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Control Loop Tuning
Control Loop Tuning
1003740
9839449
9839449
Power Plant Control System Tuning
Short Course Notes
1003740
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9839449
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Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
9839449
CITATIONS
Principal Investigators
C. Taft
The report is a corporate document that should be cited in the literature in the following manner:
Power Plant Control System Tuning Short Course Notes, EPRI, Palo Alto, CA: 2004. 1003740.
iii
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ABSTRACT
Power plant control system tuning is a continuing challenge for many power producers. To help
address the problem, EPRI began a project in 2002 to investigate improved methods for control
system tuning. One of the tasks undertaken in that project was the development of a power plant
control system tuning short course. This report provides approximately 100 slides that make up
the bulk of the course material. In addition, tuning demonstrations using computer simulation
software will be a part of the course. The course notes provided here include information on
process response concepts, control system fundamentals, PID tuning, and boiler control system
applications examples. It will be useful for plant engineers and technicians involved with control
system tuning and plant responsiveness.
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TABLE OF CONTENTS
1 INTRODUCTION.................................................................................................................1-1
2 COURSE OUTLINE.............................................................................................................2-1
vii
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1
INTRODUCTION
Power plant control system tuning is a continuing challenge for many power producers. To help
address the problem, EPRI began a project in 2002 to investigate improved methods for control
system tuning. The project has already produced several short reports on power plant control
system tuning, including one on tuning assessment and one on PID controller tuning software
programs (see Section 3 for complete reference list). The latest effort was the development of a
short course on fossil power plant control system tuning.
This technical update provides the latest information on the course. Section 2 contains the
course outline, and Section 3 provides approximately 100 slides that make up the bulk of the
course material. In addition, tuning demonstrations using computer simulation software will be a
part of the course, but are not included in these notes. The two-day course will be offered at the
EPRI Instrumentation and Control Center in Harriman, TN. The course notes provided here
include information on process response concepts, control system fundamentals, PID tuning, and
boiler control system applications examples. It will be useful for plant engineers and technicians
involved with control system tuning and plant responsiveness.
1-1
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2
COURSE OUTLINE
2-1
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Course Outline
2-2
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3
COURSE NOTES
This section contains the slides that make up the course notes.
3-1
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Power Plant Control
System Tuning
Short Course
Course Notes
by Cyrus W. Taft, PE
EPRI I&C Center
Course Objectives
2 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
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1
Tuning References
• EPRI Reports
– Tuning Guidelines for Utility Fossil Plant Process Control,
EPRI, Palo Alto, CA: TR-102052, Volumes 1-4, 1993-1994.
– Power Plant Control System Tuning, EPRI, Palo Alto, CA: TE-
113653, 1999
– Automated Control System Tuning: Issues, Available
Solutions, and Potential for Improvement, EPRI, Palo Alto, CA:
1004067, 2001
– Control System Tuning Assessment Guidelines, EPRI, Palo
Alto, CA: 1004425, 2002
– Review of State-of-the-Art PID Controller Tuning Software
Programs, EPRI, Palo Alto, CA: 1004080, 2004
3 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
Tuning References
• Books
– Astrom, K.J. and Hagglund, T., PID Controllers: Theory, Design
and Tuning, ISA, Research Triangle Park, NC: Second Edition,
1995.
– McMillan, G. K., Tuning and Control Loop Performance, ISA,
Research Triangle Park, NC: Second Edition, 1983.
– Corripio, A. B., Tuning of Industrial Control Systems, ISA,
Research Triangle Park. NC: 1990.
– Dukelow, S. G., The Control of Boilers, ISA, Research Triangle
Park. NC: Second Edition, 1991.
– Levin, W., Editor, The Control Handbook, CRC Press, Boca
Raton, FL: 1995.
4 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
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Tuning References
• Papers
– Morse, R. H., et al, Aspects of Tuning a Boiler Control System - A
Strategy for Optimization, ISA IPI 76462, pp 121-142, ISA POWID
Symposium Proceedings, 1976.
– Hubby, R. N., Pulverizer Control, A Tutorial Review, ISA, ISBN1-
55617-213-3, pp 157-164, ISA POWID Symposium Proceedings,
1991.
– Taft, C. W. and McFarland, G., A Guide to Boiler Control System
Startup and Checkout, ISA, First Joint ISA POWID/EPRI Controls
and Automation Conference Proceedings, 1991.
– Heuszel, C. B., Methods of Accurate Control for Environmental
Compliance, Tutorial presented at ISA/94 Conferences in
Philadelphia, PA, and Anaheim, CA., 1994
5 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
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Tuning Terminology
• Process - The system being controlled, e.g., the feedwater flow system or the air
flow system. Also referred to as the plant.
• Controller - the device or algorithm which is manipulating the process input to
effect a change. Most common is PID controller but there are many other
possibilities.
• Actuator - The device which moves the final control element, such as a valve or
damper, in response to command signals from the controller. May use
pneumatic, electric or hydraulic power.
• Feedback - A type of control in which a measurement of the process is used by
the controller to adjust the final control element. The concept of feedback is used
in all major control functions in a power plant.
• Controlled variable - The process parameter being controlled by the control
system. Also called the process variable.
• Manipulated variable - The controller output signal.
7 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
• Open loop - The system has no feedback in service. Also means the control
loop is in manual mode.
• Closed loop - Feedback from the process is being used by the controller.
Control loop is in automatic mode.
• Gain - The output of a system divided by its input. A measure of the change in
signal size as it passed through a system.
• Frequency response - The output of a system in response to a sine wave input
signal at many different frequencies. Usually specified as a gain and phase shift.
• Step response - The output of a system in response to a step change in the input
signal.
• Impulse response - The output of a system in response to an impulse change in
the input signal. In theory an impulse is an infinitely large and infinitely short
pulse.
8 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
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Tuning Terminology, cont’d
9 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
• There are two methods commonly used in power plant control analysis
– SAMA (Scientific Apparatus Makers Association) Diagrams
– Block Diagrams
• SAMA diagrams functional diagrams in which on block represents one
control system function, such as a summer. They are normally used by
control system vendors to describe how the system works. They
contain no information about the process being controlled.
• Block diagrams are more mathematically oriented and are used widely
in control system analysis. They show the control system and the
process being controlled.
• Both types will be used in this course.
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SAMA Diagram Example
FT LT PT FT Circle - Measurement
or readout device
Density
Compensation Measurement
∆ ∆ Rectangle -
Automatically
PI PID Κ processed function
Control
Participation
Σ f(t)
Σ −Κ Σ
f(x) f(x)
A T A A T A
Output
Diamond - Manually
controlled function
11 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
Disturbance Controlled
Variable or
Process
Setpoint Variable
8___
Kp + Ki/s
+ 38s + 1
-
Manipulated
Error
Variable
1___
4s + 1
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Process Response Concepts
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Common Process Time
Responses to Step Inputs
e
2
• Most common is 1st order with
d
ut
i
1 deadtime
ng
M
a 0 – Characterized by 3 parameters:
0 5 10 15
Integrator 20 25 30 gain, time constant, deadtime
e
4 – Gain - ratio of final change in
d
ut
i 2 output to change in input.
gn
M
a
0 – Time constant - time to 63% of
0 5 10 15
Deadtime 20 25 30 final response.
e
1 – Deadtime - time before any
d
ut
i Deadtime response begins.
ng
0
M
a – No overshoot in step response
0 5 10 15 20 25 30
Time (seconds)
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Integrator Plus Deadtime
Process Examples
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Closer Look at the Process
• Every process
Disturbance Controlled
Variable or
Process
Setpoint
processes
Manipulated
Error Variable
1___
4s + 1
• Total response is
combination of all
blocks
Process
Controlled
Variable or
Manipulated Process
Variable Variable
Desuper-
I/P Booster Diaphragm Valve
heater
Thermocouple
What
Operator
Sees
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Feedback
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Proportional-Integral-Derivative
(PID) Controller
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PID Controller Step Responses
• Proportional Output = 3
Kp * Input 2
p
or
• Integral Output = P 1
Ki * Int(Input) 0
0 5 10 15 20 25 30
• Derivative Output = 15
Kd * d/dt(Input) 10
t
nI
5
0
0 5 10 15 20 25 30
1.5
vi 1
r
e
D 0.5
0
0 5 10 15 20 25 30
Time (seconds)
23 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
• Parallel
• Kp * (e) + Ki * Int(e) + Kd * d/dt(e)
– Kp, Ki, and Kd are all independent
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Proportional Only Control
(Single-mode control)
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Proportional plus Integral plus Derivative Control
(Three-mode control)
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Cascade Control
• Two feedback loops nested together with the output of the primary loop controller
acting as setpoint for the secondary loop. This control scheme requires that the
secondary loop be much faster than the primary loop.
• Example:
– Drum level control (slow primary or outer loop)
– Feedwater flow control (fast secondary or inner loop)
∆ Outer Loop
PID Measurement
To Actuator
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Cascade Control
• Advantages:
– Disturbances arising within the secondary loop are corrected by
secondary controller before they influence primary controller.
– Secondary loop linearizes the process response improves the
speed of response of the primary loop.
• Disadvantages:
– More complex strategy, more tuning adjustments.
– Control of each variable is assumed single-loop and is designed to
operate satisfactorily, Instability may occur when both loops are
closed (in auto).
– Cascade control requires that an intermediate process variable can
be reliably measured.
– Secondary loop must be significantly faster than primary loop.
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Feedforward Control
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Feedforward Control
Process
Feedforward
Variable
FT TT
∆ A
PID
K f(x) Σ
To Actuator
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Trim Controller
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Trim Controller
Demand Process
Signal Variable
FT TT
0 to 100%
∆ A
PID
Trim Controller
-20% to +20%
0 to 100%
Main Signal
Flow
To Actuator
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Loop Error Step Response
1.2
∆
1
0.8
Loop Error
Magnitude
0.6
0.4
d
K dt 0.2
-0.2
0 5 10 15 20 25 30
Time (seconds)
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What is Digital Control?
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Digital Controller
Field D/A
A/D Controller Actuator
Transmitter Converter Converter
Analog Analog
Analog
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Digital Data Sampling
S te p R e s p o n s e
2 .5
1 .5
Amp litu d e
0 .5
0
0 5 10 15 20 25
Time (s a mp le s )
39 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
Aliasing
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Aliasing
0 .5
-0 .5
-1
0 20 40 60 80
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Control System
Performance Requirements
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Control System
Performance Measurements
1.8
1.6
1.4 Overshoot
1.2
1
Magnitude
0.8
0.6
0.4
Rise Time
0.2
0 Settling Time
0 5 10 15 20 25 30
Time (seconds)
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Power Plant Control System
Performance Goals
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PID Tuning Concepts
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Proportional Tuning Example
Controlled Variable
0.8 Gain = 1.6
• No need to do test at a gain of
1.6 because 0.8 was already to Gain = 0.8
high. 0.6
0.4
• Large offset at “best” gain. Gain = 0.2
0
0 5 10 15 20 25 30
Time (seconds)
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Integral Tuning Example
Controlled Variable
1
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Derivative Tuning Example
Controlled Variable
overshoot.
0.6
• Simulation results not always
realistic with derivative because Kd = 0.8
there is no noise. 0.4
Kp = 0.8
-0.2
0 5 10 15 20 25 30
Time (seconds)
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Analytical Tuning Methods
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Analytical Tuning Example
0.75
0.5
0.25
L L = 0.8
a = 0.22
-0.25
-0.5
0 1 2 3 4 5 6 7 8 9 10
57 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
Controller K Ti Td
P 0.7/a
PI 0.7/a 2.3L
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Analytical Tuning Example
• From previous table, for a PID controller the tuning would be:
• K = 1.2/a = 1.2/0.22 = 5.45
• Ti = 2.0L = 2.0*0.8 = 1.6
• Td = 0.42L = 0.42*0.8 = 0.336
• With this tuning, the disturbance rejection response would be as
shown below. 1
Disturbance Rejection
0.8
0.6
0.4
Controlled Variable
0.2
-0.2
-0.4
-0.6
-0.8
-1
0 5 10 15 20 25 30
Time (seconds)
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PID Tuning Software
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System Linearity Issues
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120
100
Controlled Variable (Output)
80
Pretty Bad
40
20
0
0 20 40 60 80 100 120
Manipulated Variable (Input)
64 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
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Characterization Example
Linear
Non-linear
Non-linear
Controlled
Setpoint Variable
PID F(x) Actuator Process
+ -
Measurement
90 90 90
80 80 80
70 70 70
Manipulated Variable
Controlled Variable
Controlled Variable
=
60 60 60
50
40
30
+ 50
40
30
50
40
30
20 20 20
10 10
10
0 0
0
0 20 40 60 80 100 0 20 40 60 80 100
0 20 40 60 80 100
Controller Output Manipulated Variable
Controller Output
65 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
Gain Scheduling
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Boiler Control Loops
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Approach to Boiler Control
Tuning on a New Unit, continued
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Unit Master
Throttle
Megawatts
Pressure
Excess Oxygen
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Actuator Setup and Tuning
71 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
f(t) f(x)
A
Σ
PID
Drum Level
Controller
FW Flow PID
Controller
3-Element Control
T A
BFP Demand
72 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
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Drum Level Tuning Notes
73 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
Furnace Pressure
f(x)
PID
Controller
T A
Spray Valve
Demand
74 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
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Furnace Pressure Control Tuning Notes
75 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
f(x)
> Cross
Limiting
< Programmed
O2 Setpoint
f(x)
× PID O2
Controller
Air
T A
Master
FD Fan Demand
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Air Flow Control Tuning Notes
77 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
Fuel Control
PID
Feeder
Demand
to
Feeders
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Fuel Control Tuning Notes
79 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
Σ Σ
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Throttle Pressure Control Tuning Notes
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f(x)
A
PID Final SH Outlet
Controller
Desuperheater
Outlet Controller
PID
Σ
Typical Feedforward Signals:
T A
Steam Flow, Drum Pressure,
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Steam Temperature Tuning Notes
83 Copyright © 2004 Electric Power Research Institute, Inc. All rights reserved.
A
Dispatch
Unit Demand
Σ Σ
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Unit Master Control
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Boiler Control Notes
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Thank you
and
The End !!
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