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We have installed bands and secured all tubes (as best as we could). It should help reduce vibration of the tubes. Thanks!

Good comments, Controlnovice! I hate to say it but the company has now made a decision not to install foundation fieldbus in the new plant because of all the problems we experienced.

Excellent comments, EdStainless! We will definitely follow up on it. Thanks!

Update - we found the cause of the problem. It is mechanical. Upon closer inspection, we found the tube above the holed tube was loose. The vibration actually caused the baffle plate to cut through the tube. When that happened, the high pressure H2 from the top tube would impinge on the...

Thanks for your comments, Ashereng! You are correct. We sure do not want to start up the plant and having these positioners failing on us. It would be very expensive shutting down the plant. Plus, the risk of equipment or catalyst damages is high on a plant trip.

We are in the progress of cutting the failed tube out and have it analyzed. As far as I can see the corrosion was external (on the water side). The area right next to the holes are pitted and clean. The reason it is clean, I think, is once the hole is made the higher pressure H2 from the tube...

We just have a heat exchanger tube failure. The equipment is used to cool product hydrogen gas at the outlet of a compressor. The H2 is in the tube side and the cooling water in the shell side. The tubes are made of Cu/Ni (90/10) and the tube sheet & shell are made of carbon steel. We are...

As an update to my previous post, the Valtek specialist explained to us the problem with the Valtek 3400IQ positions was configuration setup. He went through all the positioners to confirm the correct configuration last Wednesday (11/08)and made changes as needed. Since then, we have not had a...

Thanks very much for all the replies! The problem we are having is strictly electrical/electronic in nature. When it happens, the positioner will lock up and the only way to fix it is to cycle the power on and off. So far, the problem we have is only with the Valtek 3400IQ and 1400 series...

To All, We are in the middle of commissioning our fieldbus based control system and ran into many Valtek 3400IQ positioner failure problems. We are still working on resolving them. Any suggestions are welcome and appreciated.