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StarPac Intelligent System

Intelligent System

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®
StarPac Intelligent System
Components

I/P
Positioner
StarPac
Electronics
Position Module
Feedback
Arm
User Process
Access Display
Terminal

Pressure/Temperature
Electronics Conduits
Sensors

Figure 1: StarPac® Intelligent System Components


Introduction preprogrammed setpoint that is held with no external
The Kammer StarPac® intelligent system includes a communication. A personal computer can be used to
microprocessor-based controller and process sensors set operating and tuning parameters or reading diag-
mounted on a control valve. The system provides nostics; it is not needed for ongoing StarPac operation.
single-loop measurement and control of flow, pressure, DCS’s can be linked to the StarPac unit if they support
or temperature. It also allows data acquisition neces- Modbus or Fieldbus protocols.
sary for valve or process diagnostics. Maintenance procedures are improved with StarPac’s
Intelligent systems can improve plant operation at a ability to record and report on valve or process equip-
lower installed cost than conventional control systems. ment performance. For example, a signature of the
With flow, pressure and temperature sensors, and the valve or process (using StarPac sensors) can be re-
microprocessor mounted directly on the valve itself, corded by a PC upon installation of the StarPac system.
installation of a total control loop is simplified by elimi- Later, using this signature, StarPac software can help
nating separate line taps. The overall complexity and determine whether the valve or other process equip-
potential for leaks in a process system are reduced with ment needs servicing, reducing scheduled maintenance.
fewer penetrations in the flow stream. In addition, the StarPac system provides self diagnos-
The StarPac unit can be programmed to operate as a tics with easy field replacement of modular parts.
traditional control valve (responding to a 4-20 mA con- The use of intelligent systems in hazardous application
troller) or as a stand-alone controller or transmitter start-ups and shutdowns provides process insight and
requiring only a 24 VDC power source and air supply. In control – previously only available with expensive, com-
the stand-alone (controller) configuration, StarPac re- plicated equipment installations. StarPac’s “intelligent”
sponds with PID action to: a 4-20 mA analog control reaction to system failure can give the user that extra
signal, a digital signal through the serial data port, or a safety edge over conventional control-loop systems.

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StarPac Intelligent System
Benefits and Advantages

Enhanced Plant Operation


Better Process Operation Total installation costs can be as low as 20 percent of a conventional
control systems. The high turndown results in better process control over
the operating range.

Real-time System Analysis StarPac’s ability to gather and send flow and process data allows up-to-
the-minute, engineering analysis, aiding in reducing production costs and
enhancing the process.

Wide Versatility Multiple control modes– including fluid flow, upstream pressure, down-
stream pressure, differential pressure and temperature–permit StarPac
systems to be used in a wide variety of process applications. Remote
sensors can be tied into the StarPac unit for control of other process
parameters. Cascade action is also supported.

Simple System StarPac software is easy to use, allowing the system to be setup or recon-
Configuration figured quickly as needed by the user to optimize the process system.

True Distributed Process The StarPac unit can take load off a DCS by distributing measurement
Control and control to the field. This allows the DCS to function as a process
supervisor, acting on information from the whole system

Increased Safety

Fewer Line Penetrations Single-point installation limits line penetrations for sensors and reduces
potential leaks to the environment, reducing EPA reporting requirements.

Continuous Monitoring StarPac system continuously monitors the valve position and the opera-
tion of several critical internal parameters, notifying the user when im-
proper operation occurs, before upsetting the process.

System Warnings Programmable settings permit the user to set process system parameters
and to be notified when those limits are violated.

Improved Maintenance
Predictive Maintenance StarPac software allows the intelligent system to be used to diagnose the
valve operation as well as upstream and downstream equipment (such as:
pumps, reactors, heat exchangers, etc.) while in operation to predict an
acceptable performance or potential failure. Maintenance can then be
performed before process failure occurs.

Reduced Complexity With all functions located in one package, complexity of the total control
system is reduced. Locating, finding and troubleshooting the problem
is easier.

Remote On-site Service StarPac’s modem capability means low-cost, on-site, factory service is
available when needed, using telecommunication technology.

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Features

Process Diagnostics–Evaluation of process equipment is possible with the StarPac High Interchangeability - Since the Kammer 25000 series (split body),
intelligent system. By generating an initial signature of the process (and catalogued in 35000 series (top-entry) and other control valve series is the basis of the
an ASCII format) and then identifying a standard process signature, a pump, compres- StarPac system, most valve parts are interchangeable with
sor, heat exchanger, reactor, etc. can be discovered to be defective and in need of other Kammer valves, reducing parts inventory.
servicing. Process diagnostics can be performed with a personal computer or DCS
connected to the unit via its serial data port.

Local Display - Eight variables (P1, P2, temperature, gas and liquid flow,
setpoint, stem position and total flow) can be displayed on an externally-
visible display. An error indicator will show if the StarPac system
should fail any internal diagnostics or have active process alarms.

Data Logger - The StarPac system can keep a record of process


conditions at user-specified intervals (1 to 32,000 seconds) and
store them in its memory for later retrieval to aid in diagnosing
process upsets. A flow totalizer is also available with reset action.
Multiple Failure Modes - StarPac technology allows multiple
failure modes to be set, including: power, air supply, command
signal, or process failure. This ensures greater reliability
and consistency of the process in case of emergency
shutdowns, protecting the process and people.

Process Transmitters - Sensors in the valve body measure process


conditions, including upstream and downstream pressure, temperature,
and flow. Locating pressure and temperature sensors in the valve body PID Controller - Systems are equipped with a self-contained
eliminates several process connections. All sensors have at least two PID controller that can use internal process parameters (or a
seals to reduce the possibility of leaks to the atmosphere. Remote- value from an external transmitter) as the control variable.
mounted pressure sensors can be fitted with isolation and/or purge The PID parameters can be tuned for tight process control.
valves to aid maintenance of the sensors. Flush mounted sensors The ability to control flow, pressure, or temperature makes
are available for fluids that could plug the pressure sensor ports. StarPac intelligent systems appropriate for numerous
process applications in diverse industries.

Connections to Operator Interface - The StarPac can be connected to an User Friendly Software - Where the user is not connecting
operator interface (personal computer, DCS console, or hand station and the StarPac unit to a DCS, StarPac software can configure,
recorder) through three 4-20 mA analog channels, four discrete channels. operate, and diagnose the StarPac unit through a personal
Supervisory digital communications with control equipment can be estab- computer. The software has a graphical user interface,
lished through gateways, Modbus ports, or Fieldbus ports. All process and allowing most users to operate their StarPac
configuration information is available through the digital channel. systems with minimal training.

Figure 2: StarPac Intelligent System Features


StarPac Intelligent System
Configurations, Ordering Information

DCS Modbus
RS-485

Batch Control

PC RS-232 Modbus PC
or
RS-485 Controller
Box
232 - 485
Interface box

Controller
Multiple Analog
4 – 20 mA
Outputs Via Optional
Six Analog Interface Box
4 – 20 mA Analog RS-485
Signals Interface
Box
(isolated)

Output
Controller
Flow Sample Analog
Analog 4 Wires
P1 Interface Interface Box
Box Application
Recorder
Temperature

Figure 3: StarPac Intelligent System Configurations

Ordering Information 4. Electrical classification requirements


The following information must be provided when order- 5. Process control parameters and special software
ing a StarPac intelligent system: required
1. Control valve specifications: size, body pressure 6. Pressure sensor material and configuration re-
rating, material, etc. quired; pressure sensor mounting: close to valve
body (std.), remote-mounted or flush-mounted (opt.)
2. Start-up and operating conditions: inlet/outlet
pressures, temperature, flow rate, fluid physical 7. Piping installation at StarPac system
properties. 8. Valve accessories and options required: handwheel,
3. Maximum operating temperatures and pressures certified drawings, power supplies, etc.

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StarPac Intelligent System
Specifications
10 Table III: Electrical Specifications
Error (percent of reading)

Power Supply 24 VDC +4 VDC (300 mA max.)


8
Analog Command 4-20 mA (30 mA max.)
Aux. Analog Input 4-20 mA (30 mA max.)
6
Analog Output 4-20 mA
4
Discrete Inputs 12 to 200 VAC or DC
Discrete 1 A, 110 VDC or 125 VAC;
Outputs 350 mA/200 VDC or peak AC
2
Explosion-proof Class I, Division I, Groups B-D
0 10 20 30 40 50 60 70 80 90 100
(FM listed)
Flow (percent of maximum)
Non-incendive Class I, Division II, Groups A-D
Figure 4: Flow Accuracy (FM and CSA) (BS 6941, pending)
Overload Min. 500 volt isolation; 24 V
Table I: Performance Specifications Protection power fuse protected
Measurement Repeatability Serial Interface RS-485 port, Modbus
Flow 0.25% full scale
Pressure (max.) 0.1% full scale
Temperature 0.6° C Table IV: Software Specifications
Drift 1% full scale/6 months Computer System MS-DOS 3.1 or higher, 80286
Calibration Independent zero and span processor running at effective
adjustment for all sensors. rate of 12 MHz or greater
Vibration Up to 2 G’s - 30 to 500 Hz Drives Required Hard disk (approximate 5 Mb)
StarPacs per link up to 31 (depending on protocol)

Operating Temperature Range


Ambient -40 to 170° F (-40 to 76° C) Table V: Valve Specifications
Process Media -320 to 1020° F (-195 to 550° C) Body Size 1
/2 to 6-inches (standard)
Temperature -23 to 65° C (0,0335%/° C) Pressures up to ANSI 2500
Effect -40 to 85° C (0,12 %/° C)

Other Features
Totalizer Totalizes mass flow until reset;
available through digital link.
Data Logger 300 most recent samples at
user-defined intervals, from
1 second to 9 hours.

Table II: Physical Specifications


Pressure 316L stainless steel, Viton
Sensors O-ring seal; others on request
Housing Cast, powder-coated aluminum
Tubing 316 Stainless steel
Environmental NEMA 4X
Pressure Sensor Two times maximum operating
Overrange pressure with negligible change
in output.

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StarPac Intelligent System
StarPac Gas Flow Loop Turndown Ratio – 30:1
DCS Straight Runs – none needed
Pipe Insertions – 1
Diagnostic Capabilities
Data Logging
Interlock Tie Ins
Local Display

Conventional Gas Flow Loop

DCS Turndown Ratio – 4:1


Straight Runs – 10 up, 6 down
Pipe Insertions – 4
No Diagnostic Capabilities
FT PT TT No Data Logging

Figure 5: StarPac Flow Loop Comparison


While the information and specifications presented in this literature are believed to be its products. When properly selected, each product is designed to perform its intended
accurate, they are supplied for informative purposes only and should not be considered function safely during its useful service life. However, it is necessary that Valtek’s
certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained customers be fully aware of its responsibilities when using these products.
herein is to be construed as a warranty or guarantee, express or implied, regarding any
Each Kammer product may be used in numerous applications under a wide variety of
matter with respect to this product. Because Kammer is continually improving and
industrial service conditions. Although Kammer can, and often does, provide general
upgrading its product design, the specifications and information included herein are
guidelines, it is not possible to provide application specific data and warnings for all
subject to change without notice. For further information or verification, consult factory or
conceivable applications. The purchaser must therefore assume the ultimate responsibil-
Kammer representative. Specific instructions for the installation, programming, operation,
ity for the proper selection, installation, operation and maintenance of the products. It is
troubleshooting and maintenance of Kammer StarPac intelligent control valve systems are
imperative that the purchaser obtain and read the appropriate Installation, Operation and
contained in the StarPac maintenance manual. Before the intelligent control valve system
Maintenance (IOM) manual and train its employees and contractors in the safe use of the
is installed or operated, this manual should be read thoroughly and followed exactly by all
products in connection with the purchaser’s manufacturing processes.
personnel responsible for their operations. Maintenance manuals are available through
Kammer representatives or by writing Valtek directly. MS-DOS, Teflon, Lotus 1-2-3 are Kammer will continue to provide its customers with the best possible products and services
registered trademarks of their respective companies. available. Should you have questions about these provisions or about Kammer’s products
Valtek Incorporated has established industry leadership in the design and manufacture of in general, contact your local Kammer representative or the factory directly for assistance.

Kämmer is represented by factory-trained manufacturer representatives worldwide:

Valtek International Headquarters - Springville, UT 84663 Valtek Corpus Christi - Corpus Christi, TX 78408 Valtek Sulamericana Ltda. - Sao Paulo 09940, Brazil
Telefon: 801-489-8611, Telefax: 801-489-3719 Telefon: 512-289-6911, Telefax: 512-289-691 Telefon: 11-745-1011, Telefax: 11-745-2477
Kämmer Ventile GmbH - Manderscheidtstr. 19, 45141 Essen Valtek Houston - Deer Park, TX 77536 Valtek India Ltd. - Ahmedabad, India
Telefon: (0201) 2 94 07 - 0, Telefax: (0201) 29 72 51 Telefon: 713-479-9500, Telefax: 713-479-8511 Telefon: 272-813319, Telefax: 91-22-623-1055
Kämmer Vannes S.A., La Chaux-de-fonds, Schweiz Valtek Los Angeles - Santa Fe Springs, CA 90670 Durco Valtek Pte Ltd. - Jurong, Singapore 2261
Telefon. (0 39) 26 44 33, Telefax: (0 39) 26 54 22 Telefon: 310-946-0767, Telefax: 310-946-2776 Telefon: 261-2200, Telefax: 261-3935
Valtek-Sereg - 91304 Massy Cedex - France Valtek Philadelphia - Boothwyn, PA 19061 Yokogawa *Kitz* Valtek - Tokyo 141, Japan
Telefon: (1) 64.47.21.29 - Telefax: (1) 64.47.20.94 Telefon: 215-497-8600, Telefax: 215-497-6680 Telefon: 03-5434-5963, Telefax: 03-5434-5930
Valtek Baton Rouge - Baton Rouge, LA 70809 Valtek Australia Pty. Ltd. - Scoresby, Victoria 3179 Valtek Controls Ltd. - Edmonton, Alberta T6P 1K6
Telefon: 504-751-9880, Telefax: 504-755-0728 Telefon: 3-764-8522, Telefax: 3-764-0013 Telefon: 403-449-4850, Telefax: 403-449-4851
Valtek Beaumont -Beaumont, TX 77705 Valtek New Zealand Ltd. - East Tamaki, Auckland
Telefon: 409-842-0087, Telefax: 409-842-4444 Telefon: 9-274-1933, Telefax: 9-274-1812

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Issue E 07.94