Stiction Quantification: A Robust Methodology for Valve Monitoring and Maintenance Scheduling

Valve stiction is one of the most common causes of poor performance in control loops. This paper presents a procedure which allows stiction quantification. The technique permits one to estimate the unknown real stem position, and moreover, it does not need any process knowledge and requires only the data normally registered in industrial plants. It is pointed out that the real problem consists of the lack of knowledge about the true value of stiction. A general methodology is proposed to discard data for which quantification is very likely to give wrong indications and to restrict its application to appropriate cases. Simulations show that several sources of perturbations can be eliminated, thus improving the reliability of stiction evaluation. Results are confirmed by application to industrial data: a significant number of valves are analyzed for repeated acquisitions before and after plant shutdown. The proposed procedure seems to be a valid methodology to monitor valve stiction and to schedule and check valve maintenance.