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Rotork Electric Valve Flashing from PLC (TRAVELLING)

12/26/2020 3:58 PM

Hello Dear Engineering Team,

we are facing an issue, the Rotork Electric Valve is being operating from control room , open and close, but during the operation is flashing that word (TRAVELLING) is not showing open or close.

we check power supply is good, command signal ve+ and ve- all are normal.

what could you suggest us to do?

Waiting for your reply.

Davido

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#1

Re: Rotork Electric Valve Flashing from PLC (TRAVELLING ]

12/26/2020 5:03 PM

It sounds like it might have limit switches that are not being closed or opened. Just a guess...

Or maybe friction is stopping it midway...

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#2
In reply to #1

Re: Rotork Electric Valve Flashing from PLC (TRAVELLING ]

12/26/2020 5:09 PM

Ok, but in this case what should we do, should we open the positioner side and see how the limit switch is working?

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#3
In reply to #2

Re: Rotork Electric Valve Flashing from PLC (TRAVELLING ]

12/26/2020 5:15 PM

That would be a good idea...

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#14
In reply to #1

Re: Rotork Electric Valve Flashing from PLC (TRAVELLING ]

12/29/2020 2:01 PM

...or maybe there’s a substantial and unwanted chunk of wood jammed sideways in the valve. It’s difficult to see from here.

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#4

Re: Rotork Electric Valve Flashing from PLC (TRAVELLING ]

12/26/2020 6:50 PM

I would check to see if the valve is actually operating, it may have failed...If the stem is going up and down, check it manually for seating, open and closed...once seated, check the signal that it is working properly for open and close reading....

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#5

Re: Rotork Electric Valve Flashing from PLC (TRAVELLING ]

12/27/2020 12:41 AM

I Google'd , " rotork valve actuator manual " .

Many different manuals available in pdf format.

Troubleshooting, installation, set up, repair diagrams, maintenance, etc.

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#6

Re: Rotork Electric Valve Flashing from PLC (TRAVELLING ]

12/27/2020 2:15 AM

Is the valve display indicating travelling or the PLC.

It could be the PLC which is unable to determine if the valve is in the open or closed position and has been configured to display travelling when the valve is not at either limit.

We had Siemens PLCs and their predecessors Hitachi and both had been configured in engineering to indicate that once a direction had been requested and the valve moved off the limit it would indicate "travelling" on the HMI else if the valve did not move when requested to move then "travel fault" would be displayed. There were also "over torque" displays when the torque limits had been activated.

It all depends on the PLC configurer to supply enough or too much information.

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#7

Re: Rotork Electric Valve Flashing from PLC (TRAVELLING ]

12/27/2020 6:06 AM

Check some simple things first.

Is this a new installation with commissioning bugs still present?

Ask the operators if the display was correct before they last tried to operate the valve?

Is there a fully open/fully closed steady indication and is it derived directly from the limit switches? Open the box and manually operate the switches to see if it generates a correct response. Loose switch mountings or the cams loosely connected to the drive shaft will display your symptoms. The odds of both switches failing simultaneously are very small. If both switches appear to have failed look for a fault in the mechanics or their common wiring.

Do the same limit switches disconnect the motor in the home positions? If so do not attempt to run the motor further until you have physically checked the actuator. You may have burned out the motor by stalling it against a stop that was not registered by a faulty limit switch. For electrically driven, air operated and hydraulic valves we used to program a run length timer to display and trip the motor at 'over-normal-run-time'. If you have burned out a motor consider adding this feature to all the actuators in your system. Do not rely only on the fitted thermal overload relays, actuator motors generate massive torques and can be seriously damaged before the thermal trips.

Has there been any recent maintenance on the actuator? I have seen switch boxes not properly refitted signalling a fault.

The previous advice about understanding how the program is written is crucial. The technical construction file/maintenance manual should have a section detailing the symptoms that will show for most of the faults that may occur. (but I have never seen one that was fully comprehensive)

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#8

Re: Rotork Electric Valve Flashing from PLC (TRAVELLING)

12/27/2020 10:20 AM

Visually check the valve and see if it is moving.

If it is not moving while the message is displayed,there could be a shear-pin broken on the drive train, or a stripped gear,which would indicate that there is a jam in the valve.

Try to operate the valve manually to determine if it is jammed or stuck.

Does the actual vale body move, or just the indicator?

Look at the flow data when looking at the display.

Does the flow change when opening or closing the valve?

Which actuator do you have?A model number would help.

More info=better answers

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#9

Re: Rotork Electric Valve Flashing from PLC (TRAVELLING)

12/27/2020 11:57 AM

If the valve is neither open nor closed, as detected by limit switches within the valve, then the only thing the control system can assume is that the valve is <...TRAVELLING...>. The valve takes time to travel. The flashing is merely because someone has programmed that word to flash at that time.

If the valve does not reach the limit switch at the end of travel, particularly in the closed position, then the control system can only infer that it is still <...TRAVELLING...>.

It sounds as though there is no time-out timer programmed in the control system in order for the control system to fail the valve.

A <...Rotork Electric Valve...> can be programmed to stop on limit switch, or on torque, and it is more commonplace for the torque stop to be in place in the closed position. It could be that the closed signal needs reprogramming so that it appears when the valve torques-out on closed, assuming all control cables have been tested and shown to be good.

Valve set-up procedures are provided in the User Manual that came with the valve. If it is not to hand, then a telephone call to <...Rotork...> will precipitate the arrival of the replacement. A hand-held programmer is needed for this particular make of valve. If one is not to hand then a quotation to supply one can be obtained during the call.

The joint actions of the PLC Programmer and the Instrument Technician are needed simultaneously to overcome this problem. A 2-way radio would also be a worthwhile investment, if not made already. The work needs to take place while the plant is not being used for material processing.

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#10

Re: Rotork Electric Valve Flashing from PLC (TRAVELLING)

12/27/2020 3:29 PM

As PWSlack states, if the valve is not open or closed, then it is between states, so neither open nor closed. The programmer could have noted the last commanded direction, and displayed ‘closing’ or ‘opening’ rather than ‘traveling’, but there is nothing wrong with the controls or valve based on your statement.

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#11

Re: Rotork Electric Valve Flashing from PLC (TRAVELLING)

12/28/2020 1:39 PM

David: You didn't provide a PN for the actuator. Without that we don't know what limit switch configuration is being used in the actuator. Typically the limit switches are configured as a single pole single throw, where you have a normally open and normally closed contact with a single common, but not always. To save field wiring it isn't uncommon to combine the commons for the OPEN and CLOSED switches and then to use either the normally open or normally closed contact, thus three field wires per actuator status not five (assuming the commons are tied together.) Second, the PLC input indicator LED's should show the current status of the valve and this depends on which contacts they brought back to the PLC; so what indications do you have on the PLC inputs? Typically the HMI doesn't do the logic, though some can, so it's helpful to know the logic used in the PLC. Also if the valve isn't OPEN and isn't CLOSED you should have an alarm on the traveling logic such that if the valve doesn't close or open in the allocated time you get a FAILURE alarm. I had an instance where the valve limit switches where not adjusted properly and the limit switches weren't actuated in either the OPEN or CLOSED positions; so you should verify if the limit switches in the actuator are adjusted properly. If you can, it is necessary to understand the wiring between devices. Actuator come with a variety of limit switch configurations both mechanical and solid state; otherwise any comments will be all over the place depending on the assumptions made as to wiring and logic. It does seem you may have two problems, the first is the limit switches seem to be improperly adjusted and second the PLC logic appears to lack the ability to give you an alarm if the switches don't arrive in an OPEN/CLOSED position in an acceptable time. Also, you didn't say whether or not you received OPEN/CLOSED indications for the valve status.

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#12
In reply to #11

Re: Rotork Electric Valve Flashing from PLC (TRAVELLING)

12/29/2020 10:34 AM

R-I-C-H: the PN for the actuator is Size IQ20/FA14/B4

Speed: 57 rpm, Torque Max: 203Nm

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#13
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Re: Rotork Electric Valve Flashing from PLC (TRAVELLING)

12/29/2020 1:59 PM

Wonderful. That’s going on all next year’s Christmas cards.

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#15
In reply to #12

Re: Rotork Electric Valve Flashing from PLC (TRAVELLING)

12/29/2020 2:16 PM

David,

First: A link to Rotork publications:

https://www.rotork.com/en/documents?divisionID=&productID=&docCategoryID=&langDesignatorID=&keyword=PUB002-031

This link will take you to the programmer for the valve. You can then enter PUB002-003 to get to a manual for the valve. What I think is happening, from a very brief look at the programming for the valve, is you may have to program the valve for REMOTE operation. If the valve is currently in AUTO it won't let you operate the valve from the control room. It appears the valve is a legacy device so it's a bit difficult to get information, it seem the Q3 series in the current one.

Hope this is of some help.

Take care,

Rich

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