Digital valve controller helps Chinese chemical plant save $40,000 in repairs and downtime

After Emerson Process Management replaced existing valve positioners in the Shanghai Ethylene Cracker Complex (SECCO) with Fisher Fieldvue DVC6200f digital valve controllers, the SECCO plant gained better control, production efficiency and uptime - and $40,000 in annual maintenance savings.

SECCO is the largest integrated chemical facility in China. The complex includes a naptha-fed ethylene cracker and 10 downstream derivative plants with thousands of control valves of different brands, types and sizes. Temperature fluctuations in the process 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 Fieldvue DVC6200f digital valve positioner.

The DVC6200f offers 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. The instrument is easily mountable onto any valve, which was especially important in SECCO’s case. In addition, achieving high process reliability and performance is possible because of 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.

After installation, operations in the facility were enhanced with better stability and control. Production efficiency 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.