Tuning Control Loops

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http://www.scribd.com/doc/17453983/Tuning-Control-Loops[19.09.2010 9:56:51]
Tuning Control Loops

Tuning Control Loops

Page 2 of 7
Assume
50% proportional band, PB = PROPORTIONAL BAND
GAIN =
100% (span)
50% (PB)

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Tuning Control Loops

GAIN =
2
Honeywell uses letter “K" to represent GAIN, therefore K =
2.
INTEGRAL OR RESET (T1)
•

Integral action repeats the proportional controllers initial corrective signal until there
is no difference between the PV and Setpoint.
•
Integral ( T1 ) is expressed in "Minutes per Repeat"
DERIVATIVE (T2)
•
Changes the output of a controller in proportion to the "RATE" or "SPEED" at which
the controlled variable is moving towards or away from the setpoint.
•
Derivative action is expressed in minutes.
•

Represents the time that the proportional plus derivative will take to reach a certain level of
output, in advance of the time proportional action alone would produce the same output.

i.e: When derivative is applied to a two mode controller ( PI ), to make it a three mode controller ( PID ),
it's action consists of decreasing the number of repeats per minute required to drive the error back to
setpoint.

TUNING
ADJUST PROPORTIONAL BAND

Always tune proportional band with very little reset action. That is, for instance with a speed control
loop, always set the reset (integral) adjustment at, say twenty or thirty seconds or more before adjusting
the proportional band.

Then, adjust the proportional band to a smaller value (higher gain) until cycling or instability
begins.
EXAMPLE: Start with 40% proportional band (a gain of 2.5); then halve the proportional
band to 20% (a gain of 5); then halve the proportional band to 10% (a gain of 10); etc.

When cycling just begins, increase the proportional band by 50 percent. That is, from 10% to 15%; from
18% to 24%; etc. Cycling should stop. The proportional band adjustment should now be properly set
and should be left at this value.

ADJUST RESET (INTEGRAL) ACTION

This is done by reducing the time value (in seconds). Say the reset is at twenty seconds. Then reduce the
reset
Tuningto ten seconds;
Control then reduce the reset to five seconds; then reduce the reset to two seconds; etc.
Loops
When cycling
Page 3 of 7 or instability begins, increase the reset adjustment by 50%.
Berry’s Commissioning Handbook
Example: If cycling is observed at two seconds, increase the reset to three seconds. If cycling is
observed at 8 seconds, increase the reset to 12 seconds, etc. The reset action should now be properly
adjusted and should be left at this value.

ADJUST DERIVATIVE ACTION (RATE)

If a derivative adjustment is felt necessary, adjust the derivative action by beginning at a setting of one

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Tuning Control Loops

second, then two, then three, until improvement is observed and seems to be optimal. Normally,
derivative action is not needed and does not help the situation.

TUNING CONTROLLERS
Since there are a very large number of combinations of the two or sometimes three, "knobs"
provided for controller tuning, many methods have been developed over the years to aid in
their proper adjustment. A few require upsetting the process to some extent, often an
unacceptable practice in real life. These notes are intended to provide a few simple rules to
use in tuning
controllers which will minimize upsets and still get the job done.

THE CONTROLLER MUST BE ADJUSTED TO BALANCE THE PROCESS.

If the process is fast to respond (i.e. a flow loop), then the controller must be tuned fast too.
Fast or slow for a controller refers to integral (or reset).
NOT PROPORTIONAL BAND (or gain).

Do not confuse these actions or grief will be your constant companion during your controller tuning
efforts. If the process is slow (i.e. temperature control of a tray part way up a distillation column), then
the controller must be tuned slow TO MATCH THE PROCESS. If you do not have a feel for the process
characteristics or cannot find someone to enlighten you, leave controller tuning to someone else who
can get the needed information.

GENERAL RULES FOR COMMON LOOPS

FLOW

Usually, at least half of the control loops in a plant are flow loops. Set integral (I) at 0.1
minutes. Adjust the proportional band so that the measurement is not too noisy, usually about
300% although an occasional poor meter run installation may require as much as 1000%. A
loop where a valve positioner has been used will require a proportional band setting two to
Tuning
three timesControl
larger Loops
than for a loop without a positioner. Slow moving or sticky control valves
Page 1 of 7 0.2 or 0.3 minutes but are rare exceptions. If these settings do not work, inspect
may require
Tuning
the valve Control
and orificeLoops installation to find the, problem. Fix the problem. Do not adjust the
Table of Contents
controller to some ridiculous setting such as a 10 minute reset time. Use the controller in
manual or a hand valve if you think a 10 minute reset time is necessary.
TUNING CONTROL LOOPS...................................................................................................1
TUNING
IMPORTANT CONSTANTS....................................................................................................
NOTE: No controller will work when the valve is almost closed or almost wide 1
PROPORTIONAL
open. Don't attempt tuning under these conditions. Have the operator open or close a bypass. .(if
BAND (K)......................................................................... . . . . . . . . . . .one
.1
GAIN (K) CALCULATION..........................................................................................
exists) or wait until process conditions change enough to get the valve back within its operating 1
INTEGRAL
range (from 5or to RESET (T1)..........................................................................................
95% of travel as extreme limits with 10 to 90% as a safer range). Never2use
DERIVATIVE (T2).........................................................................................................
derivative action in a flow loop. 2
TUNING.............................................................................................................................2
ADJUST
LEVEL PROPORTIONAL BAND........................................................................ . . . . . . 2
Berry’s Commissioning
ADJUST RESET Handbook
(INTEGRAL) ACTION....................................................................2
ADJUST DERIVATIVE ACTION (RATE)...................................................................3
TUNING CONTROLLERS...................................................................................................3
GENERAL RULES FOR COMMON LOOPS..................................................................3
FLOW.............................................................................................................................3
LEVEL...........................................................................................................................3
LIQUID PRESSURE.....................................................................................................4
GAS PRESSURE........................................................................................ . . . . . . . . . . . . . . . . . . .4
TEMPERATURE, VAPOR PRESSURE, AND COMPOSITION.................................4

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Tuning Control Loops

CLASSICAL CONTROLLER TUNING METHOD....................................................5

CASCADE AND OTHER INTERACTING CONTROL LOOPS................................5
DEFAULT CONTROLLER TUNING PARAMETERS....................................................6
CONTROL LOOP SCAN RATES.................................................................................6
PID ALGORITHM DEFAULT TUNING CONSTANTS..............................................6

TUNING CONTROL LOOPS

TUNING CONSTANTS
PROPORTIONAL BAND (K)
•
If Proportional Band is 100%, each percent of change at the input to the controller
will produce the same percent of change at the controller's output.
•

If a Proportional Band is less than 100%, each percent change of input signal to the
controller will produce a greater percent of change at the controller's output.
•
If a Proportional Band is larger than 100%, each percent change in input signal to the
controller will produce a smaller percent of change at the controller's output.
•

The Proportional Band that is selected for a particular operating situation determines how much
corrective signal the controller can produce for each percent of change in the variable
controlled by the controller.
•
The controller's output signal determines the amount of movement that will be
produced at the control valve.
GAIN (K) CALCULATION
Ratio of entire span of measurement to percent span being used as Proportional Band.
GAIN =
100% (the entire span of measurement)
% of span being used as a proportional band
Berry’s Commissioning Handbook

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Tuning Control Loops

http://www.scribd.com/doc/17453983/Tuning-Control-Loops[19.09.2010 9:56:51]
Tuning Control Loops

http://www.scribd.com/doc/17453983/Tuning-Control-Loops[19.09.2010 9:56:51]
Tuning Control Loops

Tuning Control Loops

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