February 15, 2008

Actual Control Valve Scenarios - Part 3

By Greg McMillan

(5) A column distillate receiver has a relatively constant amplitude level oscillation
(a) The amplitude of the oscillation is relatively constant for a given tuning
(b) The amplitude and period of the oscillation increases as the controller gain is decreased*
(c) Actual readback of level valve position indicates the minimum change in valve position routinely is 0.05% but the valve position stays at its previous position for a reversal of controller less than 0.5%
(d) Conclusion - the control valve has dead band which for an integrating loop causes a limit cycle

(6) A continuous evaporator has a constant amplitude temperature oscillation
(a) The amplitude of the oscillation stays the same when the controller gain is changed*
(b) Actual readback of steam valve position indicates the minimum change in valve position is 0.5%
(c) Conclusion - the steam valve has a resolution limit that for a self-regulating loop causes a limit cycle

(7) A process dead time varies
(a) The production rate is relatively constant
(b) The dead time increases as the controller gain is decreased *
(c) The dead time increases as the change in set point is decreased*
(d) Actual readback of level valve position indicates the minimum change in valve position routinely is 0.05% but the valve position stays at its previous position for a reversal of controller of less than 0.5%
(e) Conclusion - the changes in process dead time are caused by valve dead band (dead time is dead band divided by the rate of change of controller output for signal reversal)

(8) A process dead time varies
(a) The production rate is relatively constant
(b) The dead time increases as the controller gain is decreased *
(c) The dead time increases as the change in set point is decreased*
(d) Actual readback of level valve position indicates the minimum change in valve position routinely is 0.05% but the control valve takes from 5 to 50 seconds to catch up to the controller output for a reversal of controller (time to catch up increases as the change in controller output is decreased).
(e) Conclusion - the changes in process dead time are caused by a positioner with poor sensitivity that causes a slower exhaust or fill rate to actuator for smaller changes in controller output

* - these controller tuning or set point changes provide affirmation but are not required to diagnose the problem

** - valve diagnostics confirm it is not a valve problem



1 Comment

Nice web site you have got here.


Leave a comment


Subscribe

Subscribe to site RSS Feed


Or, subscribe by email:

Archives

The opinions expressed here are the personal opinions of Greg McMillan and Terry Blevins. Content published here is not read or approved by Emerson before it is posted and does not necessarily represent the views and opinions of Emerson. © 2006-2010 Greg McMillan and Terry Blevins. All rights reserved.