Digital valve controller helps Chinese plant save $40,000 in repairs and downtime 13 December 2012

Since Emerson replaced valve positioners in the Shanghai Ethylene Cracker Complex (SECCO) with Fisher Fieldvue DVC6200f digital valve controllers, the plant is reporting better control, production efficiency, and uptime – and $40,000 in annual maintenance savings.

SECCO is the largest integrated chemical facility in China, and has a naptha-fed ethylene cracker and 10 downstream derivative plants, with thousands of control valves of various brands, types and sizes.

Temperature fluctuations in the process were causing 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, plant engineers decided to replace the facility's positioners with Emerson's Fisher Fieldvue DVC6200f digital valve positioner.

The instrument offers linkage-less, non-contact position feedback to reduce vibration-induced problems as well as diagnostics and Foundation fieldbus communication to alert operators of potential valve problems.

Since installation, operations in the facility have been enhanced, with better stability and control. Production efficiency also improved, while waste and rework were reduced.

Valve performance is more reliable, and uptime has increased because of less frequent valve failure and scheduled maintenance.

SECCO has saved an estimated $40,000 annually by eliminating the frequent replacements of positioners a well as maintenance, labour and potential production loss.

Brian Tinham

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Emerson Process Management

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