Controller Tuning, Reaction Curve Method

Background:

Many of the current controller tuning methods are based on defining the process model, a
differential equation describing the performance of the process requiring tuning and then using
the attributes of that model to define the proper tuning settings. This methodology is used with the
lambda method. This method simplifies the process to model “minimum-phase dynamics”.

When the dynamic elements in the process are assumed to be unable to shift phase beyond 90°
(first-order), the resulting closed loop will not exhibit a damped oscillation under proportional
control. The result is that the proportional gain assigned to the controller is purely arbitrary. Stable
control can obtain with almost any closed loop response. This is a good feature of the lambda
method. It does produce stable control with a minimum of effort.

Most processes in the chemical processing and allied industries are too complex to be defined in
those simple terms. A simple agitated tank or a simple pressure or flow control loop is the
exception to this rule. However for most processes, dead time is present. This dead time can be
in the form of transportation time, time for the process change to reach the sensor.
Another way for a process to exhibit dead time is through a series of interacting lags. An example
of this would be isotherms. This is the behavior a simple shell and tube heat exchanger exhibits.
One can visualize this by considering two countercurrent pipes exchanging heat. A step change
in one of the flows will result in a distributed lag as well as a dead time effect due to the
transportation times.

Control Performance
There are two generally excepted methods for determining control performance, integral absolute
error, IAE, and integral squared error, ISE.

∞
IAE = ∫ e(t ) dt
0

∞
ISE = ∫ e(t ) dt
2
0

For most processes the control performance will be improved if the controller is tuned recognizing
the process dead time or the distributed lags.
For these processes, a simple first order approximation will result in increased settling time. In
our lab, we can observe this effect with the heat exchanger used in experiment 2. Some of our
experiments can be better tuned by using a reaction curve method.

Reaction Curve Method

First place the controller in manual mode and wait for the PV to come to a steady state value.
Next cause a step change in the output of X percent, say 5 to 10 %. The process variable, PV,
will, after a time, begin to change and if it is a typical loop, the process variable will approach
some new value. The curve traced by the change is called the reaction curve. The reaction curve
has shows all the dynamics of the process as well as the valve, process sensor, transmitter. Draw
a line tangent to the curve. The time between the point where this line intersects with the original
process variable and the point where the test began is called the lag time, L. The slope of this
tangent curve, dPV/dT, is called the reaction rate or R. The output step change is DP and is
expressed in percent units.

131-122 =
9 DegF

dt, 60 sec

L = 68 sec

Reaction Curve Example

In the above curve, the initial PV is 120 degF and at the conclusion of the step test the PV is
132.50 degF for an input range of 0 to 200 degF. The response was created by a step change at
t=0, of 20 percent or DP = 20%. The time is in seconds. R is the slope, calculated in seconds,
and is:
R = %PV Change / Time = (100*(9)/200)/60 = 0.075
Lag time is the time, L = 68 seconds
With this information, the controller settings can be calculated as follows:
1) For a proportional only controller:
% PB = 100*R*L/DP = 100*0.075*68/20 = 25.5
Gain is defined as 100 / % PB = 3.92
2) For a proportional plus reset controller:
% PB = 110*R*L/DP = 110*0.075*68/20 = 28 Gain = 3.57
Reset = 0.3/L = 0.3/68 = 0.0044 repeats/second = 227 seconds
3) For a proportional plus reset plus rate controller:
% PB = 83*R*L/DP = 83*0.075*68/20 = 21.165 Gain = 4.725
Reset = 0.5/L = 0.5/68 = 0.0074 repeats/second = 136 seconds
Rate = 0.5*L = 0.5*68 = 34 seconds

General Comments on Controller Tuning by Z-N

Z-N tuning method should only be used for linear non-self regulating processes.
The PV response is different for set point changes than for disturbances. For set point changes
the PV will respond with a damped oscillation around the set point; for disturbances the PV will
respond with a damped oscillation either above or below the set point, but should not oscillate
around it. This fact is important, I have observed many co workers trying to get this elusive ¼
decay response and not understanding that set point changes are different than disturbances.
The decayed oscillatory response is not the same waveform as sin wave decayed under an
exponential curve. See the plot below.
The ultimate period method yields better results because the latter requires finding slopes and is
subject to graphical error.
For three mode controller tuning settings, the controller responses' damped period is very close
to the ultimate period.
For three mode tuning settings the damping factor, ζ, is 0.22 and the first peak occurs at 77.6
degrees not at 90. This because the decayed oscillatory response is not the same waveform as
sin wave decayed under an exponential curve.
The so-called ¼ decay possible with a proportional only controller is more often 1/3 for PI and
PID controllers.
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Reference:

Process control: As taught vs. as practiced

Shinskey, F. G.
Industrial & Engineering Chemistry Research, 41(16), pp.3745-3750
Publication Year 2002

Ziegler, J. G.; Nichols, N. B. Optimum Settings for Automatic Controllers

Trans. ASME 1942, Nov, 673.

Process Dynamics and Control

Seborg, D. E., Edgar, T. F., Mellichamp, D. A.
John Wiley & Sons, Inc. 1989