Contents

ESE652 Process Control

Optimum controller settings

Continuous-cycling method ContinuousDamped oscillation method Reaction R Reactionti n-curve r m method th d

Chapter 2: Optimum Controller Settings g

Session JulyJuly-Nov 2009 Lecturer: Dr. Ismarani Ismail (Coordinator) Dr. Mohd Hezri Fazalul Rahiman
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Controller settings for minimum error integral Loop tuning

Optimum controller settings

ContinuousContinuous -cycling method

After installation, controller setting must be adjusted for the system to operate satisfactorily. It is usually done by trial and error - so tedious and time consuming. consuming Desire to have good preliminary estimation.

Determined by trial and error is time consuming Values closed to optimum can be obtained by the following technique:

testing t ti the th closedclosed l d-loop l system t with ith proportional ti l action ti on the controller the integral time is set at infinity the derivative time is set at zero or the lowest value, and the response of the system to a step changes setpoint is obtained for various gain setting.

The controller setting recommended by ZieglerZieglerNichols are given below:

Proportional control,

ProportionalProportional -integral control, control

Kc = 0.5 Kc,max

Kc = 0.45 Kc,max Kc = 0.6 Kc,max

TR = Pu/1.2 TR = Pu/2 Td = Pu/8

ProportionalProportional -integral integral-derivative control,

Experimental determination of the ultimate gain Kc,max Typical p response p curves for proportional control with Kc/Kc,max

where Kc,max is maximum gain at constant amplitude or ultimate gain and Pu is ultimate period
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The value of Kc,max is based on tests with proportional control only Integral action makes the systems less stable because p phase lag g in the controller When derivative control is added, the phase lead of the controller helps to stabilize the system and a higher gain and lower reset time is recommended Derivative action has little effect on the system with large dead time
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Tuning procedures

Set the controller to automatic mode Switch the recorder on and mark the starting position Enter a Kc value Off integral and derivative mode by setting TR to maximum and Td to zero. Make a set point change Observe the response and if the response is not constant amplitude, change the Kc value. Stop the recorder when a constant amplitude has been achieve.
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Damped oscillation method

In many plants, sustained oscillation for testing are not allowable By using only proportional action and starting with low gain, gain the gain is adjusted until the transient response of the closed loop shows a decay ratio of

The reset time and derivative time are based on the period of oscillation, P which is always greater than the ultimate period Pu For PID controller

TR = P/6 and TD = P/1.5

where P = period of oscillation

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ReactionReaction -curve method

The control loop can be opened at any point, but the usual point is between the controller and the final control element e.g. valve With the controller on manual operation p a step p change is made to the process e.g. in the pressure supplied to control valve The process output recorded on the controller is generally an SS-shaped response

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The controller setting are based on the maximum slope of the curve, N and effective lag, L, the intercept of the maximum slope line with horizontal line from the initial value The final value and the maximum slope are proportional to the size of the step change in input

Proportional integral-derivative control

where

= fractional change in input

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The method and equation are intended to give only values close to optimum controller setting

Tuning procedure

Set the controller to manual mode Switch the recorder on and mark the starting position Record the initial Multiple p variable ( (MV) ) value Make a load disturbance of 5 to 20% change Record the maximum MV value. For SR top the recorder when steady state condition has been reached. But for NSR the recorder can be stopped when enough data can be extracted.

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Controller setting for minimum error integral

The optimum setting are usually considered to give a minimum error integral after a step change in set point or load. Ideal integral action is assumed so that the error eventually becomes zero and the error integral reaches a finite limit.

The integral of the absolute value of error (IAE) 0 e dt seems the best criterion for the process control The controller setting selected to give the best response to a step input (minimum deviation & minimum duration) are not always the best setting for plant operation

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Significance of tuning
An optimum PID setting will minimize:
Out of specification products and conversely improve product quality 2. Use of energy and conversely save cost of energy 3. Depreciation of equipments and conversely long lasting equipment functions.
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Loop tuning
"Tuning" a control loop is the adjustment of its control parameters (gain/proportional band, integral gain/reset, derivative gain/rate) to the optimum values for a desired control response Th optimum The ptim m b behavior h i r on a process pr change h or r setpoint change varies depending on the application Some processes must not allow an overshoot of the process variable from the setpoint setpoint. . Other processes must minimize the energy expended in reaching a new setpoint. setpoint.
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Generally, stability of response is required and the process must not oscillate for any combination of process conditions and setpoints Tuning of loops is made more complicated by the response time of the process; it may take minutes or hours for a setpoint change to produce a stable effect Some processes have a degree of nonnon-linearity and some parameters that work well at fullfull-load conditions don't work when the process is starting up from nonoload
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There are several methods for tuning a PID loop. The choice of method will depend largely on whether or not the loop can be taken "offline" for tuning and the response speed of the system If the system can be taken offline, offline, the best tuning method often involves subjecting the system to a step change in input, measuring the output as a function of time, and using this response to determine the control parameters

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If the system must remain online, online, one tuning method is to first set the I and D values to zero. Increase the P until the output of the loop oscillates then the P should be left set to be oscillates, approximately half of that value for a "quarter amplitude decay" type response Then increase I until any offset is correct in sufficient time for the process. However too much I will cause instability
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Finally, increase D, if required, until the loop is acceptably quick to reach its reference after a load disturbance However too much D will cause excessive response and overshoot A fast PID loop tuning usually overshoots slightly to reach the setpoint more quickly; however, some systems cannot accept overshoot, in which case a "critically damped" tune is required, which will require a P setting significantly less than half that of the P setting causing oscillation.

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Effects of increasing parameters

Parameters Rise time Overshoot Settling time S.S error

1 1. 2. 3.

Kp Ki Kd

Decrease

Increase

Small change

Decrease

Decrease

Increase

Increase

Eliminate

Small Change

Decrease

Decrease

None

Another tuning method is formally known as the Ziegler Ziegler-Nichols method, method, introduced by John G. Ziegler and Nathaniel B. Nichols. As in the method above above, the I and D gains are first set to zero. The "P" gain is increased until it reaches the "critical gain" Kc at which the output of the loop starts to oscillate.

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Most modern industrial facilities no longer tune loops using the manual calculation methods shown above Instead, PID tuning and loop optimization software are used to ensure consistent results. These software packages will gather the data data, develop process models, models and suggest optimal tuning. Some software packages can even develop tuning by gathering data from reference changes.

Mathematical PID loop tuning induces an impulse in the system, and then uses the controlled system's frequency response to design the PID loop values. In loops with response times of several minutes, mathematical loop tuning is recommended, recommended because trial and error can literally take days just to find a stable set of loop values. Optimal values are harder to find. Some digital loop controllers offer a selfself-tuning feature in which very small setpoint changes are sent to the process, allowing the controller itself to calculate optimal tuning values.
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