Chapter 10Control Loop Troubleshooting.PPT

Chapter 10Control Loop Troubleshooting Overall Course Objectives Develop the skills necessary to function as an industrial process control engineer. Skills Tuning loops Control loop design Control loop troubleshooting Command of the terminology Fundamental understanding Process dynamics Feedback control Objectives for Control Loop Troubleshooting Be able to implement an overall troubleshooting methodology Be able to determine whether or not the actuator, process, sensor, and controller are functioning properly. Recall the major failure modes for each of the elements of a control loop. Troubleshooting Loops in the CPI Control Diagram of a Typical Control Loop Components and Signals of a Typical Control Loop What is Control Loop Troubleshooting? Control loop is suspected of not functioning properly. Poor overall control performance Erratic behavior Control loop was removed from service. Identify the source of the problem. Correct the problem. Retune the controller and monitor. Overall Approach to Troubleshooting Control Loops Check subsystem separately. Actuator system Controller Sensor Process Then check performance of the entire control loop What’s been changed lately? Checking the Actuator System Apply block sine wave input changes to the setpoint for the flow controller. Determine the deadband of the flow control loop from a block sine wave test. Also, estimate the time constant for the flow control loop from the block sine wave test. If the time constant is less than 2 seconds and the deadband is less than 0.5%, there is no need to evaluate the actuator system further Block Sine Wave Test Common Problems with the Actuator System Excessive valve deadband Improperly sized control valve Valve packing is tightened too much Improperly tuned valve positioner Check the Sensor System Evaluate the repeatability of the sensor during steady-state operation. Evaluate the sensor dynamics. This may require an independent measurement of the controlled variable. Or check the