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Home eLearning Tutorials Process Control Tuning Guidelines

Tuning Guidelines
Calculating controller tuning values requires knowing considerable information about the algorithm used
by the controller.

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There are essentially three types of algorithms in use: ideal, parallel and series. Ideal algorithms are
generally found only in textbooks. Parallel control algorithms have three independent (parallel)
calculations for Proportional (Gain), Integral, and Derivative. An advantage of parallel calculation
construction is changes in the values to one do not affect the other two. A disadvantage is they are
difficult to manually tune. Series control algorithms are constructed so the output of one calculation is
part of the input to the next calculation, thus "upstream" calculation changes affect "downstream"
calculations. This is frequently referred to as controller tuning interaction. Series control algorithms are
the most common used in analog and digital controllers.

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Proportional term definition

Proportional Band % = 100/Propotional Gain

Proportional Band
(Proportional Gain)

Gain

1%

100.0

10%

10.0

50%

2.0

100%

1.0

500%

0.2

1,000%

0.1

Comparison of units used for controller integral settings

Seconds per
repeat

Repeats per
second

Minutes per
repeat

Repeats per
minute

1.00

0.0167

60.0

0.20

0.0833

12.0

10

0.10

0.1667

6.0

60

0.0166

1.0

1.0

120

0.0083

2.0

0.5

240

0.00417

4.0

0.25

480

0.00208

8.0

0.125

1,000

0.0010

16.6667

0.06

PID controllers operate on an error feedback where the output is normally characterized when there is a
difference between the PV and SP. However, it is not always advantageous for a controller to operate on
an error signal. It is common practice to allow a controller to respond differently to SP changes verses
load (PV) changes. It is important to understand which algorithm variables will be affected when the SP
is changed versus when the PV is changed. Continuous processes normally have PV load changes,
while batch processes tend to have more SP changes. Depending on how the controller is being used,
how the algorithm reacts to SP and PV changes, and how tuning constants are determined/calculated, it
is possible to have a controller perform better one way than another.

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Technical libraries contain volumes on various ways to calculate controller-tuning values. One of the
most efficient and consistent ways to collect and analyze process data is to use software from
companies. Also, most control system manufacturers offer a variety of control loop analysis and tuning
software. When software isn?t available, some useful guidelines can be applied.
Ultimate Sensitivity Method

The goal is to achieve a marginally stable controller response

(see marginally stable response chart)
Closed Loop (Loop in Automatic)

Test 1

1. Choose any GAIN setting. Place INTEGRAL at maximum time (smallest

value) and place DERIVATIVE at minimum value or turn it completely off.
2. Make a 10% change in SETPOINT (SP).
3. Record the PROCESS VARIABLE (PV) and CONTROLLER OUTPUT (CO)
responses. (If process becomes unstable, place the loop in MANUAL and do
what is needed to maintain control.)
4. If recorded response produces a stable (lagging) response, proceed to Test
2.
5. If recorded response produces an unstable (leading) response, proceed to
Test 3.

Test 2

1. Double the GAIN setting (Leave INTEGRAL and DERIVATIVE the same as
Test 1).
2. Make a 10% change in SP.
3. Record the PV and CO responses. (If process becomes unstable, place the
loop in MANUAL and do what is needed to maintain control.)
4. If recorded response produces a stable (lagging) response, repeat Test 2.
5. If recorded response produces an unstable (leading) response, proceed to
Test 3.

Test 3

1. Half the GAIN setting (Leave INTEGRAL and DERIVATIVE the same as Test
1 and 2).
2. Make a 10% change in SP.
3. Record the PV and CO responses. (If process becomes unstable, place the
loop in MANUAL and do what is needed to maintain control.)
4. If recorded response produces a stable (lagging) response, proceed to Test
2.
5. If recorded response produces an unstable (leading) response, repeat Test 3.

Repeat testing until a marginally stable response has been recorded.

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Once a marginally stable response is obtained, all the information necessary to calculate usable controller tuning constants is
available. The following table provides guidelines useful in determining usable tuning constants for P (proportional), PI (proportional
and integral), and PID (proportional, integral, and derivative) controllers.

Determining ?usable? controller settings

Controller assumptions:
z
z
z
z

Controller algorithm is series.

Proportional (P) is entered as gain (not proportional band).
Integral (I) is in minutes per repeat (not repeats per minute).
Derivative (D) is in minutes.

Proportional (P)
only controller

Multiply the ultimate gain setting in the controller by 0.56.

The result will provide automatic control but may create a PV to
SP offset. To eliminate/reduce the offset, introduce INTEGRAL (I).

Proportional and
Integral (PI)
controller

1. Multiply the ultimate gain setting in the controller by 0.45.

2. Multiply the ultimate period by 0.83.

Proportional,
Integral, and
Derivative (PID)
controller

1. Multiply the ultimate gain setting in the controller by 0.67.

2. Multiply the ultimate period by 0.50.
3. Multiply the "ultimate period by 0.125.

Repeats

A calculation of (Proportional GAIN * OFFSET).

Repeats per
minute

How many times will the controller perform the (Proportional GAIN
* OFFSET) calculation in one minute?

Minutes per repeat

How much time, in minutes, does it take the controller to perform 1

(Proportional GAIN * OFFSET) calculation?

Derivative (D)
Cautions

Derivative action is applied only one time when the PV moves

away from SP.
Derivative works on rate-of-change. If the PV rate-of-change is
caused by "noise," derivative may cause over-correction. Never
use derivative on a process with a noiseband greater than 0.25%.
Control loops likely to have significant noise are pressure and
flow. Level can also be noisy when stirred/agitated or splashing
can/is occurring.

Reaction curve (open loop) method

Many people become very nervous when a controller is placed in automatic with tuning constants that
produce cyclic, on the brink of out-of-control response. For these nervous types, a method known as
open loop (loop in manual) reaction curve testing may be less stressful.
The philosophy of open loop testing is to begin with a steady-state process, make a step change to the
final control element and record the results of the PV. Information produced by the open-loop test is the
loop deadtime and the loop time constant. Users must be accurate in determining times for T2, the point
where the PV first begins to move, and T3, the point where the PV attains 63.2% of the total PV change.
Following an open-loop test the recorded information should closely resemble the Open Loop Test
Results diagram below.

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A side benefit to conducting and recording the open-loop test is the establishment of a loop signature for future reference in
determining if the process has changed. For example, if the loop signature is for a temperature controller on a heat exchanger, a
significant change in the loop signature could indicate the heat exchanger is losing efficiency.
Using the results of the open-loop test to calculate controller-tuning constants requires dividing the percentage change in PV by the
percentage change in CO to obtain an open-loop gain. The open-loop gain (OLG) and control loops inherent gain (IG) are used in
the formula (OLG * P(gain) = IG). With terms rearranged, the formula becomes IG divided by OLG = P(gain).
Consider the following guidelines when calculating controller-tuning constants:

If a control loop has an inherent gain of one,

and the open-loop gain is four;

Then the proportional gain required for the

controller is one divided by four or 0.25.
(Place 0.25 in P constant of the controller.)

RULE #1: If loop dead time is less than or

equal to the loop time constant;

Then open-loop gain times process gain

equals one.

COROLLARY #1: If loop dead time is

approximately the loop time constant;

Then open-loop gain times process gain

equals 0.5

COROLLARY #2: If loop dead time is

greater than or equal to the loop time
constant;

Then open-loop gain times process gain

equals 0.25.

NOTE: Controller scan times should be at least eight times faster than
the loop time constant.
RULE #2: Integral time (IT) should be equal IT = LTC when LTC is in repeats per minute.
to loop time constant (LTC).
RULE#3: Derivative time should be less
than or equal to of LTC.
Integrating processes
Integrating processes are those for which only one CO setting in manual mode produces a stable
(balanced) PV. Level, batch temperature, batch pressure, and pH tanks are examples of integrating
processes. Expanding on the level example, with the control loop in manual, only one CO setting allows
the amount of liquid entering a vessel to exactly equal the amount of liquid leaving the vessel. Any other
CO setting will cause the level PV to integrate upward or downward.
Gathering data for integrating processes is best accomplished using an open loop test.

1.
2.
3.
4.
5.

Find the balance point where vessel/process input is equal to vessel/process output.
Make a 10% to 20% change in the CO setting.
After the PV has integrated 3% to 5% change the CO output back the balance point value.
Repeat step two in the opposite direction.
Repeat step three.

The reason to conduct the test in both directions is that some loops (i.e., heating and cooling) will likely
produce a different slope for each direction. When this is the case, the less aggressive slope should be
used to determine controller-tuning constants to prevent loop instability. When unexpected graphs are
produced, likely causes are stiction or backlash in the control valve. Trying to tune such loops is nearly
impossible because the controller is attempting to overcome mechanical defects that likely will become
worse with time.

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Integrating processes usually produce the best overall results with medium response tuning constants that allow some overshoot.
Use caution when applying derivative to integrating processes. If "excessive" hysteresis is found in a control valve, use only slow PI
tuning constants.

Controller tuning constants for integrating processes should utilize high gain and slow integral (small
repeats per minute).
Cascade control loops
Cascade control loops are effective when trying to maintain tight control over slow moving variables. For
example, boiler level can be tightly maintained using a level controller cascaded to a flow controller.

To have an effective cascade control strategy the dynamics of the secondary loop must be at least five times faster than the
primary loop. (Dynamics are defined as loop dead time multiplied by loop time constant.)
To tune a cascade control loop:

1.
2.
3.
4.

Place secondary loop in automatic (disconnect the secondary loop from the primary loop).
Conduct test and tune secondary loop.
Place secondary loop in Remote SP (connect secondary and primary loop).
Conduct test and tune primary loop.

Note: Ensure secondary loop does not have setpoint limits or unnecessary assigned alarms.
When embarking on a journey to tune all loops in a process, work from the raw material end to the final product end beginning with
flows, then pressures, followed by levels, then temperatures, and finally what remains.

Contrary to popular belief, control loop tuning is a science. But it begins with analysis of each component
in the loop to ensure each piece of equipment in the loop is capable of performing at its best. Once the
equipment is ready, methods have been developed and repeatedly proven to work, but it takes
knowledge and patience. The pay off to having every control loop performing at its best is a minimum 5%
quality and production improvement that could go as high as 25%.
2002 Plant Maintenance online, Site designed, developed and maintained by Reliance Infosolutions Pvt. Ltd.

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