Process Control

Stability Analysis and Controller Tuning

Riezqa Andika
 Stable vs Unstable
 1 d CV 
MV (t ) = K c  E (t ) +  E (t' )dt '−Td +I
 TI 0 dt 
20

No!
v -20

1TC -40
0 20 40 60 80 100 120

or
0.8

v 0.6

2 Yes! 0.4

0.2

-0.2
0 20 40 60 80 100 120

We influence stability when we implement control.

How do we achieve the influence we want?
 What is Stability?
First, let’s define stability: A system is stable if all bounded inputs to the
system result in bounded outputs.

Sample Inputs Process Sample Outputs

1 1

0.5 0.5

bounded
bounded

0 0

-0.5 -0.5
T6 P1
Vapor
product
-1 -1
0 0.5 1 1.5 0 0.5 1 1.5
T1 T5
T2

Feed
F1 T4 T3 L1

F2 F3

A1
Liquid
Process Steam product
L. Key
fluid

unbounded
unbounded
 Stability: Review
Let’s review how we
G(s) = Y(s)/X(s) determine the stability
of a model.
With i the solution to the denominator of the transfer function being zero,
D(s) = 0 giving s = 1, 2 , i ... .

1t  2t  pt
Y (t ) = A0 + A1e + A2 e + ... + ( B0 + B1t + B2t + ..)e
2
+
 qt
... + [C1 cos(t ) + C2 sin(t )]e + ...
Real, repeated i
Real, distinct i
Complex i

If all i are ???, Y(t) is stable

If any one i is ???, Y(t) is unstable
 Stability: Review
Quick review of model for closed-loop feedback system.

D(s) Gd(s)
SP(s) E(s) MV(s) CV(s)
+ +
GC(s) Gv(s) GP(s)
- +
CVm(s)
GS(s)

Transfer functions Variables

GC(s) : controller CV(s) : controlled variable
Gv(s) : valve + CVm(s) : measured value of CV(s)
GP(s) : feedback process D(s) : disturbance
GS(s) : sensor + E(s) : error
Gd(s) : disturbance process MV(s) : manipulated variable
SP(s) : set point
 Stability: Review
D(s) Gd(s)

SP(s) E(s) MV(s) CV(s)

+ +
GC(s) Gv(s) GP(s)
- +
CVm(s)
GS(s)

Set point response Disturbance Response

CV ( s ) G p ( s )Gv ( s )Gc ( s ) CV ( s ) Gd ( s )
= =
SP( s ) 1 + G p ( s )Gv ( s )Gc ( s )GS ( s ) D( s ) 1 + G p ( s )Gv ( s )Gc ( s )GS ( s )

The denominator determines the stability of

the closed-loop feedback system! We call it the
characteristic equation.
 Stability
Direction Solution for the Roots to determine the stability

Controller is a P-only 1 + G p ( s )Gv ( s )Gc ( s )GS ( s )

controller. Is the
KC K P K C ( 0.039 )
system stable? Let’s 1+ =1+ =0
evaluate the roots of (1 + τs )3
(1 + 5s ) 3

the characteristic
125s 3 + 75s 2 + 15s + 1 + 0.039 K c = 0
equation.

FS
solvent

FA
pure A

AC
 Stability
0.5

0.4
Plot of real and imaginary parts of the
roots of the characteristic equation -
0.3 three roots for cubic
0.2 Kc
250 0
0.1
Imaginary

-0.1

-0.2

-0.3
As the controller gain, KC, is increased,
some roots approach, then cross into
-0.4
the unstable region.
-0.5
-0.7 -0.6 -0.5 -0.4 -0.3
-0.2 -0.1 0 0.1
Real

Stable Unstable
Stability Analysis
 Stability Analysis

The denominator Set point response

determines
the stability of CV ( s ) G p ( s )Gv ( s )Gc ( s )
=
the closed-loop SP( s ) 1 + G p ( s )Gv ( s )Gc ( s )GS ( s )
feedback system!

For the mixer : 125s 3 + 75s 2 + 15s + 1 + 0.039 K c = 0

Bode Stability Method

Calculating the roots is easy with standard software. However, if the equation has
a dead time, the term e -s appears. Therefore, we need another method.
Th method we will use next is the Bode Stability Method.
 Stability Analysis
Bode Stability: To understand, let’s do a thought experiment
“steady state”
For closed loop system, if the
sine is larger in amplitude after
one cycle; then it will increase
each “time around” the loop.
Open Loop
The system will be unstable.
When the sine has a lag of 180°
due to element dynamics, the
feedback will reinforce the
oscillation (remember the - sign).
This is the critical frequency.

Closed Loop
 Stability Analysis
The Bode stability criterion states that a closed-loop linear
system is stable when its amplitude ratio is less than 1 at its
critical frequency. The system is unstable if its amplitude ratio
is greater than 1 at its critical frequency.

GOL(s) includes all elements in the closed loop.

At the critical frequency:  GOL(cj) = -180
The amplitude ratio: |GOL(cj) | < 1 for stability
|GOL(cj) | > 1 for stability
 Stability Analysis
Bode Stability: Let’s do an example: three-tank mixer with 5 minutes dead time
added

 GOL(cj) = -180 |GOL(cj) | < 1 for stability

K P e −θ s   1 
GOL ( s ) = Gc ( s )Gv ( s )G p ( s )Gs ( s ) =  K c 1 +  
(1 + s )3  
  TI 
s

Process Controller tuning w/o dead time

K P = 0.039 % A/% open K c = 30 % open/% A

 = 5 min TI = 11min
 = 5 min
Stability Analysis

Conclusion?
Stability Analysis

<1 Conclusion:
Stable

The sine will decrease

in amplitude each time
around the loop.
 Stability Analysis
S-LOOP plots deviation variables (IAE = 42.1962)
2
Controlled Variable

1.5
Stable, but
1 performance
poor, why?
0.5

0
0 50 100 150 200 250
Time

60
Manipulated Variable

40

20

0
0 50 100 150 200 250
Time
 Stability Analysis
S-LOOP plots deviation variables (IAE = 42.1962)
2
Controlled Variable

1.5
Stable, but
1 performance
poor, why?
0.5

0
0 50 100 150 200 250
Time

60

PI tuning was for the process

Manipulated Variable

40 without dead time. The process

with dead time is more difficult
20
to control. Must detune!

0
0 50 100 150 200 250
Time
Tuning
 Assignments
Watch the following video (in order):

1. Control System Lectures - Bode Plots, Introduction

(https://www.youtube.com/watch?v=_eh1conN6YM)
2. Bode Plots by Hand: Real Constants
(https://www.youtube.com/watch?v=CSAp9ooQRT0)
3. Bode Plots by Hand: Poles and Zeros at the Origin
(https://www.youtube.com/watch?v=E6R2XUEyRy0)
4. Bode Plots by Hand: Real Poles or Zeros
(https://www.youtube.com/watch?v=O2Cw_4zd-aU)
5. Bode Plots by Hand: Complex Poles or Zeros
(https://www.youtube.com/watch?v=4d4WJdU61Js)
6. Introduction to System Stability and Control
(https://www.youtube.com/watch?v=uqjKG32AkC4)
7. Stability of Closed Loop Control Systems
(https://www.youtube.com/watch?v=yf09OrHa520)