CE2PSC - Process Control

9 PID controller tuning

Chemical Engineering & Applied Chemistry

Aston University

1
Recap PID controller

2
PID controller: Characteristic summary
• A proportional controller (Kp) will have the effect of reducing the
rise time and will reduce, but never eliminate, the steady-state error.
• An integral control (τI) will have the effect of eliminating the steady-
state error, but it may make the transient response worse.
• A derivative control (τD) will have the effect of increasing the
stability of the system, reducing the overshoot, and improving the
transient response.

Response of Rise time Overshoot Setting time S-S error

the increase of
Kp Decrease Increase Small change Decrease
τI Increase Decrease Decrease Eliminate
τD Small change Increase Increase Small change

3
PID LOOP SIMULATOR
Process
Gain (K) 1
Time Constant (T) 10 Output
Set Point Controller Process Process
Delay (L) 10 C + 1/Is + Ds K/(1+Ts) * e^(-Ls)
+
Controller -
Gain (C) 1.2
Integral (I) 12
Derivative (D) 1.2

(All times in seconds)

PID Loop Simulation Process Value Set Point

1.6

1.4

1.2
SetPoint / Process Value

0.8

0.6

0.4
4
0.2
DV

e(t)=SP-PV CO, p(t) MV PV

SP +
Controller FCE Process
-

PV
Measurement

• Process can have very different dynamics. How can we apply the same
equation to so many different processes? How to achieve the dynamic
performance that we desire?

The adjustable parameters are called tuning constants. The procedure

of adjusting tuning constants to achieve the desire system performance is
called controller tuning.
5
6
Performance Criteria for Closed-loop systems

• Must be stable.
• Provide good disturbance rejection---minimizing the effects of
disturbance.
• Have good set-point tracking---Rapid, smooth responses to set-
point changes
• Eliminate steady state error (zero offset)
• Avoid excessive control action.
• Must be robust( or insensitive) to process changes or model
inaccuracies.

7
Trial and error method
• Proportional action is the main control. Integral and derivative
actions are used to trim the proportional response.
• The starting point for trial and error tuning is always with the
controller gain, integral action and derivative action all at a
minimum.
• Make adjustments in the controller gain by using a factor of 2, that
is, 0.25, 0.5, 1.0, 2.0, 4.0 and so on.
• The optimal response is one’s chosen criterion, for example, quarter
decay ratio or less.
𝑐
𝐷𝑒𝑐𝑎𝑦 𝑅𝑎𝑡𝑖𝑜=
𝑎

• When in trouble, decrease the integral and derivative actions to a

minimum and adjust the controller gain for stability. 8
PID LOOP SIMULATOR
Process
Gain (K) 1
Time Constant (T) 10 Output
Set Point Controller Process Process
Delay (L) 10 C + 1/Is + Ds K/(1+Ts) * e^(-Ls)
+
Controller -
Gain (C) 1.2
Integral (I) 25
Derivative (D) 2

(All times in seconds)

PID Loop Simulation Process Value Set Point

1.2

1
SetPoint / Process Value

0.8

0.6

0.4

0.2
9
0
On-line controller tuning

• Continuous cycling method

• Relay auto-tuning
• Step test method (process reaction curve method)

10
Continuous cycling method

• Ziegler and Nichols (1942)

– Setting D to zero and I to the largest possible value.
– Set KC to a small value.
– Introduce a small, momentary set-point change. Gradually increase KC
in small increments until continuous cycling occurs.
– The value of KC that produces continuous cycling is called the ultimate
gain, KCU.
– The period of the corresponding sustained oscillation if the ultimate
period , PU.
– Calculate the PID controller settings using the Ziegler-Nichols (Z-N)
tuning relations.
– Evaluate the Z-N controller settings. If necessary, fine-tune the settings.

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Continuous cycling method

12
Continuous cycling method

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PID LOOP SIMULATOR
Process
Gain (K) 1
Time Constant (T) 10 Output
Set Point Controller Process Process
Delay (L) 10 C + 1/Is + Ds K/(1+Ts) * e^(-Ls)
+
Controller -
Gain (C) 2.19
Integral (I)
Derivative (D)

(All times in seconds)

PID Loop Simulation Process Value Set Point

1.6

1.4

1.2
SetPoint / Process Value

0.8

0.6

0.4

0.2

0 14
-10

10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
0
Kcu = 2.19
Pcu = 55 – 23 = 32 sec

Kc = 0.60x2.19 = 1.314
I = 32/2 = 6 sec
D = 32/8 = 4 sec

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PID LOOP SIMULATOR
Process
Gain (K) 1
Time Constant (T) 10 Output
Set Point Controller Process Process
Delay (L) 10 C + 1/Is + Ds K/(1+Ts) * e^(-Ls)
+
Controller -
Gain (C) 1.314
Integral (I) 16
Derivative (D) 4

(All times in seconds)

PID Loop Simulation Process Value Set Point

1.4

1.2

1
SetPoint / Process Value

0.8

0.6

0.4

0.2
16
0
Continuous cycling method:
advantages/disadvantages
Advantages
• Easy experiment; only need to change the P controller
• Includes dynamics of whole process, which gives a more accurate
picture of how the system is behaving

Disadvantage
• Time consuming.
• The test pushes the process to the stability limits.
• Not applicable to integrating or open-loop unstable process.
• For 1st and 2nd order processes without deadtime, the ultimate gain
does not exist.

17
Relay auto-tuning

4𝑑
𝐾 𝑐𝑢 =
𝜋∙𝑎

18
Relay auto-tuning: advantages/disadvantages

Advantages
• Only a single experimental test is required.
• The amplitude of the process output a can be restricted by adjusting
relay amplitude d.
• The process is not forced to a stability limit.
• The experimental test is easily automated using commercial
products.

Disadvantages
• It may not suitable for slow processes.

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Step test method (process reaction curve
method)
• Ziegler and Nichols (1942)

20
Step test method (Ziegler and Nichols, 1942)

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Step test method: advantages/disadvantages

Advantages
• Quick and easier to use than other methods.
• It is a robust and popular method.
• It is less disruptive to implement

Disadvantages
• It depends upon purely proportional measurement to estimate I and
D controllers.
• Approximations for the Kc, I, and D values might not be entirely
accurate for different systems.

22
Step test method (Cohen and Coon)

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PID tuning

• Trial and error

• Continuous cycling method
• Relay Auto-tuning
• Step test method

• The students should be able to describe the principles underlying

classical methods of controller tuning, such as continuous cycling
and reaction curve, be familiar with the Ziegler & Nichols and related
formulae, appreciate the pros and cons of such methods.

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