OPTIMIZATION l TRAINING l CONSULTING

By Michel Ruel, P.E.

Topics
FValve problems
F Valve tests
F Observations in automatic mode
F Tests to perform in manual mode
F An example
F Conclusions
F What to expect?

1
1
 Valve problems
F Response time
è Dead time
è Time constant
è Positionner overshoot

F Amplitude
è Hysteresis, backlash, dead band
è Stiction

è Non linearity (inherent characteristic)

è Process gain

Hysteresis, dead band, backlash

Valve position

r :resolution
r b r b :backlash
d :deadband
h :hysteresis
d …. :perfect valve

Signal applied

2
2
Hysteresis, dead band, backlash
Valve position
Valve position

Applied signal
Applied signal

backlash
backlash

Valve position
Valve position

time
time

Stiction : Stick + friction

Valve position

Applied signal

stiction

Valve position

time

3
3
Our criteria: four rules of 3
Target
F Noise band <3% 0%
F Hysteresis <3% 0%
F Process gain <3 1
F Gp max (Linearity) <3 1
Gp min
F Stiction îîî 0%

Topics
F Valve problems
FValve tests
F Observations in automatic mode
F Tests to perform in manual mode
F An example
F Conclusions
F What to expect?

4
4
 Examination of the valve
è Is a simple auscultation insufficient?
è Do we need a complete scanner examination?
è Do we need an intrusive examination?
è Do we need to disconnect the vital functions?
è Is it necessary to do a complete check-up?

F The answer to all of these is NO

How to determine if the valve performs

properly while the process is running

F Without stopping the production

F Without sophisticated equipment

F In minutes, not hours!

F In manual or automatic.

5
5
Process and equipment analysis
F In Manual (preferred) or Automatic
F Check for:
è Hysteresis
è Stiction

è Linearity

è Asymmetry

è Small signal response

Topics
F Valve problems
F Valve tests

F Observations in automatic mode

F Tests to perform in manual mode
F An example
F Conclusions
F What to expect?

6
6
 Automatic mode : tuning problem
F Sine wave è tuning problem?

Automatic mode : stiction problem

F Sawtooth è stiction problem?

7
7
Automatic mode: hysteresis problem
F Variable period è hysteresis problem?

tpid tpid tpid

Automatic mode : High process gain

F CO changes are small.

8
8
 Topics
F Valve problems
F Valve tests
F Observations in automatic mode

F Tests to perform in manual mode

F An example
F Conclusions
F What to expect?

Sequence to determine valve characteristics

• noise band,
• process gain,
• backlash, hysteresis,
• positionner overshoot,
• stiction,
• slow movement 1 2 3 4 5 6

• linearity.

9
9
Hysteresis, Process gain, noise band

Stiction check

10
10
Asymmetry check

Linearity check

11
11
 Topics
F Valve problems
F Valve tests
F Observations in automatic mode
F Tests to perform in manual mode

FAn example
F Conclusions
F What to expect?

An example, a flow loop

manual mode (300-700 s)Observations in automatic mode (0-300 s)
Observations in Set-point
Low flow ≠ high flow →non linear
Strongly non-linear Process variable

Going up ≠ going down →asymmetrical

No hysteresis or small process
Enough data for evaluation of: Cycling →tuning too
stiction, aggressive
hysteresis,
non linearity, No apparent hysteresis since the cycling does
process gain.
Controller output
not last and the period remains fairly
constant.
Valve is undersized since at 100% opening,
the flow is 30% approximately. No stiction since there is no sawtooth in the
controller output.
Noise is small
Noise is small.

12
12
Hysteresis, Noise, Process gain

Stiction

Positionner overshoot
if small changes

13
13
 Linearity

Results
PROCESS GAIN 0.24 Too small, resize the transmitter span
LINEARITY 23 Too much, use a characterizer
HYSTERESIS 0.6 % OK
STICTION <0.2 % OK
NOISE BAND 0.06 % OK
ASYMMETRY ~ OK

14
14
Should this valve receive its Health Certificate?

F Yes… but:
è this process needs a characterizer to modify the
valve characteristics;
è the transmitter should be recalibrated

Topics
F Valve problems
F Valve tests
F Observations in automatic mode
F Tests to perform in manual mode
F An example

F Conclusions
F What to expect?

15
15
 Time to optimize a loop
F Hooking-up: minutes
F Tests: minutes
è flow loop: 10 minutes
è level loop: 20 minutes
è temperature loop: 60 minutes

F Reporting: minutes
F Average: 6 to 8 loops per day
or

~20 valves tested per day

Results (typical)
F Tests+Tuning
è Variability cut by 2
è Valve travel cut by 5

è If cycling, removed

è Robustness increased by 3

è Costs ~ 100$/loop

F ROI weeks to months

16
16
Th a n k you !

Booth 2509

17
17