Control Loop Tuning PDF

Yokogawa Australia
National Training Centre
Control Tuning Theory

Training Course
Yokogawa Australia Limited

Document Ref: YAU-NTC-S01
Issue: 2
Date: 23 August 2000
Contents
1. INTRODUCTION ............................................................................................................................................ 3
2. PROCESS DYNAMICS................................................................................................................................... 4
2.1 PROCESS GAIN .............................................................................................................................................. 4
2.2 PROCESS LAG ................................................................................................................................................ 5
2.3 DEAD TIME ................................................................................................................................................... 7
3. THE PID ALGORITHM ................................................................................................................................. 8
3.1 PROPORTIONAL TERM ................................................................................................................................... 9
3.2 INTEGRAL TERM.......................................................................................................................................... 11
3.3 DERIVATIVE TERM ...................................................................................................................................... 12
4. GENERAL CONTROL FUNCTIONS........................................................................................................ 14
4.1 DIRECT/REVERSE ACTION ........................................................................................................................... 14
4.2 DEVIATION AND PV BASED CONTROL ......................................................................................................... 15
5. TUNING METHODS.................................................................................................................................... 16
5.1 OPEN LOOP TUNING .................................................................................................................................... 16
5.1.1 Reaction-Curve Method (Ziegler-Nichols) .......................................................................................... 16
5.2 CLOSED LOOP TUNING ................................................................................................................................ 18
5.2.1 Continuous Cycling Method (Ziegler-Nichols).................................................................................... 18
5.2.2 Damped Oscillation Method................................................................................................................ 20
5.3 TUNING ISSUES............................................................................................................................................ 21
6. OTHER CONTROL METHODS ................................................................................................................. 22
6.1 DEADBAND.................................................................................................................................................. 22
6.2 FEEDFORWARD............................................................................................................................................ 23
6.3 CASCADE CONTROL .................................................................................................................................... 24
7. WORKSHOPS................................................................................................................................................ 25
7.1 PROCESS DYNAMICS ................................................................................................................................... 25
7.1.1 Tank Level Dynamics .......................................................................................................................... 25
7.1.2 Dead-Time Processes ......................................................................................................................... 26
7.2 CONTROLLER ALGORITHM .......................................................................................................................... 27
7.2.1 Proportional Characteristics............................................................................................................... 27
7.2.2 Integral Characteristics....................................................................................................................... 28
7.2.3 Combined Proportional and Integral .................................................................................................. 29
7.2.4 Derivative Characteristics................................................................................................................... 30
7.3 TUNING ....................................................................................................................................................... 31
7.3.1 Open Loop Tuning............................................................................................................................... 31
7.3.2 Continuous Cycling Method ................................................................................................................ 31
7.3.2 Damped Oscillation Method................................................................................................................ 32
________________________________________________________________________
 2000 Yokogawa Australia Limited

Information contained herein is the property of Yokogawa Australia Limited and may not be copied, used or
disclosed in whole or part except with the prior written permission of Yokogawa Australia Limited or, if it has
been furnished under a contract with another party as expressly authorised under that contract.
______________________________________________________________________________________
Doc Ref: YAU-NTC-S01 Yokogawa Australia Page 2
1. Introduction
The tuning of a control requires an understanding of how the control algorithm works, and
how it relates to the plant dynamics.
The control algorithm is a simple first order equation, incorporating 'three terms', as they are
commonly called. Each term has a tuning constant, and these need to be tuned to control the
process properly. This course looks at this equation and discusses how it works from a
theoretical and then practical point of view.
The process that is being controlled has gains, lags and dead-times known as process
characteristics, and the values of these characteristics need to be matched to the controller. It
is therefore necessary to have some understanding of the process that is being controlled to
enable effective tuning of the controller. This course looks at ways of understanding process
dynamics, and ways of measuring them for the purposes of control.
______________________________________________________________________________________
2. Process Dynamics
To understand how the control algorithm works, one must first understand the basic concepts
of process dynamics. The main terms here are:
• Process Lag and Integral

• Process Deadtime
• Process Gain
2.1 Process Gain
Description The process gain is the amount the process variable changes for a
given change in input (ie, controller output). Therefore, if the control
valve changes by a small amount, and this leads to a large change in
tank level (for example), then the process has a high gain.
Example Take a tank with water flowing in and out, with the inlet flow
controlled by a control valve and controller. If the controller output is
increased by 10%, then the tank level will rise by a proportionate
amount. If this value is (for example) 20% of the total tank level, then
the process gain is:
∆PV 20%
Gain = = =2
∆MV 10%
Figure 2-1 - Process Gain
∆PV
PV
∆MV
Time Figure 2-1a - Tank level schematic
______________________________________________________________________________________
2.2 Process Lag
Description In a static process, when an input to a system changes, then the

process variable will change. However, it will take sometime for the
process variable to reach it's new level. This is the process lag.
Example For example: a tank with water flowing in and out, with the inlet flow
controlled by a valve. If you increase the amount of water flowing
into the tank, the level will increase to a new steady state value. The
time taken for the level to reach 2/3 of it's final value is the process
lag.
Figure 2-2 - First Order Lag
Level
PV
Flow in
Time
Lag (ts)
Figure 2-2a - Tank level schematic
______________________________________________________________________________________
Equation This is known as first order lag. Mathematically (in the case of the
tank water level), the equation for the tank level is:
∆Level = (Flow in - Flow out) / Area ---------------------(1)
where:
Flowout = k × Pr essure ---------------------(1a)
Pr essure = Level × ρg
π
Area = × D 2 ---------------------(1b)
4
D = Tank diameter (m)
Therefore:
( Flowin − k × Level )
∆Level = -------------------(2)
(k × D 2 )
ie, as the level increases, the out-flow increases until this flow equals
the in-flow and the level stops moving.
As can be seen from this equation, the larger the tank diameter, the
longer it will take for the level to change, because the tank has a
greater volume and takes longer to fill.
Complex Systems Many processes involve a series of process elements, each with their
own lag. This is known as multi-order lags. The time constants of
these lags can be simply added together to give a single lag value.
Integral Some processes do not settle on a new value when a process

disturbance is applied. These are integral processes, i.e., the PV keeps
moving up (or down), and are known as astatic. Such processes are
inherently unstable. Examples include temperature control on
exothermic chemical reactions.
______________________________________________________________________________________
2.3 Dead Time
Description Dead time occurs where a change to the input of a system has no
effect on the process variable for a period of time.
Example Example: pH dosing into a floatation cell. The acid/base is dosed into
the tank at one end, and the pH is measured at the other end of the
tank. It takes several minutes for the change in dose to be measured
by the analyser. This is the dead time in the system.
Figure 2-3 - Process Dead Time
pH
PV
Dose Rate
Time
Dead Time (Td)
Acid Dosing
pH
Figure 2-3a - pH control of floatation tank.
Other Terms Dead time is also known as Transportation Lag. As can be seen from
the above example, dead time is often associated with the time taken
for the change in process input to move through the process; for
example, a tank or a pipe.
______________________________________________________________________________________
3. The PID Algorithm
The algorithm that operates within a controller is called the PID

equation. PID represents the three terms of the controller and is:
• Proportional
• Integral
• Derivative
The equation is as follows:
1 d
∆MV = k × (∆ε + ε .dt + D ∆ε ) ---------------------- (1)
I dt
where:
MV = Manipulated Variable (Output of the controller)

∆MV = Change in MV (ie, MV - Previous MV)
ε = Error (PV - SP)
∆ε = Change in error
k = Proportional Constant/Gain
I = Integral Constant
D = Derivative Constant
Description The amount the output changes by in a control scan is equal to:
The Proportional constant, times:
Change in error (1st Term - Proportional)

Plus
1/Integral time x the totalised error (2nd Term - Integral or Reset)
plus
Derivative constant x rate of change (3rd Term - Derivative)
in error
______________________________________________________________________________________
3.1 Proportional Term
∆MV = k × ∆ε ------------------ (2)
Description The proportional term responds to change in error. That is, if the error
changes by 10% from one scan of the controller to the next (usually 1
second), then the output of the controller changes by 10% (x the
proportional constant, k).
For example, let us take a tank full of water, in which we are trying to
control the level to a specified value (set point). Let's say that the
proportional gain is set at 1 (k=1). Then if the level increases by 10%
over a period of time, then the output to the control valve will open by
10%.
Notice here that we are talking about the level increasing. But the
equation refers to the error, ie, level - level setpoint. However, if the
setpoint remains constant then there is no difference between change
in error and change in process variable (in this case, the level).
Tuning Now, if we increase the proportional gain to 2 (k=2), then if the level
increases by 10%, then the output to the valve will increase by 20%.
This is a high gain controller, and this concept of gain is often referred
to a sensitivity. In this example, it means that the valve moves a long
way for a small change in level.
Similarly, if the proportional gain is reduced to 0.5 (k=0.5), then if the

level increases by 10%, then the output to the control valve increases
by only 5%. This is known as an insensitive controller.
A controller is tuned such that it's sensitivity is the inverse of the

process. Therefore, if the process has a high gain, then the controller
is tuned to a low gain.
Proportional Band Usually the proportional gain is expressed as Proportional Band (PB).
The relationship between the two is as follows:
PB = 100/k --------------------- (3)
In other words, the Proportional Band is the percent change in error

required to achieve a 100% change in output. Therefore, the smaller
the PB, the more sensitive the controller (ie, if PB = 50%, then k = 2),
and the larger the PB, the less sensitive the controller (ie, if PB =
200%, then k = 0.5).
Offset You will notice that the proportional term only responds to changes in
error. Therefore, if there is no change to the error, there will be no
change to the output. In other words, there may be an error, but the
controller will not change the output to correct the error if the error
itself does not change. This means that with proportional only
______________________________________________________________________________________
control, there is usually an offset between the required process value
(setpoint) and the actual process value (PV). This can be reduced by
increasing the gain of the controller. However, if the gain is too high,
then the output may over-react to small changes in the process value,
leading to instability (see below).
Sometimes it is not necessary for the process value to be controlled to

setpoint accurately, such as tank levels, but usually it is important.
This means that proportional only control is not usually satisfactory
for control applications.
______________________________________________________________________________________
3.2 Integral Term
1
∆MV = k × ε .dt --------------------- (4)
I
Description The Integral term responds to the totalised error. In other words,
while there is an error, the output ramps up (or down) at a rate
proportional to the size of the error.
For example, if the level in the tank is 10% above the setpoint, and the
proportional gain is 1 (k=1), and the integral constant is 1 second (I=1
sec), then the output to the valve will ramp up at the rate of 10% per
second.
Tuning The integral term is expressed in seconds or, in some systems,

minutes. This terms divides the integrated value, so the larger the
value the smaller the calculated output. For example, if in the above
example the integral term is increased to 10 seconds (I=10), then the
output ramps at the rate of 1% per second. This is referred to a the
speed of the controller. So, a large integral time produces a slow
acting controller, and a small integral time produces a fast acting
controller.
A controller is tuned such that the integral time approximately equals

the process lag, i.e. the speed of the controller matches the speed of
the process.
Reset Rate There are a number of different terms used to define the Integral time.
These include Reset Rate and Repeat Rate. These mean the same as
integral time. Sometimes the inverse is expressed. The term you may
hear is minutes per repeat. The equation is:
Repeats per minute = 1/I, where I is in minutes.
______________________________________________________________________________________
3.3 Derivative Term
d
∆MV = k × D ∆ε --------------------- (5)
dt
Description The derivative term is known as the predictive term. It calculates the
rate of change of the error. Thus if the error changes from 10% to
20% in 1 second, then the rate of change is 10% per second. It is not
concerned with the absolute value of the error, but the rate at which it
changes, and in which direction.
For example, if the level in the tank drops by 1% in one scan of the
controller, then the output to the valve will decrease by 1% due to the
proportional term (assuming k=1). If the tank level drops by another
1% in the next scan, then the proportional term will cause the output
to drop by another 1%. Now, the derivative term will not see a change
in the rate at which the tank level is dropping, so the derivative term
will have no effect on the output. However, if the level drops by 2%
in the next scan, then this is an increase in the rate in which the level
is dropping of 1%. If the derivative constant is 1 second (D=1), then
this will cause the output to increase by 1%. Since the proportional
term is causing the output to drop by 1%, then the two will cancel
each other out in this instance.
Tuning The derivative term in expressed in seconds, or in some systems,

minutes. This term multiplies the derivative value, so the greater the
number, the greater the calculated output. For example, in the above
example, if the rate at which the level drops increases by 1% with
each scan, then the output will increase by 1%, ie:
Scan 1 - Level = 56%

Scan 2 - Level = 55% ∆E = 1%
Scan 3 - Level = 54% ∆E = 1% ∆(∆E) = 0%
Scan 4 - Level = 52% ∆E = 2% ∆(∆E) = 1%
Scan 5 - Level = 50% ∆E = 2% ∆(∆E) = 0%
Therefore (if D = 1), at Scan 4, the derivative term will increase the
output by 1%, even though the proportional term will decrease the
output by 2% (if k=1). This leads to an actual output change of -1%.
A controller is tuned such that the derivative term is proportional to

the process lag, usually a small fraction of the lag.
Predictive As can be seen from this example, the derivative term is predictive.
That is, unlike the proportional term which reacts only to absolute
error, the derivative term reacts to how fast the error is changing,
thereby reducing the amount of overshoot in the control loop.
______________________________________________________________________________________
Figure 1 - Derivative Action in Control Loop
∆E = 1%
∆(∆E) = 9%
∆E = 10%
PV
Time
Noise Derivative cannot be used on a fast or noisy loop. The derivative term
will react to any sort of transients, calculating large and spurious
outputs, based on transitory gradients. Therefore, derivative is not
used on flow loops, most pressure loops, and level control of small
tanks. It's main application is temperature control in furnaces and
kilns.
______________________________________________________________________________________
4. General Control Functions
4.1 Direct/Reverse Action
Theory The error can be calculated in two ways:
Error = PV - SV (direct)
or
Error = SV - PV (reverse)
Depending on which is chosen, the controller will operate in one

direction or another, as follows:
• Direct Acting Control - If the PV increases above setpoint (SV),

then the output (MV) increases.
• Reverse Acting Control - If the PV increases above setpoint (SV),

then the output (MV) decreases.
Example If a tank level is controlled by a valve on the outlet, then if the level
rises, the output to the valve has to increase (ie open the valve) to
bring the level back to set point. This is a direct acting system.
If the tank level is controlled by a valve on the inlet, then if the level
rises, the output to the valve has to decrease (ie close the valve) to
restrict the flow into the tank and bring the tank level back to set
point. This is a reverse acting system.
______________________________________________________________________________________
4.2 Deviation and PV based control
Theory If the set point does not change (ie, a setpoint set once by the operator
and left at that value), then there is no difference between Change in
Error (∆E), and Change in PV (∆PV). Therefore, the ∆PV could be
used in the proportional and derivative terms in the PID algorithm.
Applications Under normal circumstances, if the operator changes the setpoint (SV)
by a certain amount, then the controller will respond to the change in
error, even though the process itself has not changed. This can lead to
significant process disruption, because a large and quick change in SV
will lead to a large change in output. Therefore, by using ∆PV
instead, the proportional and derivative terms of the controller do not
respond to changes in SV, allowing the integral term to windup
according to the new error.
Equations The equation would now look like this:
1 d
∆MV = k × (∆PV + ε .dt + D ∆PV ) ---------------------(6)
I dt
This is called an I-PD controller.
Variations of this are possible. For example, a PI-D controller uses

∆E in the proportional term, and ∆PV in the derivative term. This is
commonly used in cascade applications where the SV is always
moving, and it is necessary for a proportional response to these
changes, but where the derivative term only responds to process
changes.
______________________________________________________________________________________
5. Tuning Methods
There are several ways of tuning a control loop. Trial and error is fine for simple flow loops,
but is time consuming for anything more complicated. The two main categories of tuning
methods are closed loop and open loop. Closed loop tuning is where the oscillating response
of a control loop is evaluated for the correct process dynamics. Open loop tuning involves
opening the control loop, usually be putting the controller into manual, and monitoring the
response of the process to a step change in controller output.
5.1 Open Loop Tuning
5.1.1 Reaction-Curve Method (Ziegler-Nichols)
The controller is set to manual, so that it does not respond to changes

in input. This produces an open loop. When the process is settled,
increase the output by a certain amount (usually 10%, but this will
depend on the process). The PV will increase (or decrease) to a new
value and settle there, as per the following diagram:
Figure 5-1 - Open Loop Tuning
∆PV
PV
Slope = ∆PV/∆T
L
∆T
Time
Draw a straight line along the curve of the PV that represents the
maximum rate of increase of the PV. Calculate it's slope as:
Slope (S) = height/length

or
Slope (S) = ∆PV/∆T
This is effectively the GAIN/LAG of the process. The process gain is:
∆PV/∆MV
i.e., the change in process value due to a given change in controller

output.
______________________________________________________________________________________
Also, calculate the effective lag (L), which is the time from the step
change to the point where the process starts to respond. This is, in fact,
a combination of dead time and lag in the process.
From these two values, and the change in controller output (∆MV),
the tuning parameters can be calculated as follows:
∆MV
Proportional Control Kc =
SL
0.9 × ∆MV
Proportional - Integral Kc =
SL
Control
L
I=
0 .3
1.2 × ∆MV
Proportional - Integral Kc =
SL
Derivative Control
L
I=
0 .5
D = 0 .5 × L
As can be seen from these equations, the Proportional gain is inversely

related to the gain of the process. That is, the more sensitive the
process is, the less sensitive the controller is, and visa versa.
Both the integral term and the derivative term are related directly to
the process lag and dead time. That is, the faster the process, the
faster the controller should respond.
______________________________________________________________________________________
5.2 Closed Loop Tuning
There are two types of closed loop tuning. One is to cause a continuous oscillation in the
process and calculate the gain and lag of the process from that. The other is to observe the
process at an approximately 1/4 damped oscillation. The latter is often preferable as the first
method can be dangerous to some processes.
5.2.1 Continuous Cycling Method (Ziegler-Nichols)
Method With the controller in automatic, set the Integral and Derivative terms
to zero (i.e., turn them off), so that it is a Proportional only controller.
Set the Proportional gain to 1 (or PB to 100%).
Change the set point by 10%. Monitor the effect on the PV. Repeat
the above process for different Proportional gains until the PV is
continuously oscillating.
Figure 5-2 - Closed Loop Oscillation Response

PV
Pp
Time
______________________________________________________________________________________
Equations The period of oscillation (Pp) is related to the process lag, and the
Proportional Gain that the controller is tuned to create this oscillation
(Kp) is related to the process gain. From these, the tuning constants
can be calculated:
Proportional Control Kc = 0.5 Kp
Proportional - Integral Kc = 0.45 Kp

Control
I = Pp / 1.2
Proportional - Integral Kc = 0.6 Kp

Derivative Control
I = Pp / 2.0
D = Pp / 8
These parameters produce a 1/4 damped oscillation in the process, and

a small overshoot.
______________________________________________________________________________________
5.2.2 Damped Oscillation Method
Method Follow the same procedure as for the continuous-cycling method

except that the Proportional Gain is to be adjusted until there is a 1/4
decay in the oscillation, as per the following diagram:
Figure 5-3 - Closed Loop 1/4 Damped Oscillation Repsonse
Peak1
Peak2
PV
Peak2/Peak1 = 1/4
Time
Equations This is roughly the desired control response, and so the Proportional
Gain used to achieve this is the desired value, and the Integral and
Derivative gains are as follows:
Integral I = P/1.5
Derivative D = P/6
______________________________________________________________________________________
5.3 Tuning Issues
Noisy Loops: Never use derivative on fast or noisy loops. It is designed to react to
the rate of change in the PV, and noise is a rapid and oscillating
change in PV. This will cause rapid changes in the derivative term.
Fast Loops: Fast loops such as flow and pressure require a sensitive, slow acting
controller, i.e. plenty of gain (i.e. a low proportional band) with just a
small amount of integral (i.e. a large integral time) to remove offset.
Slow Loops: Slow loops such as level and temperature require a fast acting,
insensitive controller, i.e. plenty of integral (small integral time), and a
small amount of proportional gain (large proportional band).
Rapid Change: For processes that experience rapid changes such as furnace
temperature, but are otherwise slow acting, derivative is required to
respond to these changes. The proportional and integral times are
tuned as per a slow acting loop.
Tuning Rules: Increasing proportional band (i.e. reducing gain) stabilizes the loop.
Once stable, the proportional band can be reduced to increase the
sensitivity.
Reducing the Integral time speeds up the loop.
Derivative (if used) is approximately 1/4 of the Integral value.
______________________________________________________________________________________
6. Other Control Methods
Most controllers have settings that allow for some enhancement to the control. These include
Deadband (or hysteresis) and Feedforward.
6.1 Deadband
Description Deadband is a value around the control setpoint in which no control

takes place. That is, while the PV is within a certain value of setpoint
(SV), the output (MV) is not calculated, and therefore does not
change.
Application The advantages of this are that if the input signal is noisy, while the
PV is close to setpoint, the output will not chatter. Also, if a wide
deadband can be tolerated, then a high Proportional Gain can be set
which would ordinarily lead to instability. However, as soon as the
PV enters the Deadband, control halts and the PV stabilises quickly in
this region. This would ensure that there is fast control to setpoint.
Figure 6-1 - Deadband Action
Deadband
Setpoint
PV
Deadband
Output
Time
______________________________________________________________________________________
6.2 Feedforward
A signal can be added to the output of the controller to ensure faster

response. For example, in boiler control, if the steam flow out of the
boiler increases, then you know that the boiler level is going to drop.
A controller is reactive, that is, it acts when the level drops. But by
adding the change in steam flow to the controller output, then
corrective action takes place before the level actually drops.
SF
∆
+ LC
Figure 6-2 - Schematic of Boiler Control with Feedforward
______________________________________________________________________________________
6.3 Cascade Control
Description Many processes have several process lags in series. Since a PID
controller is designed for a single process lag, it has trouble
controlling processes involving more than one lag. Cascade control is
a system where the output of one controller cascades into another.
Each controller can be independently tuned to respond to a particular
process lag.
Example The above example (6.2) shows a boiler control scheme. There are
two process lags: boiler level and feedwater flow. A common solution
is to have a controller for the boiler level and a controller for the flow
loop, with the output of the level controller being the setpoint for the
flow controller.
In this way, the two controllers can be tuned for the part of the process
they are assigned to, rather than having to tune one controller to take
into account two separate process lags.
SF
MV
LC
SV
WFC
WF
Figure 6-3 - Schematic of Boiler Control with Cascade
______________________________________________________________________________________
7. Workshops
7.1 Process Dynamics
7.1.1 Tank Level Dynamics
Display On the HIS, select the TANK graphic. This graphic displays a single
tank with a flow in and a flow out. There is a controller on the inlet
flow.
Set up Set the following parameters by clicking on them on the graphic:
Tank Diameter = 1m
Outlet Valve Position = 70%
Controller mode = Manual
Controller output (MV) = 40%
Operation Set the controller output to 50%. This is a 10% step change in output.
Click on the trend button and observe how long it takes to reach 2/3 of
the final value, and what the final value is:
Repeat the process but this time increase the output to 70%, that is, an
increase of 20%.
MV 50% 70%
Process Lag
Final Value
Process Gain
Set the diameter of the tank to 5m and repeat the above procedure.
MV 50% 70%
Process Lag
Final Value
Process Gain
______________________________________________________________________________________
7.1.2 Dead-Time Processes
Display On the HIS, select the PH Dosing graphic. This graphic displays a
cascade control system with acid dosing control, and pH measurement
and control. The pH measuring point is a certain distance down the
line, allowing for a certain amount of dead-time.
Set up Set the following parameters by clicking on them on the graphic:
Line Delay = 60 sec

Line Lag = 1 sec
Main Line Flow = 5 m3/min
Main Line pH = 10
Flow Controller MV = 20% and in manual
Operation Make sure that the flow and pH values are steady. Increase the
controller output to 80%. Monitor the trend (the trend available by
clicking on the trend button may be easier to read), and observe the
time it takes for a change in pH to be measured.
Repeat the process, but this time, set the Line Lag to 60 sec, and then
reduce the MV to 20%. Notice that after the initial delay of 60 sec, it
then takes 60 sec for the pH value to move to it's final value.
______________________________________________________________________________________
7.2 Controller Algorithm
7.2.1 Proportional Characteristics
Display On the HIS, select the TANK LEVEL graphic.
Set up Set the tank diameter to 1 m.
Set the controller to auto and the SV to 50%. When the level is steady
on 50%, put the controller into manual. Set the following parameters
by clicking on the controller and then selecting the tuning panel
display:
P = 100
I = 9999 (i.e. no integral action)
D=0
Operation Put the controller into AUT. On the graphic, click on the "INCR
LEVEL" button (and also make sure that STATIC is selected) and
observe that the level increases by 20M. On the trend in the tuning
panel, observe the output (MV). Note the output change in response
to the change in PV. It should be a 1/1 step change.
Repeat the exercise for values of P of 200% and 50%. Note the size
of the response in the MV, and the size of any offset.
Astatic Processes Click on the "ASTATIC" button and repeat the above exercise. The
process response should be similar, except that there is no offset. In
fact, the process itself provides the integral response, so that a
proportional only controller behaves like a PI controller.
(Note, the ASTATIC button freezes the out flow calculation, so that
the outflow does not vary with tank level. This simplifies the control
characteristics).
______________________________________________________________________________________
7.2.2 Integral Characteristics
display:
P = 0 (i.e. no proportional action)

I = 60 sec
D=0
Operation Put the controller into AUT. On the graphic, select STATIC process
and click on the "INCR LEVEL" button and observe that the level
increases by 20M. On the trend in the tuning panel, observe the
output (MV). Note the output change in response to the change in PV.
It will be integrating up and down according to the PV. There is no
step response due to the proportional term.
The controller should now be unstable. Set the Integral to 120 sec and
observe that the MV is now ramping at half the speed as before. It
should now return to set point.
When it has settled, decrease the Integral to 60 seconds, and click on

the "INCR LEVEL" button, and observe the response.
Astatic Processes Repeat the above exercise with Astatic process selected. Note that
regardless of the integral value used, the loop is always unstable. This
is because the controller and the process are both integrating.
______________________________________________________________________________________
7.2.3 Combined Proportional and Integral
Set up Using the above example, set the PID parameters as follows:
P = 100
I = 20
D=0
Operation Select STATIC process and increase the level as described above and
observe the response of the controller output to the step change in
level.
There will be a corresponding step change in output (MV), followed

by the integral action. Notice the speed in which the PV returns to
setpoint.
Repeat the exercise, keeping the Integral time constant and varying
the PB, firstly to 50%, then to 200%, and compare the overshoot and
time to setpoint for the three settings.
Repeat the exercise, keeping the PB at 100% and setting the Integral
to 40 and 100 seconds, and compare the overshoot and time to
setpoint for the three settings.
Repeat the exercise with a tank diameter of 8m, with a PB of 100%,

and Integral of 100, and then 400 seconds.
Conclusion For a fast process, the proportional gain has greater effect than the
integral time, and the greater the gain, the faster the return to setpoint,
but the greater the overshoot. However, for systems with longer lags,
the integral time becomes a greater factor in the control, as the reset
term winds-up the controller output in response to a slow change in
error.
Astatic Process Select ASTATIC process and set the PID parameters as follows:
P=100
I = 20
D=0
Note that the faster the Integral time, the less stable the control is. In
fact, the control is most stable when there is no Integral action.
Integral should not be used in astatic processes.
______________________________________________________________________________________
7.2.4 Derivative Characteristics
display:
P = 100
I = 9999 (i.e. no integral action)
D=1
Note that it is not possible to have derivative only control.
Operation Put the controller into AUT. On the graphic, select STATIC process
and click on the "INCR LEVEL" button and observe that the level
increases by 20M. On the trend in the tuning panel, observe the
output (MV). Note the output change in response to the change in PV.
Repeat the exercise for derivative values of 5 and 20.
Repeat the exercise with a tank diameter of 8m.
Astatic Process Repeat the exercise with a 1m tank, for an Astatic process, and
compare the response to the Proportional only control.
Conclusion The derivative adds to the proportional response during the initial step
change in level, causing the level to return to setpoint very quickly. In
addition, as the level moves towards setpoint, the derivative term pulls
back, reducing the effect of the proportional term, to dampen any
overshoot.
The derivative term works best on fast processes, having little effect
on the control for systems with a lot of lag.
Proportional-Derivative control is highly suited to Astatic

applications, providing a very quick return to setpoint without
overshoot.
______________________________________________________________________________________
7.3 Tuning
7.3.1 Open Loop Tuning
Display On the HIS, select the TANK LEVEL graphic. Click on the controller
to display the controller tuning panel.
Set up Set the tank diameter to 3 m, and select Static process. Set the MV to
50%, and allow the PV to settle.
Operation Set the MV to 60% and monitor the process response on the tuning
panel. Print out the tuning display, and using a ruler, calculate the
slope and lag as per section 5.1 of the notes.
From these values, the PID constants are calculated. Enter these into
the controller tuning panel and run the controller in automatic to check
that the values provide good control to setpoint.
7.3.2 Continuous Cycling Method
Operation Set the controller to automatic and set the SV to 60%. Reduce the PB
(i.e., increase the Gain) until the PC is continuously cycling. Print out
the tuning display, and using a ruler, calculate the period between the
peaks.
______________________________________________________________________________________
7.3.2 Damped Oscillation Method
Operation Set the controller to automatic and set the SV to 60%. Reduce the PB
(i.e., increase the Gain) until the PV produces a 1/4 damped response.
Print out the tuning display, and using a ruler, calculate the period
between the peaks.
Note that each of these methods produces a different set of tuning parameters. The open loop
tuning method is generally thought to be the most accurate.
______________________________________________________________________________________

Control Loop Tuning PDF

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Control Loop Tuning PDF

Загружено:

Авторское право:

Доступные форматы

Yokogawa Australia

National Training Centre

Control Tuning Theory

Yokogawa Australia Limited

 2000 Yokogawa Australia Limited

• Process Lag and Integral

2.1 Process Gain

Figure 2-1 - Process Gain

Description In a static process, when an input to a system changes, then the

Figure 2-2 - First Order Lag

Figure 2-2a - Tank level schematic

∆Level = (Flow in - Flow out) / Area ---------------------(1)

Integral Some processes do not settle on a new value when a process

Figure 2-3 - Process Dead Time

Figure 2-3a - pH control of floatation tank.

The algorithm that operates within a controller is called the PID

The equation is as follows:

MV = Manipulated Variable (Output of the controller)

The Proportional constant, times:

Change in error (1st Term - Proportional)

∆MV = k × ∆ε ------------------ (2)

Similarly, if the proportional gain is reduced to 0.5 (k=0.5), then if the

A controller is tuned such that it's sensitivity is the inverse of the

PB = 100/k --------------------- (3)

In other words, the Proportional Band is the percent change in error

Sometimes it is not necessary for the process value to be controlled to

Tuning The integral term is expressed in seconds or, in some systems,

A controller is tuned such that the integral time approximately equals

Repeats per minute = 1/I, where I is in minutes.

Tuning The derivative term in expressed in seconds, or in some systems,

Scan 1 - Level = 56%

A controller is tuned such that the derivative term is proportional to

4.1 Direct/Reverse Action

Theory The error can be calculated in two ways:

Depending on which is chosen, the controller will operate in one

• Direct Acting Control - If the PV increases above setpoint (SV),

• Reverse Acting Control - If the PV increases above setpoint (SV),

Equations The equation would now look like this:

Variations of this are possible. For example, a PI-D controller uses

5.1 Open Loop Tuning

5.1.1 Reaction-Curve Method (Ziegler-Nichols)

The controller is set to manual, so that it does not respond to changes

Figure 5-1 - Open Loop Tuning

Slope (S) = height/length

i.e., the change in process value due to a given change in controller

As can be seen from these equations, the Proportional gain is inversely

5.2.1 Continuous Cycling Method (Ziegler-Nichols)

Figure 5-2 - Closed Loop Oscillation Response

Proportional Control Kc = 0.5 Kp

Proportional - Integral Kc = 0.45 Kp

Proportional - Integral Kc = 0.6 Kp

These parameters produce a 1/4 damped oscillation in the process, and

Method Follow the same procedure as for the continuous-cycling method

Figure 5-3 - Closed Loop 1/4 Damped Oscillation Repsonse

Reducing the Integral time speeds up the loop.

Derivative (if used) is approximately 1/4 of the Integral value.

Description Deadband is a value around the control setpoint in which no control

Figure 6-1 - Deadband Action

A signal can be added to the output of the controller to ensure faster

Figure 6-2 - Schematic of Boiler Control with Feedforward

Figure 6-3 - Schematic of Boiler Control with Cascade

7.1 Process Dynamics

7.1.1 Tank Level Dynamics