Asset management tools for the automation industry have been available for many years. These tools are focused on streamlining maintenance tasks, troubleshooting field devices, making ongoing maintenance more efficient and documenting maintenance activities.  Saving time and avoiding expensive equipment failures are key benefits to asset management programs.

A large pulp mill’s reliability team launched a project to evaluate critical maintenance tasks and improve system reliability.  During this evaluation, it was determined that a large number of valves, critical to system operation, were being removed during the annual shutdown period for evaluation, repair and replacement.  Because the valves were critical to the operation of the mill, it was considered necessary to physically check their condition annually, even though the cost was high and frequently revealed nothing was wrong.

The team implemented a pilot program using Asset Management Software to evaluate data from these valves. This allowed continuous monitoring of their operation and reported their condition without removing them. 

The mill uses Rockwell Automation ControlLogix PLCs for process operation. The controllers are networked via Ethernet to a network server that catalogs process data.  Spectrum Controls' Analog I/O Modules with HART Protocol interface to the valves. Installation cost was limited as no additional wiring to the valves was needed. HART communication protocol allowed the user to retrieve cycle and position data real-time.

The benefit to this system is significant. Technicians are now able to perform fast troubleshooting, minimizing the number of unscheduled shutdowns. HART communication also allows faster and improved diagnostics. Control routines built around the HART data advise operators of alert conditions and atypical system operation.

The end result is an integrated system that not only improved diagnostic capabilities but also improved control and monitoring capabilities.