PROCESS CONTROL

Determine the effect of P, PI and PID controller

Abstract
For the design of a process control system identification of control objectives,
selection of appropriate measured and controlled variables and their effect on the
process variable are paramount

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Jindal.me@live.com

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Process Control
Ravi Kumar 17CHE217*
*Department of Chemical Technology, Institute of Chemical Technology, Mumbai, India.

Abstract:
For the design of a process control system identification of control objectives, selection of appropriate
measured and controlled variables and their effect on the process variable are paramount. Furthermore,
it becomes important to study the various control loop configurations applied to the system. It also requires
analysis of the response curve of the system to variations in control parameters. Here, response curve
of process variable (for flow control and level control systems) controlled by a pneumatic valve is studied
for the 3-main type of single loop control systems Proportional (P), Proportional-Integral (PI) and
Proportional-Integral-Derivative (PID), for different tuning parameters. The above 3 feedback control
mechanisms are compared against one another. Further, tuning of the feedback control system is done
using Zeigler Nichols standard tuning method.

Keywords: Process variable, Response curve, single loop control systems, Ziegler Nichols tuning

1. Introduction:
As a result of the increasingly complex structure of chemical processes (due to betterment of energy and raw
materials) the design of control system for the complete plant now constitutes the focal point of engineering
interest, rather than the controller designs for single processing units. Furthermore, the design of control system
has become intimately related to the process itself. Designing of control system implies identification of control
objectives; selection of appropriate measurement sand manipulations, as well the determination of loops
connecting these, and identifying the proper control laws.

Figure:1 Control Panel

A good understanding of physical and chemical phenomenon taking place in a chemical process is essential for
the design of simple and effective control schemes.

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The primary incentives for using a control system can be given as follows:

Safety safe and sustained operation of a chemical process is of primary importance

Consistently meeting the required production specifications
Compliance with the prevailing environmental norms
Satisfaction of the operational constraints
Economic considerations operation must be at optimum parameters for efficient utilization of resources

2. Theory:

In this experiment, a pneumatic valve is used as the primary control element. Valves are widely used and
due to ease of control and well documented and widely understood characteristics.
It is a device that regulates, directs or controls the flow of a fluid by opening, closing or partially obstructing
various passageways. Valves are technically fittings. Control valves are normally fitted with actuators (An
actuator is a component of a machine that is responsible for moving) and positioners. To reduce the effect of
these load disturbances, sensors and transmitters collect information about the process variable and its
relationship to some desired set point. A controller will then process this information and decides what must be
done to get the process variable back to where it should be after a load disturbance occurs.
The control valve manipulates a flowing fluid, such as gas, steam, water, or chemical compounds, to compensate
for the load disturbance and keep the regulated process variable as close as possible to the desired set point.
Fundamentally, there are two types of control loops: open loop control and closed loop (feedback) control. In
open loop control, the control action from the controller is independent of the "process output". In closed loop
control, the control action from the controller is dependent on the process output. Closed loop controllers are
also called feedback controllers. The definition of a closed loop control system is control system possessing
monitoring feedback, the deviation signal formed as a result of this feedback being used to control the action of
a final control element in such a way as to tend to reduce the deviation to zero.

Proportional Controller- The actuating control signal is proportional to the error.

(1)
Where,
Kc = proportional gain of controller,
CS = actuating signal for zero error.
() = error function

Proportional controller is usually characterized by Proportional Band (PB) where:

(2)

Proportional-Integral (PI) Controller- It is also known as actuating signal as a function of error is given as:
(3)

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Where = reset time or integral time.

The PI controller causes the controller output to change as long as error persists. Hence, a PI controller can
eliminate smaller errors.
Proportional-Integral-Differential (PID) controller- The controller output is given by-
(4)

Where = derivative time constant

PID controller applies a control action proportional to current rate of change of error. It reduces the sluggishness
of the response of the curve by applying large controlling action to fast changes.

We will choose the set of PID values for which we get minimum error.

There are three types of error calculation methods used in process control.

I. Integral of Square error (ISE):

= 0 ()2 (5)

II. Integral of Absolute error (IAE):

= 0 |()| (6)

III. Integral of time weighed absolute error (ITAE):

= 0 |()| (7)

If the errors are small, we will go for IAE since squaring will make the errors even less. When the response time
of system is high we use ITAE.

For tuning, we are using one of the standard and widely used controller tuning method, the Ziegler Nichols
tuning technique for obtaining the controller parameters (for P, PI & PID system) with the goal of achieving good
regulation (disturbance rejection).It attempts to produce good values for the 3 PID gain parameters - Kc, ,
. The two measured feedback loop parameters required are:
1. the ultimate period Pu of the oscillation frequency at the stability limit
2. the ultimate gain margin Ku for loop stability.

T ABLE 1: ZEIGLER NICHOLS TUNING C HART

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Cohen-Coon technique of Controller Tuning

In this method the process reaction curve is obtained first, by an open loop test as shown in Figure, and then the
process dynamics is approximated by a first order plus dead time model,

It is observed that the response of most of the processes under step change in input yields a sigmoidal shape.

Figure 3 Response curve

Such sigmoidal shape can be adequately approximated by the response of a first order process with dead time.

The controllers are designed as given in table.

T ABLE 2: C OHEN COON T UNING C HART

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3. Process Flow Diagram:

F IGURE 4: PROCESS F LOW DIAGRAM

4. Materials & Methods:

The equipment used to study hydrodynamics of extraction is a The LL1100 PC-based Parameters Setting Tool
by Yokogawa is a software package for setting various parameters of the US1000 Digital Indicating Controller
from a personal computer. The LL1100 tool offers the function of setting parameters such as P, I, D necessary
for controller operation. The auto-tuning function allows automatic optimization of PID parameters. PID
parameters, operation mode, and others can be changed while monitoring the trend graphs of PV (Process
Variable), SV (Set-point Value), and MV (Manipulated variable) on the computer screen.

To begin the flow control experiment, first start the control setup and the air compressor making sure the
compressor valve is closed. Then, open the compressor outlet valve once the pressure is approximately 10
bars. Start the main water supply till the main tank fills up. Also, make sure the water drain is closed when the
tank is filled up to the required height. Meanwhile, open the LL1200 application on the computer and after
selecting PARAMETERS in the dialogue box, select TUNING and set the controller on auto mode. The
preliminary setup is now complete.

After careful observation of the entire control setup, ensure that the appropriate valves are open and all other
valves are kept shut. In the flow control experiment, flow is the process variable whereas the pneumatic valve
opening is the manipulated variable. Select Loop 2 in the application and make sure that the loop is OPEN.
Now, give a necessary set point and observe the variation of the process variable i.e. flow rate. Change the
values of the control parameters (P, I, D) and observe and analyze the corresponding changes in the plot by
selecting EXECUTE to run the real-time plot.

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5. Experimental Setup:

F IGURE 5: A CTUAL SETUP & C ONTROL PANEL

F IGURE 6: S OFTWARE INTERFACE D ISPLAY

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6. Controller Tuning:

First, note whether the required proportional control gain is positive or negative.
To do so, step the input u up (increased) a little, under manual control, to see if the resulting steady state
value of the process output has also moved up (increased). If so, then the steady-state process gain is
positive. The required Proportional control gain Kc has to be positive as well.
Turn the controller to P-only mode, i.e. turn both the Integral and Derivative modes OFF.
Turn the controller gain Kc up slowly and observe the output response. Note that this requires changing Kc
in step increments and waiting for a steady state in the output, before another change in Kc is implemented.
When a value of Kc results in a sustained periodic oscillation in the output (or close to it), mark this critical
value of Kc as the ultimate gain (Ku). Also, measure the period of oscillation which becomes the ultimate
period (Pu).

7. Results and Discussion:

7.1. Variation of PV with set point:

The variation in the process variable for a given set point deviation was obtained for proportional, proportional-
integral & proportional-integral-derivative control systems.

The parameters for each of the systems and output curves compared. For Proportional (P) controller:

PV vs time (For P controller)

P=100 P=150 P=200 SV = 400
400

350
PV (ml/s)

300

250

200
0 5 10 15 20 25 30 35
time (s)

F IGURE 7: VARIATION I N P ROCESS VARIABLE WITH TIME (FOR DIFFERENT P VALUES)

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From the curve, it can be observed that the proportional controller cannot drive the offset value to zero. A
constant finite deviation from the set point remains after steady state has been attained. Further, the offset
increases with increase in the Proportional Band (P) value, but PV becomes more and more stable and it gives
no peak that can destabilize the system. ISE should be used as criteria to decide tuning.

For Proportional-Integral (PI) Controller:

PV vs time (for PI) [P=100]

430
PV (ml/s)

330
I = 10 I=3 I=5

230

130
0 20 40 time (s) 60 80 100

F IGURE 8: V ARIATION I N PROCESS V ARIABLE WITH TIME (FOR DIFFERENT I V ALUES)

For the PI controller the offset is completely driven to zero. This is due to the integral action of controller, which
acts as long as the error term exists. Higher I values increase the response time of the system. The order of
dynamics of the system increases. Final value is attained fastest for I = 3. ITAE should be the criteria to decide
the best tuning as it takes longer time to converge to set variable.

For Proportional-Integral-Derivative (PID) Controller:

PV vs time (for PID) [P=100, I=5]

500

450
PV (ML/S)

400

350

300
0 5 10 D15= 1 D=3 D 25
=4
TIME (S) 20 30 35

F IGURE 9: V ARIATION I N PROCESS V ARIABLE WITH TIME (FOR DIFFERENT D V ALUES)

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7.2 Controller Tuning:

Using the tuning process described, sustained oscillations were obtained at Proportional Band (P) = 20, while
I and D both set to 0 (i.e. OFF). Using measured parameters, the tuning settings were obtained using
Zeigler Nichols controller tuning table.

TYPE KC
P 2.5 - -

PI 2.27 3.33 -
PID 2.94 2 0.5

Table 4. Zeigler Nichols controller tuning table

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8. Annexures
Annexures 1: Sample Calculation

When P = 10, I = 0 min, D = 0 min:

Sustained periodic oscillation is obtained with period of oscillation = 5 sec

P = Proportional Band = 100/Kc, i.e. Kc = 100/P = 10

So now Ku (ultimate gain) = Kc = 10, and

Pu (ultimate period) = 5 sec

Now we can do controller tuning using Ziegler-Nichols method.
Using tuning charts, (Table 1: Zeigler Nichols Tuning Chart lets calculate the parameters: -
Tuning for PID Controller:
New Kc = Ku/1.7 = 5/1.7 = 5.88

So P = 100/Kc = 100/5.88 = 17.006

= I = Pu/2 = 5/2 = 2.5 sec
= D = Pu/8 = 5/8 = 0.625 sec

Sample calculation for 1st reading of 1st calculation table :

Error = SV PV = 400 207.1 = 192.9
Abs. error = || = 192.9
Error square = Error2 = 192.9*192.9 = 37210.41
For calculation of ISE, area under the curve is calculated using Simpsons rule.

Annexures 2: Calculation Tables:

P = 100
t(sec) PV(ml/s) () |()| ()2 |()|
0 286.5 113.5 113.5 12882.25 0
2 366.9 33.1 33.1 1095.61 66.2
4 359.6 40.4 40.4 1632.16 161.6
6 367.6 32.4 32.4 1049.76 194.4
8 358.9 41.1 41.1 1689.21 328.8
10 367.5 32.5 32.5 1056.25 325
12 360.3 39.7 39.7 1576.09 476.4
14 366.7 33.3 33.3 1108.89 466.2
16 360.7 39.3 39.3 1544.49 628.8

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18 365.5 34.5 34.5 1190.25 621

20 362.9 37.1 37.1 1376.41 742
22 362.3 37.7 37.7 1421.29 829.4
24 363.3 36.7 36.7 1346.89 880.8
26 363.5 36.5 36.5 1332.25 949
28 362.9 37.1 37.1 1376.41 1038.8
30 364 36 36 1296 1080
32 363.8 36.2 36.2 1310.44 1158.4
34 364 36 36 1296 1224
IAE = ISE = ITAE =
733.1 35580.65 11170.8

T ABLE 4: SAMPLE C ALCULATION TABLE F OR P C ONTROLLER

P=100,I=10
t(sec) PV(ml/s) () |()| ()2 |()|
0 135 365 365 133225 0
5 164.3 335.7 335.7 112694.5 1678.5
10 201.3 298.7 298.7 89221.69 2987
15 247.2 252.8 252.8 63907.84 3792
20 275.1 224.9 224.9 50580.01 4498
25 314.8 185.2 185.2 34299.04 4630
30 352.2 147.8 147.8 21844.84 4434
35 380.6 119.4 119.4 14256.36 4179
40 414 86 86 7396 3440
45 436.1 63.9 63.9 4083.21 2875.5
50 447 53 53 2809 2650
55 456.8 43.2 43.2 1866.24 2376
60 467.9 32.1 32.1 1030.41 1926
65 475.1 24.9 24.9 620.01 1618.5
70 484 16 16 256 1120
75 488.2 11.8 11.8 139.24 885
80 492 8 8 64 640
85 494.3 5.7 5.7 32.49 484.5
90 496.2 3.8 3.8 14.44 342
95 498.7 1.3 1.3 1.69 123.5

IAE = ISE = ITAE =

2279.2 538342 44679.5

T ABLE 5: SAMPLE C ALCULATION T ABLE FOR PI CONTROLLER

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P=100,I=10,D=1
t(sec) PV(ml/s) () |()| ()2 |()|
0 300.9 199.1 199.1 39640.81 0
2 317.4 182.6 182.6 33342.76 365.2
4 353.2 146.8 146.8 21550.24 587.2
6 381.5 118.5 118.5 14042.25 711
8 406.7 93.3 93.3 8704.89 746.4
10 426.6 73.4 73.4 5387.56 734
12 439.8 60.2 60.2 3624.04 722.4
14 452.1 47.9 47.9 2294.41 670.6
16 461.5 38.5 38.5 1482.25 616
18 468 32 32 1024 576
20 474.1 25.9 25.9 670.81 518
22 479.8 20.2 20.2 408.04 444.4
24 486.5 13.5 13.5 182.25 324
26 491.7 8.3 8.3 68.89 215.8
28 493 7 7 49 196
30 496.2 3.8 3.8 14.44 114
32 498.1 1.9 1.9 3.61 60.8
34 498.3 1.7 1.7 2.89 57.8
IAE = ISE = ITAE =
1074.6 132493.14 7659.6
T ABLE 6: SAMPLE C ALCULATION T ABLE FOR PID CONTROLLER

Annexures 3: Response curve for Tuning:

PV vs time (P=10)
440

420

400
PV (ml/s)

380

360

340

320

300
10 15 20 25 30 35 40 45 50
time (s)

F IGURE 10: RESPONSE CURVE FOR TUNING

Annexures 4: Error Analysis:

The observations made have an error of uncertainty owing to the least count of the instruments used.
These errors due to uncertainty propagate in calculations.
The following formulae have been used to perform error analysis. Error expressions have been
derived by rules of error propagation to determine the error due to uncertainty for all variables.

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z = x y; z = ()2 + ()2 (8)

z 2 2
z = x*y Or z= x/y; = ( ) + ( ) (9)

Annexures 5 :Checklist:

Switch ON the main power supply.

Start control setup and the air compressor (ensuring control valve is closed).
Start the main water supply till the main and warm tank fill supply.
Make sure the water drain is closed when tank is filled up to required height.
Ensure valve -1 and valve-6 are partially open.
Ensure valve -2 and valve-4 are open, and valve-3, 5, 7 are closed.
Start the pump.
Ensure following connections are made:
1. FY-1 TO MV-1.
2. FT-1 TO PV-3.
3. LT-1 TO PV-1.
Open the LL1200 application on the PC.
Select loop 2 in the application and make sure the loop is open.
Give a necessary set point for the flow.
Observe the variation of the manipulated and process variable (valve opening and flow respectively).

Also change the values of the control parameters (P, I, D) and observe and analyze the corresponding change
in the plot.

9. Conclusions and Comments:

Conclusions:

The study of determination of effect of PID controller were studied and verified. It was observed as a general trend

that as the change of controller from P to PID, the stability of the controller increases and reach the
steady state fast. Also, a second-order polynomial as fit to the plot of COP v/s Set Point. The fit was a
good fit as observed from a R2 value of 0.1505.

Comments:

1. The layout of the system should be expanded, as there is very less space to stand and perform the experiment.
2. Proper knowledge of least count all equipment unknown.

10. Precautions:
The performance of this experiment warrants certain precautionary measures which safeguard the performer as
well as the equipment. These precautions are listed as:

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1. Proper handling of Pressure.

11. References:
Stephanopolous,G.; Chemical Process Control, Prentice-Hall, 1984

Seborg, D.E., T.F. Edgar, D.A. Mellichamp; Process Dynamics and Control, John Wiley & sons,1989

Coughanowr D.R.; Process System Analysis and Control,2nd edition McGrawHill,1991

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