Chapter 14

PID Implementation Issues

 Overall Course Objectives
Develop the skills necessary to function as
an industrial process control engineer.
Skills
Tuning loops
Control loop design
Control loop troubleshooting
Command of the terminology
Fundamental understanding
Process dynamics
Feedback control
Reset Windup for PID Controllers
Windup results when the manipulated
variable is not able to control to the setpoint
resulting in sustained offset causing the
integral of the error from setpoint to
accumulate.
When control returns, accumulated error
causes an upset.
Windup can occur when a control valve
saturates or when a control loop is not being
used (e.g., select control).
 Reset Windup
y
ysp

Time
Note that controller output saturates causing area
A to accumulate by the integral action.
After the disturbance returns to its normal level,
the controller output remains saturated for a period
of time causing an upset in y.
 Anti-Reset Windup

ysp y

Time
When the manipulated variable saturates, the
integral is not allowed to accumulate.
When control returns, the controller takes
immediate action and the process returns smoothly
to the setpoint.
 Methods for Anti-Reset Windup
Turn off the integral when a valve saturates
or a control loop is not in use.
Clamp the controller output to be greater
than 0% and less than 100%.
Apply internal reset feedback
Apply external reset feedback
 Industrial Approach

External reset feedback

Controller output clamping
Digitally turn-off integral calculation
 Internal Reset Feedback
1/(Is+1)
F(s)

E(s) Kc ++ C(s)

C (s)
K c E (s) C ( s)
Is 1
K c E ( s) K c E ( s)
C ( s)
1 Is
1
Is 1 Is 1
1
C ( s) K c E ( s) 1
I
s
 Conventional PI Controller

E(s) Kc 1/Is ++ C(s)

1
C ( s) K c E ( s) 1
Is

Therefore, internal reset feedback is equivalent to

a conventional PI controller.
It still has windup, but controller output can be
clamped.
 External Reset Feedback
1/(Is+1) Um eas(s)
F(s)

E(s) Kc ++ C(s)

An extension of internal reset feedback, therefore,

it is equivalent to a conventional PI controller.
When u saturates, windup will cease preventing
windup.
Less windup than clamping, but requires umeas.
 Bumpless Transfer
When a control loop is turned on without
bumpless transfer, the process can become
unduly upset.
With bumpless transfer, an internal setpoint
is used for the controller and the internal
setpoint is ramped at a slow rate from the
initial conditions to the actual desired
setpoint to order to provide a smooth startup
of a control loop.
Comparison of True and Internal
Setpoints

True Setpoint

Internal Setpoint

Time
Control Performance With and
Without Bumpless Transfer

w/o bumpless transfer

w/ bumpless transfer

Time
 Split Range Flow Control
In certain applications, a single flow control
loop cannot provide accurate flow metering
over the full range of operation.
Split range flow control uses two flow
controllers (one with a small control valve and
one with a large control valve) in parallel.
At low flow rates, the large valve is closed and
the small valve provides accurate flow control.
At large flow rates, both valve are open.
Split Range Flow Controller

FC
FT

FT
FC
Coordination of Control Valves
for Split Range Flow Control

Smaller Control
Signal to Control Valve

Valve
(%)

Larger Control
Valve

Total Flow Rate

 Example for Split Range Flow
Control
RSP

FC

FT FT
NaOH
Acid Solution
Wastewater

pHC pHT

Effluent
 Titration Curve for a Strong
Acid-Strong Base System
14
12
10
8
pH

6
4
2
0
0 0.002 0.004 0.006 0.008 0.01
Base to Acid Ratio

Therefore, for accurate pH control for a wide

range of flow rates for acid wastewater, a split
range flow controller for the NaOH is required.
 Other Split-Range Flow Control
Examples

When the controlled flow rate has a turn

down ratio greater than 9
See value sizing examples in Chapter 2
Split Range Temperature Control

Split-Range
Temperature
Cooling Controller
Water

RSP
Steam
TT

TT TC
 Split Range Temperature Control
100
Signal to Control Valve

80

60
(%)

Cooling Steam
40 Water

20

0
Error from Setpoint for Jacket Temperature
 Overview
All controllers that employ integral action
should have anti-reset windup applied.
Bumpless transfer provides a means for
smooth startup of a control loop.
When accurate metering of a flow over a
very wide flow rate range is called for, use
split range flow control.