PID Tuning Training Course

Day-1 1 PID Control Basics

2 Tuning Tutorial in Centum VP

Day-2 3 Tune VP Application

4 Tuning using Tune VP in Centum VP

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 1
 PID Control Basics

1. PID Control Evolution

2. PID Algorithm and its Implementation

3. Process Models

4. PID Controller Tuning Methods

5. PID Tuning Guidelines

6. Regulatory Control Strategies

7. PID Tuning Tutorial

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 2
 PID Controller Evolution

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 3
 On-Off Control

Copyright © Yokogawa Electric International Pte Ltd

 On-Off with Dead Band Control

Copyright © Yokogawa Electric International Pte Ltd

Proportional Control (TI = 5000 & D =0)

K = 2.4

DMV = K* DE
K = 1.8

K = 1.0

Proportional Control will always have offset

Copyright © Yokogawa Electric International Pte Ltd
PI Control (D =0)

K = 1.6 TI = 50

DMV = K* DE + E/TI
K = 1.8 TI = 70

K = 1.0 TI = 300

Adding Integral will eliminate offset

Copyright © Yokogawa Electric International Pte Ltd
 PID Control Algorithm and Implementation

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 8
 PID Basics
PID controller
PV Cold water
Process variable SV PV
DV

SV
Setpoint value

MV Hot water
Manipulated output value MV
Steam
DV
Disturbance variable

Steam heating temperature

control system

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 9
 PID Algorithm

 Tune PID controller parameter (PB, TI, TD) to achieve a

satisfied performance

Yokogawa PID

PB  (0-1000) Control action 

TI  (0.1-10000) Control action  vice versa
TD  (0-10000) Control action 

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 10
 PID Algorithm - Implementation

PID - Proportional - Integral - Derivative

PID Controller – The most widely applied controller
in industrial processes

DV
Proportional
+
SV
- E
Integral
+ MV Controlled process
Gp
PV
+
PV +
Derivative

Control system block diagram

E=PV-SV (Yokogawa DCS)
PV-Process Variable, SV-Set-point Variable, MV-Manipulated Variable, DV-Disturbance Variable

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 11
 PID Algorithm - Implementation Discrete form

DMV = K* DE + E/TI + D* DE/ DT

SP
E PV
DE

DMV
MV

Current time

Copyright © Yokogawa Electric International Pte Ltd

 PI Controller – Impact of P & I values

Copyright © Yokogawa Electric International Pte Ltd

 Process Models

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 14
 Dynamic Model of a Level in a Tank

Fin

LT
L
Fout

dL
 Ac  Fin  Fout
dt

Copyright © Yokogawa Electric International Pte Ltd

 Stirred-Tank Heating Process

dT
V C  wC Ti  T   Q (2-36)
dt

Copyright © Yokogawa Electric International Pte Ltd

 System: Gas Surge Drum with volume V, inlet and outlet flow rates
qi and qo respectively.

Transfer Function of First order system

Copyright © Yokogawa Electric International Pte Ltd

 Step Response of First Order System

445 84

440
82

435
80

430
Engineering Units

78

425

76
420

74
415

72
410
INPUT
OUTPUT
405 70
1 11 21 31 41 51 61 71 81 91 101 111 121 131 141
Time

Copyright © Yokogawa Electric International Pte Ltd

 Second Order System

Copyright © Yokogawa Electric International Pte Ltd

 Step Response of Second Order System

445 84
40.00
Input
2009.00
440 Output
82
35.00
2007.00
435
80
30.00

Output - Engineering Units

2005.00

Input - Engineering Units

430
Engineering Units

78
25.00
425 2003.00

420 with x  t1/2*t2 > 1 76

2001.00
20.00

415 Over-damped 74
1999.00
with x  t1/2*t2 < 1 15.00

410
INPUT
72
1997.00
Under-damped 10.00

OUTPUT
405 70
1995.00 5.00
1 11 21 31 41 51 61 71 81 91 101 111 121 131 141
1 6 11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96 101
Time
Time

Copyright © Yokogawa Electric International Pte Ltd

 Second Order - Zero Gain

Copyright © Yokogawa Electric International Pte Ltd

 Second Order - Beta

Copyright © Yokogawa Electric International Pte Ltd

 PID Controller Tuning Methods

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 23
 Tuning Methods

1. Open Loop Method

1. Ziegler Nichols
2. Cohen-Coon technique

2. Closed Loop Method

3. Model based Methods

1. Internal Model Control (IMC) Method
2. ISE, IAE & IATE based Methods

4. Manual Tuning - Trial and Error method

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 24
 Ziegler Nichols - Open Loop Method

Gp is the process gain -

the change in measured
value (%) divided by the
change in output (%)

Gain Reset Derivative

P L/GpD — —
PI 0.9 L/GpD 3.33D —
PID 1.2 L/GpD 2.0D 0.5D

Copyright © Yokogawa Electric International Pte Ltd

 Cohen-Coon technique - Open Loop Method

Copyright © Yokogawa Electric International Pte Ltd

 Ziegler Nichols – Closed Loop Method

Copyright © Yokogawa Electric International Pte Ltd

 IMC(Internal Model Control) Tuning Relations

Copyright © Yokogawa Electric International Pte Ltd

 ISE, IAE & ITAE Tuning Rules (for non
Integrating process)

Copyright © Yokogawa Electric International Pte Ltd

 PID Tuning Guidelines

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 30
 Manual Tuning – Some guide lines(..1)

1. Before starting the tuning, set the output limits to narrow range around
current operating point (MH/ML limits) to clamp the control valve
opening limits.
2. If offset is observed, first increase the Gain and then decrease the
Integral time.
3. If oscillation is observed high, the increase the TI. If this is not making
much impact, then reduce the gain.
4. If the process has dead time, then give TD, but start with small value
first. Before giving TD, ensure that PV signal is noise free by using
appropriate filter.
5. If it is cascade loop, tune the slave loop first and then tune the master
loop.
6. In case of cascade loop, the slave loop should be tuned for faster
response.

Copyright © Yokogawa Electric International Pte Ltd

 Manual Tuning – Some guide lines (..2)

Flow Control Loop

1. Flow is usually controlled using a PI controller.
2. The Signal from the flow sensor is noisy due to turbulent flow so that a
large proportional band is used.
3. A small integral time is used for good set point tracking.

Level Control Loop

1. Most liquid levels provide surge capacity for filtering outflow disturbance.
2. In order to filter outflow disturbances, the level should be controlled
loosely.
3. P controller is sufficient, but PI also used for level control.
4. Small Proportional band (PB), Large integral time (I) is used for level
controller.

Copyright © Yokogawa Electric International Pte Ltd

 Manual Tuning – Some guide lines (..3)

Pressure Control Loop

1. The dynamics of pressure in a pressure control loop can be very fast
(Flow like) or slow (Level like) depending on the process system.
2. PI controllers are used for pressure loops with a small proportional band
and integral time (10 to 250 Sec) for tight pressure control.
3. Tight pressure control is usually desired in most processing situations.

Temperature Control Loop

1. Moderately slow due to sensor lags and Heat transfer lags.
2. PI and PID Controllers often used.
3. Small Proportional band and medium integral time and small derivative
time.
4. Ex: PID controller used for Furnace temp
5. Ex: PI controller used for stripper tray temp

Copyright © Yokogawa Electric International Pte Ltd

 Manual Tuning – Some guide lines (..4)

Proportional Integral Derivative

Sl No Loop Type Scenario What is required? Action Action Action

Fast Response (Good SP Tracking, as operator

change flow loop set point regularly)
Since PV is noisy, we need less proportional
PV is generally Noisy action.
1 Flow PI Controller is sufficient Less More Nill

Need to control within desired range.

Tight control not P Controller is sufficient but some times PI
2 Level required Controller also used More Less Nill
Tight control
3 Pressure required. Generally PI is used More Medium Nill

Sensor and Heat Generally PID Controller is used. But some times
Transfer Lags. Some PI also sufficient if there is not much delay in the
Temperat times process will process.
4 ure have delay These loops generally require very tight control More Medium Less

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 34
 Regulatory Control Strategies

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 35
 Simple Feed Back Control

Copyright © Yokogawa Electric International Pte Ltd

 Cascade Control

Copyright © Yokogawa Electric International Pte Ltd

 Cascade Control (Terminologies)

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 38
 Constraint Handling in PID Controller

Copyright © Yokogawa Electric International Pte Ltd Confidential

GSD/YEI Page 39
 Ratio Control

Copyright © Yokogawa Electric International Pte Ltd

 Ratio and Feed Back

Copyright © Yokogawa Electric International Pte Ltd

 Feed Forward and Feed Back

Copyright © Yokogawa Electric International Pte Ltd

 Split Range Control

Copyright © Yokogawa Electric International Pte Ltd

 PID Algorithm types

Copyright © Yokogawa Electric International Pte Ltd

 PID Tuning – Exercise

1. Tune the given process loop using the following four methods**
2. Record the PID tuning values and Total Absolute Error(TAS) observed

Controller Integral Derivative Total Absolute

Sl No Tuning Method Gain (K) Constant (t) Constant (d) Error

1 Trial and Error Method

2 Ziegler Nichols Open Loop Method

3 Ziegler Nichols Closed Loop Method

4 IAE Model Based Method

3. Which method gives the minimum TAS?

4. In your opinion which method gives best tuning values? And why you
think so?
**Use the spread sheet provided for each method for finding the tuning value
Copyright © Yokogawa Electric International Pte Ltd