Ca...

Page 58: ...r messages 1 Press at CLR ERR on either the MANUAL or NORMAL mode menus Exiting from the VIEW ERR menu returns the previous menu SINGLE PRESSURE UNITS T S ON OR T S OFF SIG HIGH VIEW DATA ACTUATOR TYP...

Page 59: ...and a possible cause of the fault 4 3 8 3 Return to Normal Operation Always return the positioner to NORMAL operating mode to resume control by the input signal Use this procedure to return to NORMAL...

Page 60: ...QUICK50 CUSTOM PSI BAR KPA T S OFF T S ON ENGLISH FRENCH VALUE VALUE Menu Pressure Units Menu Tight Shutoff Menu Language Menu Air to Menu CONFIG CONFIG Charact Menu Language Menu Tight Shut off Menu...

Page 61: ...tage EQUAL50 21000 series Model 21X1X or 41000 series Model 41X1X with LINEAR TRIM Linear LINEAR 21000 series Model 21X1X or 41000 series Model 41X1X with LINEAR TRIM Equal Percentage EQUAL50 21000 se...

Page 62: ...ure trim wear can occur To prevent leakage that can occur in the second case configure TS ON and set a value of position setpoint below which the actuator applies maximum seating force As the position...

Page 63: ...make any change to the valve mounting kit components you must run the find STOPS calibration again Figure 34 Calibration Menu SETUP Calibration Menu STOPS RUNNING STOP OP TUNE TUNE ERR STEP 1 3 STEP 2...

Page 64: ...o adjust 5 SIG HIGH Allows for rescaling the mA input signal setpoint value typically for split ranged devices for 100 position Use buttons to adjust 4 3 10 1Calibrating Travel Range using Find Stops...

Page 65: ...set the PID parameters for best positioning response When Autotune proceeds numerical messages display indicating the procedure is working When Autotune is complete TUNE appears 2 Press repeatedly un...

Page 66: ...ror messages or run through the FAILSAFE menu view error messages enter MANUAL mode and RESET RESET restarts operation When failsafe occurs 1 Press to move to VIEW ERR 2 Press to view the first error...

Page 67: ...0 if ATC You can set a special case of FAILSAFE You can set a Position Error Band and a Position Error Time 2 that forces the valve to its failsafe position if the position error exceeds the band for...

Page 68: ...guration and calibration routines Connect the HART Handheld Communicator or HART capable host system to the SVI3 as shown in Figure 36 on page 68 Refer to the product manual for the HART Communicator...

Page 69: ...eilan SVI3 Installation and Maintenance Manual 69 2021 Baker Hughes Company All rights reserved 4 4 1 SVI3 DD Menu Structure The menu structure shown below starts in the upper left hand corner of the...

Page 70: ...change mode to Setup 5 Tap back arrow 6 Tap Find Stops You are led through a series of screens run the process 7 Tap Change Mode and change back to desired mode 4 4 4 Run Open Stop Adjustment 1 Open...

Page 71: ...Tap Status Diagnostics 3 Tap Status Faults On this screen you can tap Current Faults to view only active faults Clear Current Faults to clear the faults The faults will reoccur if the cause is not fi...

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Page 73: ...d install the cover for upgrade to display Remove and install the Pneumatics Module containing the IP and Pneumatic relay Addition or replacement of the Options board 5 1 1 Repair Only qualified servi...

Page 74: ...andard Construction 720083049 999 0000 SVI3 Pneumatic Module Spare Part Kit Construction Low Temperature 720083057 999 0000 SVI3 User Interface Spare Part Kit Construction 720083059 999 0000 SVI3 Blan...

Page 75: ...d SVI3 Options Module Replacement SVI3 User Interface Kit Replacement SVI3 Threaded end cover Replacement SVI3 Pneumatic Module Replacement Standard temperature Low Arctic temperature SVI3 Conduit Ent...

Page 76: ...N A Information only No Yes N A N A No Action 2 0 1 LOW_POWER Low Power Check Function Yes when Input current 3 25 mA No No Input current 3 15 mA increase input current 3 25 mA 3 0 2 ACTUATOR Actuato...

Page 77: ...ule for loose cabling 2 Replace Pneumatics Module with known good Pneumatics Module 7 0 6 KEYPAD Keypad Fault Maintenance Yes Yes No Pushbutton failure 1 Check UI module for stuck push buttons and pot...

Page 78: ...totune Error Check Function Yes If the self tune process succeeds Yes No Device could not tune automatically need to manually tune system 1 Increase air supply above spring final value 10 psig 2 Check...

Page 79: ...o the device for 2 minutes and restart the device 2 Clear the alarm using ValVue or HART Host 3 If the failure persist replace the complete device or Pneumatics module 16 1 7 Reserve d 1 7 N A Informa...

Page 80: ...tes and restart the device 2 Clear the alarm using ValVue or HART Host 3 If the failure persist replace the complete device or Options module 23 2 6 OPT_TEMPE RATURE_SEN SOR_FAILED Options temp sensor...

Page 81: ...Yes No Firmware Failure 1 Remove power to the device for 2 minutes and restart the device 2 Clear the alarm using ValVue or HART Host 3 If the failure persist replace the complete device or electroni...

Page 82: ...ed and wiper is connected verify wiper voltage between 0 and 1 25 volts 4 If correct sensor selected replace electronics module and report the problem at svisupport bakerhughes com 35 4 2 CURRENT_S EN...

Page 83: ...ns when overpressure is applied or Sensor is damaged 1 Remove power to the device for 2 minutes and restart the device 2 Clear the alarm using ValVue or HART Host 3 If the failure persist replace the...

Page 84: ...d Not readable 1 Remove power to the device for 2 minutes and restart the device 2 Clear the alarm using ValVue or HART Host 3 If the failure persist replace the complete device or Option module 47 5...

Page 85: ...ERROR Options Module not found Maintenance Yes Yes No The main electronics and options module had a brief communications failure 1 Remove power to the device for 2 minutes and restart the device 2 Cle...

Page 86: ...ve power to the device for 2 minutes and restart the device 2 Clear the alarm using ValVue or HART Host 3 If the failure persist replace the complete device or Pneumatics module 59 7 2 OPTION_NO_ TC_T...

Page 87: ...the failure persist Replace the Options Module 63 7 6 AI_POS_SEN SOR AI POS out of range Failure Failure No Yes No Hardware Failure 1 Remove power to the device for 2 minutes and restart the device 2...

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Page 89: ...05 per psi unit 73 per bar unit Relative Humidity 10 to 90 non condensing Humidity Effect Less than 0 2 after 2 days at 104 F 40 C 95 relative humidity Insulation Resistance Greater than 10 G Ohms at...

Page 90: ...shutoff Yes 0 20 of Input Auto Tune SVI3 performs automatic determination of the optimal valve positioner control parameters In addition to P I D the position algorithm uses damping symmetry for exhau...

Page 91: ...Opera tion 5 mA Upper Range Value for Split Range Operation Between 8 and 20 mA Minimum input span 5mA Lower Range Value for Split Range Operation Between 4 and 14 mA Minimum input span 5mA Wire Size...

Page 92: ...Motor Stainless steel 300 400 series Mounting Bracket 300 series stainless steel Magnet Holder Corrosion Protected Anodized Aluminum 6061 T6 Pole Ring 416 stainless steel Levers 300 Series stainless...

Page 93: ...ice Type HART 7 65AA 170 DD Registered with FieldCommTM Group Yes available through FieldCommTM Group Integration with HART host software Integrates with leading DCSs with full DTM and EDD sup port in...

Page 94: ...s Device Table 17 HART Device Information Continued Table 18 Device Variables Variable Code Variable Name Unit 0 Position 1 Actuator Pressure1 psi 2 Supply Pressure psi 3 Actuator Pressure2 psi 4 Setp...

Page 95: ...late Storage Temperature Range 55 C to 93 C 6 1 2 Protection As a minimum all positioners are cleaned fitted with pneumatic and electrical port plastic caps and packed with carton box This protection...

Page 96: ...llow instructions carefully on product labels for use and storage to prevent any accidents Never store hazardous products in food containers keep them in their original containers and never remove lab...

Page 97: ...Air Only Direct Bleed Extreme Temperature 55 C to 85 C Silicone Diaphragms f d Construction Display 1 Aluminum No Display 2 Aluminum Display with local interface e Communication 1 4 20mA HART Communic...

Page 98: ...r Registered Address 123112 Moscow Presnenskaya naberezhnaya 10 room III 3 floor room 22 Tel fax 7 495 771 72 40 If you have bought SVI3 Unit with Part Number SVI3 XXXXXX12 The equipment that you have...

Page 99: ...Pressure X X X Time Open X X X Time Closed X X X Time Near Closed X X X Accumulated Valve Strokes X X X Accumulated Valve Cycles X X X Stroke time Open X X X Stroke time Closed X X X I P Current X X L...

Page 100: ...X Upper Spring Range X Lower Spring Range X Obstruction Flag X Position of Obstruction X Offset Error X Stick Slip Flag X Amplitude of Slip in Stick Slip X Confidence Indicator of Stick Slip X Cycle R...

Page 101: ...using HART communications with a modem and SVI3 DTM Refer to the ValVue3 Instruction Manual for complete instructions on these and other procedures 7 1 Adjusting Speed of Response The SVI3 provides i...

Page 102: ...A negative value SLOWS stroking speed and helps minimize over shoot A posi tive value INCREASES stroking speed and may add some over shoot The recommended values for Aggressiveness is 0 for control va...

Page 103: ...lues Parameter Rise Time Overshoot Settling Time Increase Value Decrease Value Increase Value Decrease Value Increase Value Decrease Value P Decrease Increase Increase Decrease Small Effect Small Effe...

Page 104: ...ve Trim When staged trim is used in High Pressure Liquid Letdown Valves Tight Shutoff can be adjusted to move the valve from the seat to begin throttling at the minimum operable CV level Using the tig...

Page 105: ...ng the KPI calculations will help with proper setup and support analysis of data for proper actions The following section defines the KPIs and provided insights to the common use cases 7 4 1 2 Data St...

Page 106: ...omatically color coded for easy identification of out of spec data This interface is best used to request most recent data for analysis or to pull up specific historical values for investigation Histo...

Page 107: ...e KPIs are continuously monitored by the SVI3 and can trigger a series of configurable alerts if the data was to drift out of the allowable range Users have the option to enable disable each alert mas...

Page 108: ...ifying changes in the valve performance over time Friction is calculated away from the stops not near seat not near full open Movement of the valve is necessary for the Friction calculation to be vali...

Page 109: ...ng for instances where setpoint moves smoothly while position moves in jumps Like Friction the Stick Slip data is only collected when travel is not near the stops of the valve and ignores very small m...

Page 110: ...e calculated and a rate is determined based on the number of cycles in an hour If no cycle is determined in 20 minutes the rate will reset to zero Tight shutoff cycling can occur if the DCS is control...

Page 111: ...needs You can use ValVue to specify the criterion for time spent near closed a valve position such as 4 for example See also Tight shutoff Application to High Pressure Liquid Letdown Valve Trim 7 4 5...

Page 112: ...ch is a sufficient maximum 7 5 1 Compliance Test Setup 1 Configure a test setup as in Figure 38 Figure 38 Compliance Voltage Test Setup 2 Send 4 mA to the test setup 3 Increase the potentiometer value...

Page 113: ...compliant current sources are supplied with the correct impedance versus frequency characteristic In Non Compliant Current Sources there may be a noise reduction capacitor across the output that lower...

Page 114: ...up to three control valves connected to a single controller output Minimum input current span for each SVI3 is 5 mA For each positioner the upper range value is between 8 and 20 mA and the lower rang...

Page 115: ...to three SVI3 to be operated from a single 4 20 mA DCS output Each isolator has a low compliance voltage input requirement and a high voltage output capacity Up to three isolators can be connected in...

Page 116: ...mA IN SVI3 HandHeld HART Communicator Hazardous Area Non Hazardous Area Single Channel Zener Barrier I S Galvanic Isolator REMOTE PV 1 5Vdc D I 4 20mA OUT 1 SW 2 SW 1 2 3 4 20mA IN REMOTE PV 1 5Vdc D...

Page 117: ...ircuited 7 7 4 Verify Wiring and Connections Use the following procedure to ensure that the SVI3 split range system is properly powered Connect a DC voltmeter across the input terminals For an input c...

Page 118: ...struments PLC Measurement Technology Limited www mtl inst com or R Stahl Inc www rstahl com All installations must comply with plant standards and local and international electrical codes There are th...

Page 119: ...irections Both passive Zener diode barriers and active galvanic isolators are offered with HART compliance Consult the manufacturer or refer to the documents listed at the end of this instruction manu...

Page 120: ...single channel Zener diode barrier can be used If the outputs are separated from ground a dual channel Zener barrier is required CAUTION z Do not connect a HART modem and a PC to a control circuit un...

Page 121: ...oblems An Intrinsically Safe galvanic isolator operates with all three types of output channels isolated grounded or separated from ground and provides sufficient compliance voltage The galvanic isola...

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Page 123: ...ghes com Copyright 2021 Baker Hughes Company All rights reserved Baker Hughes provides this information on an as is basis for general information purposes Baker Hughes does not make any representation...