In a recent plant turnaround, our instrument people replaced an old flow control globe valve. It was originally installed in early 80's where the actuator functions through an I/P converter. Apparently, the new globe valve was installed and fitted with the old actuator together with the I/P converter. When it comes to start up, it was found that the valve is not able to close despite sending direct output signal from the DCS. This is because the new control valve high DP pushes it upward against the supply pressure from instrument air. (Note that it is a failed open control valve).
The instrument later fitted the control valve with a positioner which then enable the valve to travel from open to fully close position.
However, the flow control was quite poor where it oscillates (approx 1 m3/hr) around the setpoint. Initially, I placed the old tuning value to this controller and it resulted in heavy oscillation which indicates that the valve performance is no more the same as before. After all, it is a new valve and it's characteristic is already different though they both are an equal-percentage valve.
Despite executing close loop response tuning, I still could not bring the performance equal to the old valve. In fact, with Proportional Band of 330% and Integral time of 500, it is impossible to put the controller in auto as it oscillate the flow heavily. Note that the DCS is Yokogawa Centum.
I did an open loop step response (1%) and to my amazement, the flow responded rapidly with an overshoot. In stepping up (open), there was 2 to 3 overshoots while 1 to 2 overshoots when stepping down before the flow settle to a new value.
What can we say about this valve?