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    control theory

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    PID Tuning Methods

    Загружено:

    mustardbassman
    control theory

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    © All Rights Reserved
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    из 37
    PID Controllers And Their Optimal Adjustment The material which follows describes each of the 3-terms @, I, & D), commonly used in process controllers and provides guidance on their usage. A procedure for tuning 3- term controllers (Ziegler-Nichols “ultimate” method) is also described. Lefto PID CONTROLLERS AND THEIR OPTIMAL ADJUSTMENT. Experience has shown that a high proportion of operating problems on production plants can be obviated by the correct adjustment of the conventional feedback contolers, Maladjustment of control settings can, in extrome cases, causa process instabilty, bu more ofen resuils In sluggish or poor control with consequent drift of process variables, In most cases the efficiency improvement fllowing the optimisation of centoler settings more than adequately repays tha effort involved, and in some cases the results can be spectacular. In this arfcle the function ofthe proportional, integral and derivative actions of a convertional FID contrller are described. An inaicaton Is gien a& to the choles of the various contol actions in different appications and this is folwed by @ deseripon of @ simple and reliable ‘method of agusting contrat for near optimal response on-line INTRODUCTION ‘Although the imperance of the optimal adustment of control loops has been appreciated by ‘contol species for many years it's unfortunate that in ganeral nat enough affor mada by Plant managamant to ensure that the basic feedback contol lonps proved on ther equipment Dlant are working to ther best advantage, Nowadays, more and more sophisticated contol systems are being provided on new and ‘existing plant to increase efficiency. The retun trom these Investments can be very high but it the maximum retum is to be achieved itis very important thatthe basic control structure, thats to say the indivdual feedback loops, be chosen correctly forthe job to be done and adjusted correctly for optimal dynamic response, This is particularly important when the application of distributed Control System (OCS) is contemplated, CONTROL ACTIONS: ‘The base contol actions of feedback contol are desecbed in this section. The plant and controler might be considered as in Fig 4 CEST 6 Fig 1 Diagrammatic representation of fesdback contol fon. 2eft0 1) On - off Control ("Bang Bang" Contral) “The simplest form of conto is known as on-off contol and i the form of control widely used in domesic electric applances where the appliance Is tuned fully on or fly of, There are also ‘more complex systems where a numer of termostats ae used. In a domestic central heating system for example, one thermostat sted in the house might be used fo control the bumer vine a second on the heat exchanger might be used to conto! both the circulation fan and ‘iso the bumer in the event of excessively hich temperatures, Absolutely steady temperatures can never be obtained with on/off contr! because of inherent thermal lage in the system, However, for many applications it Is good enough and it has the dstinet advantage of being relatively Inexpensive Proportional Control (P) Much better control than onoff can be oblained by adjusting the regulated variable Continuously over the range from ful on to ful off In the case of electric heater given sbove this would mean roguiating the heat output ofthe heater to approximate the heat loss from the oom. In this case the regulated variable may be adjusted by an amount proportional ta the difference between the measured temperature end is desired value, Le, he contol eran this cate ‘The contrller output A in response to 2 given emor signal eis then expressed as Asskere whore K is the gsin of the contoller and 6 is the bias at zero error; usually *2mA in an lectronic contrller 2. mid-range. ‘The sign dapends on whether a direct or reverse acting contol is used, Proportional Band (On many contolers, gan is net referred to ciecty, but instead a proportional band adjustment is provides, The relationship ie vary simple, Proportional band in per cent = 100/Gain ‘The proporicnal band may be defined as the change in input signal which would cause the contol valve to stroke fly, expressed as percentage of ful scale cefecton, In this article the term "gain’ and the tem "proportional band” are beth used quite fresly. itis Important that the reader be equally fatiiar with both terms as some instrument manufacturers se the former term while others use the later, ‘The term proportional band width is used for the following reason : consider @ temperature contoler witha full scale span of O to 200°C and assume that fall in temperature opens @ fuel valve and a rise in temperature closes i Further assume that at 1008C (Ihe desired value (©.¥)) the vave is half open. ‘The instrument scale would be as shown in Fig 2. Ifthe proportional bané of this controler is ‘100% (Gain = 1) then when the temperature 19 2009C the fuel valve wil be fully closed and when OC the fuel valve wil be fully open, It 5, however, more than Hkely that in any typical ayo | appfcation full control action (valve fuly open and closed} would be required before these extreme temperatures are reaches, fen Fig2 It-@ proponional band of 20% is used, the region in which full control action is obtained is shown ih Fig 3 Le, 20% of the ful scale. If the desired value is 50°C then the contcl region. ‘over which the valve operates is shown in Fig 4 Figs ow « proportional adjustment of between 0 and 500% is provided on conventional ‘ut, n general, adjustment should be restricted to bstween approximately 10% and 200% because ofthe design ofthe controller. Ifin any application a proportional band outside ‘these limits is incicated, consideration should be given to changing the measurement span. By this metrod the proportional band of the controler may be altered while retaining the same final Ccontoler output respense to a given contal err. For example, it ean be dearly seen from Fig Athat a cnange in measurement span ftom 0 - 200°C to 0 to 100% must be accompanied by = ‘Broportonal Band change from 20% to 40% if the controler is to have the same output response to a given input temperature change. 49f'a offset {A simple proportional contoller has disacvantages in cattain applications. This can be most easiy demonstrated by means ofthe simple level contol system shown in Fig. Fig 5 Simple Level Control System ‘Suppose that withthe tank half fll the valve is half open and as much liqudis being removed as is being added, |e, he system isin state of aquilbrium wih te tank level at is desired value. Suppose now thatthe low rate of quid into the vessel a increased and maintained at the new higher valve. itis obvious that the output contrel valve must permanently assume ‘more open poston if the vessel is not to overtiow eventually, Then, ifthe valve opening Is Proportional tothe liquid level, the level wil be permanently above its previous positon even ‘though the desired value ofthe level has not been altered ‘Although this offet in the measured variable is not usually important in an appication lke the ‘one described, there are applications where itis most important. For exemple, the simple ‘dynamic equations deserting hest flows and temperature in a reactor ara similar to those ‘governing iqud Nlows and level in a buffer vessel, z= Hi-Ho=e at Hest ow C= Mase x epecite heat FI-FO=A dL F=Liquidflow a ea of oss - section Liguid teva Thus 3 temperature controlled reactor with @ proportional only contoller would behave in ‘exactly the same way as a level controled vessel Itis obvious that an increase In temperature due to an increase in hest generated in a reactor ‘could be most undesirable and could lead to a thermal runaway if te resction was exctnermic {and temperature dependent. Consideration of the example (Le, level contro!) above wil shaw that the offset between the measurement and the desired value wit be decreased as the gain ofthe controller is inreased (oroportional band decreased). There is however, an upper mt fo the gain which can be tolerated in any contol loop beyond which instabity wil occur, If offset cannot be reduced Soto suffciently by increasing the controller gain, integral action should be introduced into the ‘conta oop, Integral Action () As described above, proportional nly conto results inthe measured variable being offset from the desired value, flowing a load change. However, ite correction applied 1 the process, in dition to being dependent on the magnitude ofthe error is made éependent on time for which the error exists, then ican easly be seen that iis ill esutin the erfor being reduced. Le conection se errorx time or concn fo a Controllers normally used on chemical plan include proportional action as well as integral and 0 the controller equation becomes Awke+ 4 (Kea 7, Where 6 = ecor ‘On most controllers the amount of integral action is expressed as an integral action timo Ti For example, an integral action time of ten minutes means that the Integral response of the conivoler changes by Ke miflamps fer every tan minutes that a proporional response of Ke ‘exists (Kis tho proportional gain ofthe controler defined as before), LAT and Repeatsiminute (On some controllers the integral action adjustment |s not catbrated dlrecty In integral action time (LAT) But is calbrated in repestsiminute, The reialonship between repealsrminute and UAT is reciprocal Le Repeatsinin le, 10min aT WAT) 0.1 repeats Disadvantages of intogral Action “The introduction of integral action into a conta loop has @ numberof disadvantages. 2 Integral action reduces the stability margin ofthe loop. This means that i will probably be necessary to recuce the contraller gain, The result of his wil be that the controller wil respond more slowly to cisturbances, 1A controler wih integral action can saturate. if the measured value deviates from the desired value the integcal action in the controler wil cause the output sgnal to tise or fal Uni balance is again restored. it may not be possible to restore the balance however. For ‘example, consider a fow contol oop. If the flow i stopped upstream ofthe flow contol, the Control vaive willbe opened to its maximum by the P+ controler in an effort to restore the flow Dut without, of course, being able to de so, Once this state of alas has been established it wil then take tie forthe contraller to respond to @ resumed flow and the controler wil, for a ‘ime, be ineffective while the integral Belows in @ pneumatic controle, or the integral eapactor in an electronic conto, discharges. In fat the integral capacitor wil not begin to dscharge ntl the messured value reaches the set point and an excessively large fow wil result dung this period ‘There are, therefore, imitations inthe applications in which Pal contollere should be used and the likely effects of Saturation should be carefuly considered. Panicular care should be taken with batch processes. Saturation can be best avoided by using a controller which does not include integral action. In applications where ite essential that integral action De Included In contol, various integral Gesaturaton devices afe available which can be attached to te controler i) Iftoo much integral action (1.2. integral action time too short) is used in a particular control loop instability can easly occur. itis no exaggeration to state that in the majoniy of eases where process instabily is caused by maladjustment of he controller. its due to an excess of Imegral action, Derivative Action (0) Derivative action -sometimes called "Preact’s ofen used where, asthe latter name suggests ction is required quicly, to correct an error before it becomes too large, In ths case the correction applied is proportional o the rate of change (or derivative) of the error le, corection « _(eror) at ‘Thus, although the actual magnitude of the eror might be too small to cause proportional or Integral action to take appreciable efoct, the derivative acton couls cause a large correcting signal to be applied. ‘Such contol action is often used In temperature contol systems where there ise large thermal capac ‘The contro function away’ Incuces propestional action and so the contol function becoras= ko Td ake a where Talis called the derivative action ime. Ifthe derivative action tine were § min, a rate of change of err of 0.5mA/rrin would cause a controler output output change of 2.5mAlmin. (K controler gain defined as previcusly) Disaavantages of Lerwative Action [As with integral action an excess of derivative action in any contol logp ean cause instbliy Darivave action is often used to "speed up" the response of a process wih along lag. Ifthe lag is exponential (capacitive) og. a thermal lag, this is legitimate, but i the lag is @ transportation ag - or cstance/velocty lag the derivative action wil not help and it cou, dus to the fact that derivative acion amplties high frequency signals, causa instabily. Tee Discussion Proportional integral and derivative actions ars the tee normally found in conventional single - loop feedback controlers and all three control actions can be used in ary one contol loop. In some applications proportional plus integral contol is used and in ethers proportional pis ‘derivative, In a few simple appieatons proportional only control is sufficient and, i Its. it should be used. In any appiicaton the relative effects of the preporional, Integral and derivative terms can be varied to sut the particular application. In tying to improve the Controtabiliy of a piece of plant it should be remembered that control oops should not be Vreatod in isclation, 2, the results of contro! action in one loop ean have an effect on another. ‘This Is important wnen “tuning” loops but perhaps more important when ‘rying to remove Instablity rem a paricular loop. Care should be tsken to ascertain whether the instability arises within the loop iseif or whether the contol loop ie being forced into what looks lice Instablity by some instabilty or process disturbance elsewhere, CHOICE OF CONTROLLER It is impossible to lay down hard and fast rules ragarding the choice of controler for eny particular applications. itis possible, however, to give general rules which will apaly In most It.should be bore in mind, nowever, thatthe time constants and characterietes of contol loops vary widely and exceptions may 6 found othe folowing rues, Level Controt ‘Most level control aplications are ofthe averaging or lw smoothing type and with his type of ‘conirol It has been shown thatthe best resuts re obtained with proportional only contra. In ‘ddtion, especialy with locally mounted controls, star-up is made easier by avotding Integral Ssturation, Pressure Control Good fast acting pressure contro can usually be obtained with propotonal + integral cont Flow Control Here again, proportional + intearal control should be used: typically a wide propertional band Is used wth a shor integra action time, ‘Temperature contro! ‘his is probably the only common appliestion where a term proportional + integral + derivative contreller may be used with advantage. For most appictions the maximum integral ‘action time shouldbe fay long; at least 20 te 30 mins In some applcations, particulary where the system can tolerate a high loop gain, t may be possible to eliminate the integral acon and use a 2term proportional + derivative contrlle. Beto ADJUSTING THE CONTROLLER ‘Adjusting the values of controler gain, integral acton time and dervatve action time, by tal {and error methods in an attempt to find the optimal seting for a paricular system, can be very time consuming and usualy results in much pocrer control than can be achieved by sating up the controller accorsing to the simple rules given in this section, Many methods of adjusting controllers for optimal responce are available in the Iteratura but the metnod of Ziegler and Nichols for the cosed loop described here has the advantage of being simpler to apply on operating plant and i usually resus In a response which is Taily cose to tho optimal. Many other methods depend on finding a point of iiexion In the response of a system on open leep contra. Unfortunately such methods, athough theoretically they may give very good predictions of optimal controller settings, are extremely dffiult to _=ppiy in practice, particulary with a noisy signal ora process subject to random disturbances. In such circumstances itis impossible to locate the point of ifexion of the open loop response with any degree of certainty but is retatvely easy even under such creumstances to decide vinon the systam is exhining sustained oscation Values close to the optimum can be obtained quite easily by testing the closed loop system with erly proportional actonin the controller, The procedure is as follows: 2) Set the integral ime to maxémum and the derivative time to minimum, ') Obiain the response of the system to a step change in setpoint for various gains settings. Increase the gain setting until continuous eyeing of constant amplitude Kmax. The period of cyeling at the maximum gain is ealac the "uimate” period Pu, Depending on the type of controler being used, the controller, gain Ke, integral ima TI and ‘erivative time Td should be adjusted as below: Proportional Contat Ke= 05 Kmax Proportional + Integral Contal Ke= 0.45 Kmax We Pun2 Proportional + Integral + Derivative Cantrol Ke= 0.8 Kmax T= Pua T= Pus, Note: that f Pus very small it may be found that Pu/8eTd min, In this case a P+ | controllers indicated Proportional + Derivative Control In some appicstons a P+ D controler may be desirable eter because he Ti indicated above is greater than can bo obtained on valle inure, orto avoid satratlon eects In these cases ts ocommended fot he adjusrnom has ghen forthe Storm conroler Be apple aug tay practic be found possible to operate wth Ke>0.8 Kx I¢fio a piscussion “The controlar settings given above have been foun, for a variety of processes, to glve an accoptable response to cisturbances with a period af cacilation coe to the ultmate period and {a reasonable overshoot or peak error. The atractin ofthe method ists simply, the relative speed with which acceptable settings can be predicted and is application to most processes. If application ofthe given method resuits in inadequate corto), the reader would be well advised ta seek the assistance of a contol paca, AVERAGING LEVEL CONTROL (FLOW SMOOTHING) ‘There fs one common contol application where the above method of controller adjustmant is ‘ot to be used, thet isn averaging level control where the level convoied vessel is used a & buffer capacty and tnere is na need to hold the level precisely atthe desired value, Rather, the love tower fo vay (Song as tha vessel never Smpies or overiows) and he result that the controlled output flow i smoother than the input fow. In this case a proportional only controller should be used withthe band seting of approximately 100%, PID Tuning Worked Example Tuning Example The enpertre conor 9 the hot svar beater stowa in Figure 216 wil be wed state {be lime leeonp ning meted. Te si fe tunog proses to determine the coro aor poe onal and which wold cane suraines sntampened tllion (FE) an o messi te carespening peed of (Slaton called the uate pea (Puy The sep in it ‘unig sequence arses 1 Switch he temperate conor (TC) om manual se ‘opt otha he valve coe, 2. Setll ecole dyna ver In ter wor the Integral infinite (or sani) mates pr repel ‘aro (x minim eepents per mine ad Set devatve (© 20 (oe ais) mia. 2 Beng te bot water beter ap w i somal Ios by Iecesieg be water ow thocgh co the feel whieh key wm be the piel demand fr Ro wate +, Woo ie emperatie console TIC) in tase. ane aly ineeare the seam fow roe ntl the eons ‘avale (= T,) Hest the desired setpoint 5, Sette gino proparonal ban at some bia value rearthe espace vatiog own) crt = (PB = 1008) if ao bene nfrmason i avalible 6. Switch he coal to ttemate and let it sbliae Ding stpoine ce the epee on spit dab, inves an upset Thesleplesc wy fcing ttaistomove the epeinsupordown asafe amet or example move by 10 degrees fora half mint) ae then rem te serie ro ts ogi vale 7. The fs il be an ups in he ot water empertce ssemblng the chastise of cave A, Boe Ch gure L2le te vesponse s enpenc (uve A) the gin or operon sting made tp $ ws 00 Nek (ropartomal aow invent, the reponse ‘amped (curve C). he gain (or propionl seting Inne instep 3 was too low (ropornal wie), Thee fore, if he vespone eens care A he conals fini nresrds i reembes cure Che gain Fedaced, and the tis repeated om 3 5 1, Afer one or more train the sat of rind, on armpened ciation wl be cained (eure B), and he Timi cee) Al ict reine eo rsd the propoiorl td which cated ie sane owlaen, we called he "ultimate roprionl nd” (PB) snd mes Sure the ulema pened of xilson (shown gues [2c and (218 9, Once the vals of PBa a Pu re known coe might use toe recommendations of Zialee Nichol (given bei", eae + tt yo 4 i's uthndte sen or osckatTion Maroon of eng the PID coat of ha water hee PID Tuning Worked Example (Continued) “Tose te nina gin and the uit period to cbain ‘xs f the proportional conor te decay ratio vs. gan {the confer expres a aacdon of be ate gin for sever systems From te rete they cole tat ¢ ‘aloe o ginal 0 etal theta pie woul of ve cay rao fe = 05K, 65 2004) ‘By ansogou easning an esting the folowing equations ‘sre found to ive eesenably good sings for noite ‘acting two of te node canals: Prperiontuseet ln Kena, B=22m ( Tema Paperiet losdevnive pore) oF tana “Taos made (roprtona pie pardecvaie K=06k, = 148rBe Tost, sno ‘Aztinit soul be ete the shove eqution are epi ‘alan excepts sbound, “Thee ae fe exept © ing pocede de served here. tees it some cases deening te qa Inaes te proces ore usable In hese caste tate math wil ot ve god stings say nese tts pe the stm abe gh sd ow valet of {sin ut enue a intensive. Th te {infor stensof tis ope tas aaa mening Tee the ulate method forth ees, he lower vate ofthe tate gin suse “The min advange of else oop ting meted hai iaes nt evn te ane of al sy ne and href vest eit a te ad were the ests pafoned. Ate abvasag hatte readings ‘of Fu and Pu we wake dh perio elton ema be acral seen fhe mesic! is sy. Toe Aisadvanages of the cotscop tng method et at ‘tes tening uinown proces tbe spo of toe hnpene osclatons eam become exeesive (una) and thatthe test ke ong perform, One ea se Oat oa it can tke «log time efre sate of ssn, sndampeced osclion shiv teough sa nd tor ecnigue Forth ests, eer tng tehnigoes ‘ave also been developed, ome of whieh ae desbed teow amped Osctaion Metiag 4 sign modifeiog of the pevious procedre hae been Proposed by Haron. Fer max procese sot fee 0 flow sustained guia and thts the uli sweod cant be we, In this mocfeton a he te ‘eho the gain (woperienal cool oa) ir ade. Using eps aogour o hoe wed inulin metod, Uni a esponse curve with» day rao ef Ys obtained However, wi thls uoiag meted. is necesito pte ‘onthe peog Pf the reponse, Wit this valee Phe integral ad decvative modes are oet for 8 onitring ‘onl a Tro reps Afr tes modes ae st thesensvy i agnnasted ntl a espns cv witha dey rai of oben This meiod estat regres wow the same amount of work te ulate mets, snc olen mses) fo ‘eine ae een sy Tn gene thre re twp obvious esvannges to hse retods. rst, both a eerily tl abd em, set ‘Svea valoes of gain tbe teed before the ule tno th gui ive decay rao deemed. To ‘ake ont expecially a vales nar be Jase gait ‘fe acer wa rhe compen of several ol. ‘ons before sean be determined ifthe nl vale of gus te dese one. Senna wl oe log being tee in ‘his manoe ts ctr may afc sever her fog tes possibly upseting an ene unit Wale ll unas methods ‘aur that some changes be madein he orl oop, ther ‘echnigues eqose ony ane tx and no severe ain he lose oop etna. PROCESS REACTION CURVE ‘Wea he seuy te of proces wpe by astep change ince os np (loa arabe) he esuing repose fn Ssbaped facvon cure, seh a te one shove io Figure.) Most of thas reaction ces canbe spon sme ty & ded ine and te ens nd thee pero ‘mations can be sed to mae the anal whic controls that proces. Mos presses in this univer spond wih ‘Sh Shaped react caves, nat ny indus! procesrer. For exampl, the glotl economy sponds to a change in ‘he cost of ney othe weather eons a change a "actor dowide costo the smasher I hi sn 8) the reaction curve ae te dend ine (Lor, ad the ine ‘onst (7 Kaowing these parameters of scones process St ‘seal fer owing hom to cml asa ine roses ‘F lobal economy the dead ine of ponding oa esa inthe eos of i canbe 6 months za the ine const hat proces can be 210 3 yeas andthe wild ade ut ‘ndetsand tat reaionship in ode to make Si come Son effcsive ap instal sone mas also Hom te peso froze before can coal hat prose, ‘Thedead ee ofthe res he ime ped afer 0 ope PID Tuning Worked Example (Continued) oe ri ; S| ee fo FG. 1.4) Response of processes with several equal tine consiams in We constan cH) Z 2 80re = nescnOn are = EFFECTIVE Beso Tm FG. 1.10 Process reaction or response curve, showing both deud-time ad sine-constant ‘oa change) tng which contol vada note ‘xgendieg. The tne contre the tne pexod between the 8 espn ese ete a heme et hs seacted 6325 of is fal pew sense) value X-L00P TUNE ‘sing the ot water hese example in Figue 121d ig ‘rout cnt ofthe flowing sp 1, Swen he emperae contr (TIC) on ans and cir opt 20 ta th ave i honed. Nove ha it ‘ohingtesbrigue doer So te the cones nd ‘aloes ony the dys ofthe proces. Threlors, fone ould fave a sbemoneter Ibe bot waler ne ‘stead of te TC 2 Bang te hot water eater up wis somal load by ‘eeesing the water dow Ovough te eel whic aly ete he ypc mand for box wu mos be 3. Wi he emer comer (TIC) in anil, mana sly ioent he near Bow cate ol the cond arable ie oie ot water tempers [TD se © (be ese somal vale 4. Once me out epee Mas sbied a ts oe ‘ah ivodves tn pac The peat way of sing at 16m ioduce «sep change in he sem Now foe eater by manaly changing the conzl valve opening wp of down. Inthe expe sed in Figure U2. the ‘ho valve opsning a enanged ty 10% (rom 208 0 cos) 5, Reveal of he outdid sep cage, be PID Tuning Worked Example (Continued) proses wll espond by caving ot Shaped “rescon Sore” which eves i pero" eluasns ‘heretpone core one et to deemioe he ded ie (Us the reac eare Ry) of he proces, 6. I 2iegler Nicol eecrnendaons ae 1 be followed. ‘ne weld obtain the das in Figure (2te by dang 2 "ange though tein pn of te reacton cure {bd idenying te time beoven erection wih he Previous seat vale andthe ine when te sep Shane as iodide be ced ime (L) Net one ‘onl determin he slope of his gent the reaction ‘he, R) oy ding the Snount of eager He ‘elie to the previous neds (Al bythe Une Be ‘ween he tangent incon athe ive corespoed- Ing the infection pin (One he aes of Land Rem AB fave been serie, ey can be pugeee Ino beequaton atlaed tte Beer of Figure 2le {o obiain the recommended toning setings for ronnterarng P,P. a PID cons Shey 'secomendaions ae tobe followed, one Stoner the de time (T= L) Net aoe won eerie te ime woud ake) have he emgerae (are oe y she same percentage was he sepebange | the manipulated variate (Am). Once tbe valtes of, nc x have been determined hey an be plgged it ot ‘qutlonsrabulstes atthe Soto of Figure 1.216 ‘bain the fecommensed tuning stings fOr non Unracting B, PL and ID cool. ‘The advances of his tanigtechigu. eave fo he cleeslonp one inclu is spend: one does no need 0 wat fog several penis of ostlaion during several ian PID Tuning Worked Example (Continued) wee aE, = RECOMMENDED REGLER WesIL8 SETH NOH HERACTING) ACTION RATE = Bem neon sermnes, gene Behe rroronrona. | aufGRESRNs) | octwaTwe PROPORTIONAL Ain = = FIG. 1.216 Open-toop tuning of the TIC on the ho water heater in Figure 1.2, using the Ziegler-Nichols recommendations for ‘ung @ noniareracting controller Optimum Settings for Automatic Controllers (Ziegler & Nichols Method) The wisdom, in respect of the tuning of automatic controllers for the process industries, has not really changed in over fifty years. Here is the original paper by J. G. Ziegler and N. B. Nichols of 1942. eee Test0aicg lise 1 Technical Data — In this paper, she three principal contol clfcts found fa prexeoe somtroliers ate examined and prsetieal nance and oni Sf mes sstement ce proposed for exch etfece. Conetpeadiog, voles ste proposed fora classification of indusuiat rocetion ie {emma of the so principal chaacisitice affectiog thats oa llabitity. Foomlns ie piven which enable rhe. consceliey esings 10 be deteimiand [ou she caperimental or calevinced sleet ihe ts fe nf the process to $e Eentzoiled. Then ner ferm she taste of a gulel aos foe ' Ssdivecing a concinlle on the jab, The wlfcct of ferping seek oneoller setting ia shan In'a setivs af than wectiee Ieee lelieved thar aie conceptions wf sant presence fe ths pope I be of aasiscance in of exiing constoice pplication aad in the desigs A purely mathematical approach to the stucy af automatic contvel is certainly the most Vesirable course trom a stondpaint of accuracy and brevitn, Uae forunately, however, the mathematic; uf eentrol involves such a bewildering ‘astortment of exponential and trigonometric functions that the average anginece, cannot afford the time necessary to plow trough them to a delecion ot h current problem. fon of the three principal It is the purpose of this paper to exzcine the act sign practical values co control effects found in present-day inetrumente gach effsct, see what adjustment of ench does to the final control, and give o method for exriving quickly at the optimum sctlings ef cach suvirel eitect ‘Thepaper will thas first endeavor to answer the question: "ow ean the proper gontzolier adjustments bn quicily devsrunined on any control epoiieeeee st After that a new method will be prossated which maves possibie ¢ reasonably accurate auswer to the question: "How ean the sewing of a conteciley bede terinined botore it is installed on en enizting sopleation?™ Except (or a singie lussrative example, no attempt will be made io present 'y and field data, to develop mathematica! relations, or to mobo of material rom published litoratare. A paper covering the ‘mathe! derivations would be quite lengthy uz would alee & pepur covers ing laboratory and field-test reuults. Work on these phases f the subject 1s still under way, and it is expected thet the results will Le published at ¢ lace PRES Pew ea Ae ee ee eae EE time when convenient. It fa beliaved advtaahle te publish the precont paper without delay in order to make the information available for wse by the many persons interested in the application of automatic-control instruments. ‘To these persons the present subject matier is of much greater interest than the other phases of the study which are being omiited, To simplify terminology we will take the most common type of control circult in which a controller int»rprets the movement of ies recording pen into a need for corrective action, and, by varying ite output air pressure, repositions a Aiaphragm-operated valve, The controller may be measuring temperature, pressure, level, or any other variable, but wa will completely diveres the measurement portion of the control circuit and speak only of the pea move= ment in inches; 1 in, of pen movement might xepresent 1 or 1000 deg F, oF a flow of 1 or 1000 gpm, ‘The actual graduation will be of ao moment ina study of contyol, ‘Our controller will translate pen behavior into behavior of avaives the velation between the two behavior patterns is determaned by the setting of each control effect, The termvalve cavers any similer device, i.e., a'damnper oF Theostat which must be operated by the controller in order tomsintain correct process conditions. PROPORTIONAL RESPON In spite of the multitude of siz, liquid, and alectvically operated controllers fon the market, all are similar in that they ineerporate ane, two, vr at most three quite simple controleffects, These three can be called "proportional, “automatic raset, "and Mpresact, " Proportional Response, By far the most common effect is “proportional re Sponse, "found in practically ailcoatrollers, It givasa valve movercnt pro pertinasl to the pen movement, that {s, 2 2-degras pea movernent gives twice AS much valve movement as a I-dagree pen movement, Simple spring-loaded bressure-reducing valves are really propoxtional~sesponse controllers #n that, over a short range of pressure, the valve is moved proportionally from one extreme £0 the other. sitivity. ‘The measure cf proportional rexponse ts called "sousitivity or ottling vange:""the former being valve movement per pon movement, the latter its reciprocal or the pex movement ancessary to give full valve moves mont, Either sensitivity or theotiling range describes the magnitude of prow portional response, though in this paper each response will be measured in units which increase as the relative valve action per pen action increasna In the case of proportional response, the unit will accordingly be called "sene sitivity," Proportional~zesponse sensitivity in seme controllers is not adjustable: in most, however, it may be adjusted oither continuously or in siups over a cone siderable range. If we define sensitivity as the output pressure change per tach of pen travel, it is apparent that the limits would be {rom zero (manval control) to infinitely higis (on~oif control), Perhaps the widest range of ad~ Justinent is foundin one controller with sensitivity continuously vaviable from 1000 to 1 pai per in, A sensitivity of 1000 gives 1 pat output change for each 0,001 in, of pen travel. pose 2 Sensitivity adjustment ie necessary if optimum contral stability is to be ate tained, IL {5 common knowledge that control with infinitely high proportional responce is always unstable, oscillating continuously. ‘True, on certain ap= the oscillation may be of such emall magnitude that it is not ob= je and, if the surges in supplyare not serious intheir eifecton other portions af the process, the contral obtained may be entirely acceptable, Industry generally demands control of the "throttling" type rather than "on-off" since 2 propoxtional-response contrellor set in any sonritivity below some maximum, will produce a damped oscillation and eventually straight-line con- trol. Amplitude Ratio, Sensitivity adjustment affects primarily the stability of con rol, On any application there i adefinite and easily determined point called the “ultimate sensitivity" (S,), above which any oscillation will inerezse to some maximum amplitude, and delew which on oscillation of any size wilk diminish to straioht-line control, Stability may be measured in terms of ‘amaplitude vatio, " the relative amplitude of any wave to that of the wave which precede it, A controller set at the ultimate sensitivity gives an oscillation with an amplitude ratio of 1} above the aliimate sensitivity, an aniplitude greater than 1; and below the ultimate, an amplitude ratio less than Amplitude Ratio Versus Sensitivity. Fig. 1 shows the elfoct of sensitivity adjustment on a typical application, The oecillation war started by & mozaentary change invalve position, Curves (0) and (6) were produced the ultimate sensitivity, which inthis case was 10 poi per ia. Curve (3) was produced at 3 concitivity of 11 psi per ts, (110 per cent af S,). Curves (a) to {2 show the success ively smaller amplitsde ratios pro- duced as the sensitivity was lowered to 90, 89, 50, 20, and 10 percent of the ultimate (2, 6, 5, 2, and 1 pei per ine Jn Pig. Land succeeding charts, each divisionis 0.1 in, and each time in terval represents 0,625 min, Rogardiess of the ultimate sensitivity of any control application, the rela~ tionship between amplitude ratio and. ™ sensitivity, given se per cent of alti= mist sensitivity, remains about 22 eras Shown in Fig. 2.) The ultimats see tivity thes appeaze to bee #00 ‘common point for consideration of Site sensitivity adjustment on most con= trol applications, poae 3 C Ht rape me Offset and Load Change, 1, the Th congidering the curves of Fig. 1, most desirable setting from 2 stability standpoint would be (h), produced at quite # low sensitivity (10 per cent nf ultimate), 1 should be noted in passing, however, ‘that as sensitivity is reduced the period of oscillation inereases slightly, which in itself is undesizable, Tha real draw back of using sensitivity settings a great deal lower than the ultimate valve stems from the limitation of proportional ze- sponse, e.g. that only one valve position cam bs maintained when the pon is at the desired set point, A “load change", and Gistusbance in the process requiring a sustained alteration of valve position, will cause the pon to shift awayfzom the point fav enough to give the required valve movement. ‘The magnitude of this shift cr "offset!" varies invareely with the sen yy setting used directly with the required change in valve position, Fig. 3 curves (a) to (ej, illurtrates Bais point, Curye (a) shows the offect caused Ly aload change requiring 2 2.3 pai change in output pressure with sensitivity at 10 psi per im. Since this the ultimate setting, an amplitude ratio of 1 results and a lowar setting is indicated. As the sensitivity is decreased tu 9, 8, 5, and then 2 psi per in., the offset from this load change increases ani the amplitude ratio decreases, Amplitude Ratio Versus Offset, The rational adjustment of proportional-re- ‘Sponce sensitiviiy is then slinply « matter nf halancing tha two avile of eifoct and amplitude ratio, Fox most applications a good compromise is the sens sitivity which gives an amplitude ratio of 25 per cent, This seneitivity will bo very nearly one half that of the ultimate sensitivity, aa shown in Fig. 2. ‘An oxcellent and rapld method of sensitivity adjustment is tofind the ultimate sensitivity and then simply cut it i balé. Fig. 1, curve (f), shows that an amplitude ratio of 25 per cent is achieved by this getting on the application undor test, Tig. 3, curve (d), vhows the result of a load change requiring 82,8 psi chaugs in controller output predsure, ‘The sensitivity setting of 3 Psi per in, allows an offset of 2.8/5 or 0.56 in, with a 25 per cent amplitude ratio. age 4 On most aiz-oporated contvollers, the sensitivity adjustment is calibrated either in terms of sensitivity or thvottling zango, On auch instruments the trick of halving the sensitivity to obtain 2 good setting is quite simple; on those ‘calibrated in throttling range the setting should be doubled, since this unit is the reciprocal of sensitivity, ‘The sensitivity of older inftrements with ar- bitvary adjustment scales may be casily found by moving the pen e detinite Gistance and noting the roeulting ovtput-pressure change, This teet run at a few points will enable the user to plot a sensitivily-conversion scale, ‘The etstement that a sensitivity setting of one half theultimate with attendant 25 per cent amplitude ratio gives optimum control must be modified in some cases, At times a lower sonsitivity is preferable. For example, the actual level maintained by a liquid-level controller mightnot be neasly aa important as the effect of sudden valve movements or further portions of the proccss. Jp this cose the sensitivity should be lowered to reduce the amplitude

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