During a recent presentation at Emerson Exchange 2025, Daniel Busch, Emerson Senior Valve Condition Monitoring Analyst, and Jordan Cain, Account Manager at Control Southern Inc., presented “Using Smart Positioners to Make Smart Decisions.” An attendee asked, “Do you think AI can replace the Valve Condition Monitoring Analyst role? What are the advantages and limitations of AI in valve monitoring compared to the expertise of a human analyst?”
Their response was clear: “While AI offers efficiency, it lacks the expertise and lessons learned from years in the field and the deep understanding of the data and resulting subjective experiences. Emerson experts react to alarms, diagnostic data, and anomalies to provide consultative action steps. Experts like Daniel and Jordan emphasize the importance of human knowledge in urgent and complex situations, creating a perfect duo with technology for efficient troubleshooting. AI can enhance efficiency, but the combination of human expertise and smart technology is unbeatable.”
The Challenge: Navigating Workforce Reductions with Smart Technology
Industries across the globe are facing reduced workforces and diminished knowledge, making it imperative to leverage technology for efficient operations. Smart positioners have emerged as a vital tool, providing extensive data that allows experts to identify mechanical degradation and abnormalities over time. Diagnostic service plays a crucial role, offering a snapshot of valve health and performance during actual operation, rather than offline. This real-time insight is invaluable for maintaining the integrity of industrial processes and reducing turnaround downtime.
Predictive Maintenance Tools and Distributed Control Systems
Emerson understands there is no ‘one size fits all’ approach to valve condition monitoring. Key solutions include Fisher™ FIELDVUE™ DVC6200 Digital Valve Positioners, ValveLink™ Diagnostics Software, Ovation Distributed Control Systems, DeltaV Distributed Control System (DCS), and Historical Valve Maintenance Data. These digital tools help boost the productivity of technicians, enabling high reliability and the implementation of a predictive maintenance strategy.
A Case Study: Real-World Application and Insights
In a recent customer case study, the Fisher™ FIELDVUE™ positioner reported that the valve travel was not responding to control signal changes.
The system also identified other potential challenges, such as internal positioner temperatures exceeding outside rated operational limits. Recommendations included checking the valve’s packing area and the surrounding area for steam leaks, which could contribute to elevated ambient temperature. The client identified two different sources contributing to the high temperature, took action to correct the issue, and prevented further degradation of the positioner elastomers, thereby avoiding premature failure.
Monthly VCM Customer Report
Valve Analyst Workspace Page
Quantifiable Success: Savings and Impact
The success of valve condition monitoring is evident in the savings achieved. Consider the following scenarios:
- Issue #1: Ambient Heating Issue on Unit 1 resulted in 3 hours of downtime, losing 280 MW on GT and 100 MW on ST.
- Issue #2: Ambient Heating Issue on Unit 2 resulted in similar downtime and losses.
- Issue #3: Positioner Circuit Failure on another unit resulted in 3 hours of downtime, losing 280 MW on GT and 100 MW on ST.
Generating revenue at 14.63 cents/kWh, the total lost generation of 3,420 MWh equates to $500,346. Regular data readings by Emerson experts, tailored to customer preferences, ensured timely analysis and recommendations, preventing such losses.
Technology and Its Impact: Enhancing Daily Operations
Smart positioners significantly improve operations for maintenance managers. Weekly or biweekly recommendations from dedicated experts help prevent potential issues, minimize valve outages, and save time and money during maintenance. This technology empowers maintenance managers to make informed decisions, enhancing operational efficiency.
How Emerson’s Valve Condition Monitoring Experts Interact With You
The program assigns a dedicated Analyst to the facility who acts as an extension to the plant maintenance and reliability teams, supported by a team of experts with extensive knowledge in valve maintenance, diagnostics, and troubleshooting. This team remotely monitors valve conditions, offers tailored recommendations, and builds strong, personalized relationships with customers. This service allows reliability and plant managers to focus on other priorities while ensuring optimal valve performance. By partnering with Emerson, you gain access to OEM-certified technicians who collect vital valve health data from the field, providing realistic valve failure information that surpasses modeling capabilities.
Contact your local Emerson sales office to learn more about Valve Condition Monitoring and request an asset criticality assessment to take the next step in improving the performance of your entire process.
