Control Valve Maintenance Support System Plug-in Valstaff - more predictive maintenance -

Early detection of control valve’s being in poor condition, appropriate maintenance planning, and efficient maintenance.


On-site work efficiency

More sophisticated decision making

2nd category

Remote control of operation and inspection

From anomaly detection Prevention of accidents

O&M improvement by predictive detection

Automation of operation and inspection


PLUG-In Valstaff communicates with smart valve positioners that support FOUNDATION fieldbus and HART communication, and monitors control valve diagnostic parameters 24/7.
In addition, its automatic adjustment/setup of positioners and step response testing achieves quick and accurate startup. Additionally, control valve status indexes generated from this data help users to create maintenance plans that are appropriate for the level of deterioration, minimizing overhauls.

■Prevention of unexpected problems and unplanned operation downtime
By collecting diagnostic parameter data from smart valve positioners during plant operation and monitoring data trends, operators can catch control valve deterioration that would have escaped notice previously, preventing unexpected problems and unplanned operation downtime.

■Dramatic reduction in time required for loop testing in regular maintenance
In a step response test, whether valves operate correctly and smoothly in response to opening commands is checked. The results of testing, which are displayed in graphs, allow easy discovery of deterioration and control valve problems and evaluation of their performance. Multiple control valves can be checked simultaneously, which drastically reduces the time required for regular maintenance and inspection.


PLUG-IN Valstaff is a control valve maintenance support system designed to perform online trend monitoring of diagnostic parameters for Azbil Corporation’s smart valve positioners during plant operation. The system detects irregularities in control valves and positioners at an early stage to minimize problems, and provides visualization of information that is necessary for decision-making with regard to control valve maintenance, thereby facilitating efficient maintenance work.

PLUG-IN Valstaff monitors diagnostic parameters of control valves around the clock, 365 days a year by communicating with smart valve positioners compatible with FOUNDATION Fieldbus or the HART communications protocol. The diagnostic data helps detect control valve failures and facilitates preventive measures for any problems caused by such failures. In this manner, the system ensures continuous operation of the plant in a safe and reliable manner.

In addition, PLUG-IN Valstaff supports swift and accurate startup by automating both step response testing and the adjustment of the positioner according to the characteristics of the control valve. Moreover, the system facilitates optimized maintenance planning according to the extent of deterioration and the overhaul of control valves by providing indicators of their condition based on the diagnostic data obtained during operation and the step response testing conducted after shutdown.

Achievements and examples

● A petrochemical customer has avoided unexpected valve failure by detecting non smooth valve motion caused by polymer stuck on Gland packing.
● A plant site signuficantly reduced loop checking time after a turn-around (periodic shutdown maintenace) from 7 days with 2-3 engineers/technitians by the conventional method to 2 hours with 1 engineer/technitian using Valstaff automatic testing future.


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Company information

Azbil Corporation

100-6419 19F Tokyo Building 2-7-3 Marunouchi, Chiyoda-ku, Tokyo, Japan

Tel : +81-466-52-7037

Website :

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