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Basics of Process Control and Loop Tuning

Thursday, 13th of October 2022 | Technical Topic Webinar

Presented By
Dr. Steve Mackay – EIT Founder and Dean of Engineering
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Introduction - Presenter

Dr. Steve Mackay

EIT Dean of Engineering
Founder of EIT
His leadership has inspired EIT’s unique and distinctive approach to
engineering education.
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Agenda

1 Welcome and Introduction

2 Introduction to Process Control
3 Tuning
4 Cascade loops
5 Dead time issues
6 Conclusion and Q&A
Introduction to Process Control
Loop Controllers and Process
Concept of Tuning
Objectives of Tuning (1)

1 - Minimize Integral of error

Objectives of Tuning (2)

2 - Minimize Amplitude of error squared

Other Aspects of Tuning (3,4,5)

3 - Minimize wear and tear

4 - No overshoot at Start-Up

5 - Minimize effect of known disturbances

Loop Controllers and Process
Steps of Open Loop Tuning (Reaction Curve)

1. Put controller in manual mode

2. Make a step change to the OP
value
3. Observe Reaction Curve
4. Calculate timing constants
Continuous Cycling - Ziegler & Nichols

› Find critical value of K for continuous oscillations

› Do not use I or D - control
› Observe critical frequency for 180° phase shift
› Stabilize loop by reducing K and ensure that I & D
› Control still gives a phase lead
P-only for Continuous Cycling Method
Continuous Cycling Method

1. Put controller in P - control onlyDo not use I or D – control

2. P - control on ERR = (SP - PV)
3. Controller in Auto
4. Step change to SP
5. Double value of K until continuous cycling
6. Calculate tuning constants
Calculation of Tuning Constants

P – Control KC = 0.5  KU

PI - Control KC = 0.45  KU
PU
Tint = 12
.
PID - Control KC = 0.6  KU
PU
Tint = 2
PU
Tder = 8
First Order Lag
First Order Lag Response Curve
Cascade Control
Single Loop Temperature Control
Two Controller Basic Cascade Control
Tuning of Cascade Loops (cont…)

› Cascade Control - Secondary Controllers

• Mainly flow controller
• No D - control as mainly stable
• K<1

› Cascade Control - Primary Controllers

• Observe critical frequency for 180° phase shift
• Stabilize loop by reducing K and ensure that I & D
• Control still gives a phase lead
Long Process Deadtime in
Closed Loop Control & The
Smith Predictor
Process Deadtime

› Difficult problem to overcome long deadtime in feedback control loop

› Especially when deadtime more than 20% of total time taken for PV to
settle to its new value after last setpoint change
Example of Process Deadtime

Illustration of a long conveyor

system giving an excessive
deadtime to the control loop
Overcoming Process Deadtime

› Depends on operating requirements of process

› Easiest solution: de-tune controller to slower response rate so that
controller will not over compensate unless deadtime excessively long
› Integral mode of controller very sensitive to deadtime since during
period of PV inactivity, integrator ramps output
Want to learn more?
We have a range of courses you can learn more about process control and tuning controllers.

Course Intake/start date

Professional Certificate of Competency in Instrumentation, Automation and Process Control 14 March 2023

52886WA Advanced Diploma of Industrial Automation Engineering 7 March 2023

Bachelor of Science (Industrial Automation Engineering) 13 February 2023

Graduate Certificate in Industrial Automation Engineering 2 January 2023

Graduate Certificate in Programmable Logic Controllers and SCADA 2 January 2023

Master of Engineering (Industrial Automation) 2 January 2023

See our full course schedule here: www.eit.edu.au/schedule/

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