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STICTION
∗
Department of Chemical and Materials Engineering,
University of Alberta, Edmonton AB, Canada, T6G 2G6
∗∗
Mitsubishi Chemical Corporation,
3-10 Ushiodori, Kurashiki, Okayama 712-8054, Japan
Abstract: Stiction is a common problem in the widely used spring-diaphragm type control
valves in the process industry. Several methods are available for detecting stiction in
control valves. After detection of stiction, a test is required to confirm that the valve
in question is indeed suffering from stiction. This paper presents a simple closed loop
test, based on changing only the controller gain, for confirming the presence of stiction.
The method does not require that the loop be put in manual, which can otherwise upset
the plant. The usefulness of this test is demonstrated through simulation studies and an
industrial application.
Keywords: Control loops, Control valves, Dead band, Process control, Nonlinearity,
Static friction.
F E
usually the valve positioner (actual stem position
se
gp
J
data shows a pattern similar to that described in
mo
J
J Figure 1, it can be concluded that this valve has
D
slip jump, J stiction. Unfortunately, most industrial valves
B
A
C (more than 95% cases) are not smart valves
deadband stickband because of the high initial and maintenance costs.
s
The lack of availability of the valve positioner
valve input
data restricts the application of this simple test to
(controller output, op)
only a few cases.
(3) Changes in Controller Gain: This study de-
Fig. 1. Typical input-output behavior of a sticky valve scribes a simple alternative test that can be ap-
plied online without affecting the plant produc-
The phase plot of the input-output behavior of a valve tion significantly. Presence of stiction in a con-
“suffering from stiction” can be described by Figure 1. trol loop produces limit cycle oscillations in the
It consists of four components: dead band, stickband, process output (pv) and the controller output(op).
slip jump and the moving phase. When the valve Changes in controller gain cause changes in am-
comes to rest or changes the direction at point A in plitude and frequency of these limit cycle os-
Figure 1, the valve sticks. After the controller output cillations. Once stiction is detected in a loop,
overcomes the dead band (AB) plus the stickband changes in oscillation frequency due to variation
(BC) of the valve, the valve jumps to a new position in controller gain can help confirm the presence
(point D) and continues to move. Due to nearly of stiction in the loop.
zero velocity, the valve may stick again in between
points D and E in Figure 1, while travelling in the
same direction (EnTech, 1998). In such a case the 4. SIMULATION STUDY
magnitude of dead band is zero and only stickband is
present. This can be overcome if the controller output In this section, the effect of changing controller gain
signal is larger than the stickband only. Once the valve on the behavior of a control loop with sticky valve is
slips, it continues to move until it sticks again (point E shown through simulation examples. Figure 2 shows
in Figure 1). Formally stating, the block diagram of the simulation study. The PI
noise
Composition
sp e PI op Stiction mv pv
Process
+ Controller Model
-
Level
Fig. 2. Block diagram of a simple SISO process with
stiction nonlinearity in the valve
Level
equation:
µ ¶
1
C(s) = Kc 1 + (1)
τi s 0 400 800 1200
Sampling Instant
A two parameter stiction model developed by
(Choudhury et al., 2004a; Choudhury et al., 2004b) Fig. 3. Effect of changing controller gains on the
was used to introduce the stiction behavior of limit cycles generated by a sticky valve. The top
the control valve in the closed loop process. Two plot corresponds to the concentration loop, the
parameter are deadband plus stickband (S) and slip middle plot for the level loop, and the bottom
jump (J)(see figure 1). A 3% stiction (‘S’) with 1% plot for the composite concentration and level
slip jump (‘J’) were used in all simulations. loop. Controller gains were doubled after each
400 samples.
Simulation results are shown in figure 3. For all cases,
the limit cycles were present even though the set point 4.2 A level control loop with a sticky valve
to the loop was zero. That is, they were internally
generated and sustained by the loop in the absence of The transfer function for this level loop was a pure
any external setpoint excitation. integrator in the form of 1s . The middle plot of Figure
3 shows the result of increasing controller, Kc , gain.
Again, the gain of the controller was doubled after 400
samples and it was again doubled after 800 samples.
4.1 A concentration control loop with a sticky valve This plot also shows that an increase in controller gain
for level loop increases the frequency of oscillation but
The transfer function model for this loop was obtained reduces the amplitude of oscillation.
from (Horch and Isaksson, 1998). The process
describes mixing of pulp and water to attain a desired
concentration of pulp at the outlet. The transfer 4.3 Connected concentration and level control loops
function model describes the dynamics of mixing pulp
with water from the inlet of the water flow control This case demonstrates propagation of oscillation(s)
valve to the outlet of the mixing chamber. The transfer from one loop to another. This simulation case
function for the process (G(s)) has been given by: has been formulated by feeding the output of the
3e−10s concentration loop as disturbance to the level control
G(s) = (2) loop. The stiction block from the level control loop
10s + 1
was removed. In reality, it may describe a scenario
where the outlet of a mixing chamber in a composition
The first panel of Figure 3 shows the limit cycles loop is used to feed another processing unit, e.g., a
induced in this control loop by the sticky valve. stock tank, and the level of the tank is controlled
After the first 400 samples, the controller gain, Kc , by another PI controller. The level of the tank
was doubled and it was again multiplied by two may oscillate due to the presence of stiction in the
after 800 samples. Please note that for all cases data concentration loop control valve. This oscillation can
representing transient behavior right after the change be considered as an external oscillatory disturbance
of controller gain has been removed and the steady to the level loop. All stiction detection algorithms
limit cycle oscillations are presented in order to better (Horch, 1999; Rengaswamy et al., 2001; Stenman
visualization of the change of frequency of the limit et al., 2003; Choudhury et al., 2004c) will detect
cycle oscillations. The top plot clearly shows that stiction in both loops because all of the algorithms
with the increase of the gain, both the amplitude and work only on the assumption of single loop basis
frequency of the limit cycle oscillation have increased. and do not consider the interaction among the loops,
especially this kind of propagated oscillation. Now to describing function which depends on the magnitude
differentiate between the loops suffering from stiction of the controller output Xm . When condition (3) is
and the loops oscillating due to propagated oscillatory met, the system will spontaneously oscillate with a
disturbances, the proposed method of controller gain limit cycle. The variation of the quantity −1 /N (Xm )
change can be applied. with signal amplitude implies that signals initially
present in the loop, e.g. noise, can grow until they are
The results for this composite loop are shown in the
big enough to satisfy the equality and hence provide
bottom row of Figure 3. This describes how the level
a self-starting oscillation. The solution to the complex
changes with the changes of the gain of concentration
equation Lo (iω) = −1 /N (Xm ), if one exists, may be
loop controller and level loop controller. After 400
found graphically by superimposing plots of Lo (iω)
samples, the gain of the concentration loop controller
and −1/N on the same set of axes.
was doubled. This increases the frequency of the
oscillation generated in the concentration loop, which
1
in turn increases the frequency of oscillation in the
level control loop. After 800 samples, the gain of 0
the level controller was doubled, but the frequency 1/N curve
imaginary axis
it remained constant. This confirms that this is an J = S/3
external oscillatory disturbance and not generated −2
within the loop. So, the level control valve is not
−3
suffering from stiction.
L (iω)
o
−4 K
Kc3 Kc2 c1
4.4 Conclusion from the simulation study
−5
−1.5 −1 −0.5 0 0.5
real axis
The following conclusions can be drawn from the
simulation study:
Fig. 4. Graphical solutions for limit cycle oscillations
• If a limit cycle oscillation is generated internally in the concentration control loop. Dotted line is
within a loop due to valve stiction, an increase the −1/N curve. The solid line, the dash-dotted
in controller gain will increase the frequency of line and the dashed line are for the frequency
oscillation. response function of the overall process, Lo (iω),
• If a limit oscillation enters in a loop as an where Kc1 < Kc2 < Kc3 .
external disturbance, a change in controller gain
will not change the frequency of oscillation.
• There is no consistency in the change of the 5.1 Expression for describing function
amplitude of limit cycle oscillations with the
change of controller gain. The describing function of a non-linearity is given as:
Yf
N= (4)
X
5. DESCRIBING FUNCTION ANALYSIS where X is a harmonic input to the non-linearity
having angular frequency ωo and Yf is the funda-
In this section, describing function analysis is used
mental Fourier component with angular frequency
to provide a justification for the observed closed loop
ωo of the output from the non-linearity. As shown
behavior due to changes in controller gain.
in (Choudhury et al., 2004b) the describing function
A non-linear actuator with a stiction characteris- for the two parameter stiction model can be repre-
tic may cause limit cycling in a control loop. Fur- sented as:
ther insights into the behavior of such systems may 1
N =− (A − iB) (5)
be achieved through a describing function analy- πXm
sis (Cook, 1986). The non-linearity is modelled by where,
a non-linear gain N . The inherent assumptions of ³π ´
Xm
this approximation are that there are periodic signals A= sin 2φ − 2Xm cos φ − Xm +φ
present in the system and that the controlled system 2 2
acts as a low pass filter and responds principally to + 2 (S − J) cos φ (6)
the fundamental Fourier component. The condition for
Xm Xm
oscillations in a negative feedback loop is that the loop B = −3 + cos 2φ + 2Xm sin φ
gain be −1 or: 2 2
− 2 (S − J) sin φ (7)
1
Lo (iω) = − (3)
N (Xm ) µ ¶
where Lo (iω) = G (iω) C (iω) is the loop gain −1 Xm − S
φ = sin (8)
evaluated at frequency ω, and N (Xm ) is the Xm
Heat
Column 2
Exchanger FC
Chain LC LC LC 3
LC
8 9 10 FC
7
8 TC
FC 2
FC FC 7
5 6
LI
5
LI LI
1 LC 4
LC
3 6
PC LC
FI 1 11
2 LC
2 AC
2 TI
4
PC PC
PC
TC PC 4 5
2
1 3
LC
1 LC
LI
LC 5
LI 3
FI 4
2
1
Compressor
FC SI
AC 1
1
Column 1 2
TI
TI 6
2 FI
4
Fig. 5. Process flow diagram for the industrial process showing the variables oscillating with same time period as
condenser level (LI1). The plant-wide nature of the oscillations should be noted.
loop
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All content following this page was uploaded by Shoukat Choudhury on 04 June 2014.
Date 2005
URL http://hdl.handle.net/10220/6032
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