Diagnosis of Stiction-Related Actuator Problems

Control valves are the most commonly used actuators or final control elements in the process industries. Many surveys indicate that about 20–30 % of all control loops oscillate due to valve problems caused by valve nonlinearities, such as stiction, hysteresis, dead-band or dead-zone. Many control loops in process plants perform poorly due to valve static friction (stiction) as one of the most common equipment problems. Valve stiction in control loops causes oscillations in form of limit cycles. This phenomenon increases variability in product quality, accelerates equipment wear, or leads to control system instability. This chapter is devoted to the illustration of the actuator stiction effect on control-loop performance and to a review of the most important techniques for automatic stiction detection, to be incorporated in performance monitoring. A basic oscillation diagnosis procedure is then proposed.

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