Professional Documents
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PID Book
PID Book
PID Book
A Pocket ~ u i d e
By Gregory K. McMillan
ISBN 1-55617-726-7
ISBN 1-55617-726-7
Signal
(%)
+L
_t point
0 Time
(secs)
setting. Otherwise, there would bc a spike in the
output.
If the tcmpcrature is below set point for a reac-
tor, as shown in Figure 2, should the steam or
water valve bc open? After looking at a faceplate
or the digital value for temperature on a graphic
display, most people think rhc stcam valve in
open when the temperaturc is below set point.
Reset provides a direction of action that is con-
sistent with human expectation. However, the
proper direction for a change in controller out-
put and the split-ranged control valve depends
upon the trajectory of the process variable (W).
Ifthe temperature is rapidly and sharply increas-
ing, the coolant valve should bc opening. Gain
and rate action will recognize that a set point is
being approached and position the valves cor-
rectly to prevent ovenhoot. Yn contrast, reset has
no sense of direction and sacriticcs future results
for immedia~esatisfaction. Most reactors, evapo
rators, ctystallizers, and columns in the process
industry have too much reset. On two separate
applications in chemical plants, for example, it
was reported that the controller was seriously
malfunctioning because the wrong valve was
rupposedly open. when in reality it was just gain
and rate doing their job to p m n t overshoot.
BC6T OF THE E A S I ~ S
Figure 2 - Reset Gives Them What They Want
temperature
m
cii steam
valve
V) opens I set point (SP)
water
valve
opens
I
time
Controller Measurement
-
."Open Lwp" Imp is in manual (PID algorithm is suspended)
."Closed Loop" - loop is in auto (PID algorithm is active)
The block diagram in Figure 6 shows all the dead
times, time constants, and steady-state gains in a
control loop. Feedback control corresponds to
the signal making one complete circle around
the block diagram. The total dead time is
approximately the sum of all the pure dead
times and small time constants as you traverse
the loop. The dead time from valve dead band is
inversely proportional to the rate of change of
the controller output, and the dead time from
transportation delays is inversely proportional to
throughput. The diagram in Figure 6 has many
uses--including preventing guests from overstay-
ing their welcome. Just show this slide and start
talking about dead time and you will be amazed
at how quickly the place empties. There is a
safety issue, however, in that guests can get tram-
pled in the rush for the door.
K, = 0.25 * TC / (TD* %)
BESTOF THE BASICS
If the loop is dead-time dominant (TC/TD<< l),
then the controller gain is proportional to just
the inverse of the open loop gain:
K O = -AAI
=- AFR APV AAI
AMV -
AAO F
AAO AMV ~ F R V
K.= 1
density area
Were:
Ff
K,
-
feed flow (pph)
= level loop integrator gain (ft/lb)
K, = overall open-loop gain (one per hour
for level, otherwise dimensionless)
GV= manipulated variable (valve or VSD)
steady-state gain (pphP10)
Kf, == flow ratio steady-state gain (inverse of
feed flow) (l/pph)
TUNINGSETTINGS
AND METHODS
Tible 2 - Default and Typical PID Settings (scan in sec, reset in rep/min, and rate in
i minutes; h = Lambda, CLM = Closed-loop method; SCM = Shortcut method)
z
0 Application Type Scan Gain Reset Rate Method
(seconds) (repeats) (minutes)
Liquid Flow/Press 1 1 (0.2-2) 1 0.3 (0.2-0.8) 110 (5-50) 10.0 (0.0-0.02) I A
z
0
V)
Tight Liquid Level
I 5 (1.0-30) 5.0 (0.5-25):
l
0.1 (0.0-0.5) 0.0 (0.0-1.0)
1l
CLM
D
Z
0
as pressure (psi.)
Reactor pH
I 2 (1.0-5)
I
0.2 (0.02-1) 5.0 (05-20)
I I
0.2 (0.1-1.0) 0.05 (0.0-0.5)
SCM
Column Temperature 10 (2.0-30) 0.5 (0.1-10) 0.2 (0.05.0.5) 1.2 (0.5-10) SCM
An errorlrquare algorithm or gain scheduling should be used for b v e l loops wHh gdnr < 5
P
a
Table 3 - Default and Typical PID Settings (scan in sec, reset in sec/rep, and rate in sec;
h = Lambda, CLM = Closed-loop method, SCM = Shortcut method)
Application Type Scan Gain Reset Rate Method
(seconds) (seconds) seconds)
Liquid FlowE'ress 1 (0.2-2) 0.3 (0.2-0.8) 6 (1-12) 0 (0-2) A
Tight Liquid Level 5 (1.0-30) 5.0 (0.5-25)* 600 (120-6000) 0 (0-60) CLM
Gas Pressure (psig) 0.2 (0.02-1) 5.0 (0.5-20) 300 (60-600) 3 (0.30) CLM
48 TUNINGSEITINGSAND METHODS
Figure 8 - General-PurposeClosed-loop Method
1 Check loop,scanlime 1
4
Adjusi gain to get dosired degree oramoothnes of holh PV and M V
Figure 9 - Slight Oscillation
Oscillation
PV Period To
4 b
(%I
2
Z Offset
Z
D
i
f Set Point 4 t d
5
PD
Z
0
5
I
0 Time
(secs)
8
V)
A list of steps for the "Closed Loop Method" is
as follows:
TUNINGSETTINGSAND METHODS 51
6. Reduce the gain until the oscillation just
disappears so recovery is smooth.
52 TUNINGSETTINGSAND METHODS
forward, and add rate if there is no inverse
response or interaction.
TUNINGSETTINGS
AND METHODS
Figure 10 - Change in Ramp Rate for Non-Steady State
Process
Variable
(%)
Time
(min)
particularly if the oscillations develop into a
limit cycle after being bounced back and forth
between the flat ends of the titration curve. The
period of such a limit cycle is extremely long and
variable, and it will occur for a large range of
controller gains.
Kc = - Y
Ki TD,
l
TD, = DB eTD,
K, l AoIoAVP
AOIoAVP = IAO/oAOl - DB
-
2
Td = C, l (TD,+ TD,)
TUNINGSEITINGSAND METHODS
Rule 15- Use the shortcut
method when you want a quick
estimate for a very slow or nonlin-
ear loop, provided that the valve
dead band is 0.25 percent o r less
and the step size keeps you near the operating
point. Make sure there are no load upsets during
the test and that you measure the new rate of
change of the PV for at least two dead times. You
should repeat the test for both directions and
use the most conservative tuning.
I4
T98
' Time
(min)
tuning is only sultable for self-regulating
processes. EnTech has expanded the actual
Lambda tuning rules to cover a wide variety of
processes.
TUNINGSETTINGSAND METHODS
6. The reset setting (repeatdminute) is set
equal to the inverse of one-fourth of the
response time.
7, The controller gain is adjusted to be one-
fourth of the inverse of the open-loop gain
(h= 4).
The equation for reset time setting is as follows:
TUNING
SETTINGS
AND METHODS
3.0-Measurements and
Valves
MEASUREMENTS
AND VALVES
dead time and chatter fiom the analog/digital
converter (AID). For level measurements, you
should minimize sensitivity to bubbles,
sloshing, and coating.
pneumatic positioner
requires a negative
signal to close valve
\
Signal
dead band (%)
worse for piston actuators and rotary valves.
Most valve manufacturers will choose a valve
position and step size that is near the minimum
shown in Figures 13 and 14. For large step sizes,
the time required to move large amounts of air
into or out of the actuator increases the response
time.
66 MEASUREMENTS
AND VALVES
Figure 13 - Dramatic Rise in Response Time as You Approach the Resolution Limit
g Guess what step size the vendor will choose
C
n to determine the responsetime of the valve
rn
z
Z 400
d
B
0
5
I-
40.0
c
rn
Response
V) Time (set9
4.0
0.4
0.1 1.a 10.0 100
Step Size (%)
%
Figure 14 - Response Erne Depends upon the Wve, Shaft, Size and Connections,
Actuator, and Positioner
40.0
Response
Time (see)
4.0
V, 1- sliding stem valve with diaphragm nduator and diQtal postioner with pulse width modulated s o l e d d s
I0 -
2 sliding stem valve with diaphragm actuator and digital positioner with nozzle flapper
3 - sliding stem valve with diaphragm actuator and pneumatic positioner
4 - rotary valve with piston actuator and digital positioner
< 5 - rotary valve (tight shutoff) with piston actuator and pneumatic positioner
5
CI
6 -very large rotary valve (Hi")with any type of pasitioner
7 -sliding stem valve with a digital positioner
Table 4 - Dynamic Classes of Control Valves (Four
classes A -t D for each of the four categories 1 -t 4)
1-Minimum Step 2-Maximum Step
Classes Classes
Class A - 3.0% f 0.3% Class A - 5% f 0.5010
Class B - 1.0% f 0.1010 Class B - 10% f 1.0%
+
Class C - 0.5% 0.1% Class C - 20% f 2.0%
Class D - 0.2% f 0.1% Class D - 50010 f 2.0%
3-Response Time 4-Minimum Position
Classes Classes
Class A - 15 sec Class A - 30%
Class B - 5 sec Class B - 20%
Class C - 2 sec Class C - 10%
Class D - 1 sec Class D - 0%
Note: The response time is the time it takes the trim
(not the actuator) to stay within 10 percent of step
or within 0.1 percent of span, whichever is largest.
(Overshoot is O K if recovery is within this offset
from the desired position of the trim)
MEASUREMENTS
AND VALVES 69
control loops are given in the following list. To
choose a typical class, use the loop type that
actually throttles the control valve. For cascade
loops, you should use the slave loop.
70 MEASUREMENTS
AND VALVES
then attach a travel indicator to the butterfly
disk or ball to check whether they track the
hanges in the actuator shaft.
valve
shaft? OK?
poor
valve
I false *Cheek slop on schlsl curve
valve
that ind- the wrktion in
pmmm drop available to the
cootrl valve due to changes
in system drop and pump head
measurement, splined shaft connections, and a
short large-diameter shaft.
MEASUREMENTS
AND VALVES
4.0-Control Considerations
Measurement
0 Time
(min)
-
e = sq rt (a2 n2) If n = 0, then e = a
alternative to n is a filter to smooth PV
Figure 17 - Enhanced Pretest and Pretune
Measurement
Ramp time identification
(%) and shortcut estimate of
conholler tuning settings
1nitia1P V ~ N
'Dm,,
Output (AO)
(XI +DB/2
I
valve dead band idenHRcation
Time
(secs)
coated (velocity > 5 fps) and that the signal is I
fast (minimum transportation delay) and
smooth (no noise). For pH loops with an operat- I
ing point on a steep titration curve, the greatest
need is for an exceptionally precise control valve
(dead band < 0.15%). Characterizing the signal
of the process variable according to the titration I
curve can help reduce the oscillations.
78 CONTROLCONSIDERATIONS
have Scotty and warp drive, you are stuck with
the dead time caused by equipment, piping,
instrumentation, and control valves in your
loop.
P
0
P valve
8rn
P
3
5
z
rn
measurement
Rde 23 - The reset time should
b e set to be about one-fourth ('14)
o f the uncompensated dead time
to get the most out of a dead-time
compensator. The reset time can be
decreased by an order of magnitude by adding a
dead-time compensator that has just a 10 per-
cent underestimate of the dead time.
CONTROL
CONSIDERATIONS
Figure 19 - Feedforward Tuning
C/L t -
?'
none!
petfect!
pvwJ
lime
b too late!
Time
pv
not enough!
lime
pv h/L
loo early!
nme
t-lx- too much!
lime
You can greatly improve a loop's set point
response by adding the percentage change in set
point into the controller output as a feedfonvard
signal that has a gain of about half of the con-
troller gain, an action opposite to the control
action, and a slight filter. This provides the kick
you would normally get from a high gain set-
ting. The loop can then rely on reset action to
make the rest of the transition to the new set
point.
filter too lo
rate too h
false false
Lambda Tunmg
Take out the reset!
Figure 21 - Diagnostics for Loops in Automatic
1 false
~ m upseu
t aan out
as a pressure change
reset too hi
rate loo lo burp and flash
V
false
Take out the reset !
rebet too h!
rate too lo loops rate too hi
The oscillation can be made much faster and
tighter by using higher gain and rate action.
INDEX
dead time evaporator col~tml
tuning 14.
ofvalve 47,53,35,S4 58, ZI,86
60,71,71
dead time or time delay
RKpollac 30-34,53-57,
78,79,80, 82,85,87
dcnd h c lo lime conrum
ratio 16.35
dtad-tirne cornpunsuer
tuning 78,79,80-82.98
dead-time dominant feedback cuntrul2,33,71
response 16, 19.35.36. fwdforwnrd coi-tml52, 82-
52.58, PI, 98 RS. Rb
delay firldbu. b n c t i w blnckr 4,9,
fwm tranrponrtion 33, ""
YY
INDEX
rlircst digital control OUIPUI lncking 6
(DDC) 7 overrhonl cnnlml 8, 14,24,
lieldbul 6. 7 25, Y I
i n i l i a l i z ~ t i ~nlanud
u
(IMnn) 7 P
interel 7, 10-11 patterns ol'resporre 82
locd (nrc nuto) 6 performance
locd override (LO) b cwtrol rnd tuning 28,
manunl (Mnn) 6 33,82, 86, 101
nperntionnl 6 pHeunlrul tuniny27,29,31,
nutput tmckinl6 36.53
proportiot1al7.9-12 oH control vulvc 70.78
nmote (ate escadc) h
rcn~olecnrcadc (RCas) 7
m u t e uutput (ROud 7
rcmutc uct point (RSP)6 fbccplate 14
yupowivury 7 hnclion blocks 4
!andel prcdietivcmntml (m #can thne l I. 28.29,45,
conrtri~incdcnt~ltivnrioblc 46,53,63,75,85,87,
prcdictivc rontml) 97. 100
PID ;algorithm 9,47
N Pll9:~ndogoulput 1 2 4 0
piprlinr cuntnrl tuniny 19,
24,27,38,58,79
positiunrr
digitill 64.71
Ipneulnalic 64.70
0 aliwt (roc digital
o l l k l control 12,24,86,99 positiuaer)
on.08ilctinn R9,91,97 v d v s 4,64-71
opcn loup 6,47,53, 58 puwcr spectrum rigaal 95.96
opcn+mp pain mapmrc 34- prenaurc
42,57.60,61 hctuutions nr wwcr 119,
a p e r ~ ~ ~ ~111ndc
a n a l6 9n
.-
oacillallona I6.21.24.25.34. pressure control tuning 16,
48-SS,SR. 70, 75,7R 24, 35,36,37,44,48,51,
control and n8ponw 16 75, 86, YO
outpur liniit$51,1(7,1(8 prcasurc conlml valve 66,71
pnssurc wovm R9, Yl met fimc to n~cillation
pretest period 24,48.52
auto tuner 77 signal.tonoirc 63
primarl loop (also known a8 aHctorcontrol tunin8 14, 16,
mamr loop) 8 21.22,44,4R.51.86.99
primary loop (olno h o w n na relay ~iielhod
m a w ) 56, R5-88 mtn lunef 75, 76
pmcesr aelion 2-6 remote ear;cade mwle 7
pmccnr variable 2,3,R, 9, lI, mole mode (see cmcsdr) 6
14, 16, 19,27,31,36,40, mmole output (Rout) modr
51,57,58,60, 78, R0 7
prolwrtiond action (wc main)
proportional band tul~ing9.
11.20
pwpurtional mudc 7,9-I2
pulp and paper control
tuning 20
pump contwl tuning 37, JY
Q
quarter-mnipli~ude
rcsponle
21.22
R rr~~l~tion
meuurcmcnt27.28.100.
ramp rate 39,40,41, 53,54, 101
55,97,99, 100 valve 27,28,29,64
m e nrolution valve 71
tuning 8. LO, 11.25-27, rcsponvc
47,58 abrupt 19,27
rrtc action 8. 14.21.38,52, analyzer#27
85,87,91, 92, 95 chalter 28
rate time to dead time rntin dcrd lime or time delay
52
--
5347.78, 7Y, 80, R2,
ratio
dead time to timc
-~.
85.87
dcad4me dominant 16.
cnnrtunt 16,35, 91 IR, 19,35, 36,52, 58,
flow (bed) 36-40 91.98
rare time tn dead timc 52 h l a r orhcaitatr 16, Y I
intcgratiny 47-98 rccendery loup ( a h b o w n
intelrntor 39.40.41 a8 ulave) 8,48, 85-88
inverse27.52.53.61.8U, s d ~ r c p l a t i n grcaponac 40
82,84 arnritivily ofvalvc (rrc vnlve
nolllinearity I,36,47,58, resolution)
84.85 rclllitivity m mtUsU~~lnelll
open-lwp gain 57.60, 61 (lee measurement
urcillatioes 70 resolution)
o- ~. t -~
t e...~~ nRZl i
~ SCMOr
quarlrcnmplit~de21, 22 coating 63.64.75
runaway 47.48.98 driR 63.64
~l®uhting 40 rerponre 63
sensor 63 rcyuence e o n m l tuning 19.
44
set point 44,48. 51,52, 7.
15.60 ~ l t p o i n t c o n t m l l l4.16.17.
,
IR. 20,23
rrt point range
litnitn 87. 88
sel poilrl rerpolirr 44,48,51,
32. SS. 60
.. xct puint velocity 8, 19
tirnc constant8 (TC) 57 rrt puint velocity linhr 52
time to steady stale 18- vetrings fortunin&43,45,51,
62.66.67,68,69 53
lrajcctory 14.29 shahofvalvc 66,68,71,73
reversal aiwa(wcb)wntrol tuning 19.
ofripal3-6 20,24.58
rotary valve 66,70,71 shortcut lullin8 75
runaway nsponnc 47,411, 98 signal
rcxponbc diarinp 95
run9wHy 22 analog l o Jigitrl
cunverter(AID)27,29,
S 63
scan time 28,29,45,46,53 currmt.to.pncumatiu
I'IU ll,63,75,85,87,97, lnnlduccr (It9 4
IOU tiltcr8, 12, 19,27,Sl, 55,
rccondrry (olru known an 60,84,85,87
sluvr) 85-88
INDEX
signal nvenel 3-6
nignul-lo-noiwc ratio 63
sim
T
tcmpcrelurc contrul tuning
14,24.27,28,29.35,38.
48,52
..., Icnlprsturc co~llmlv d v r 70.
..
71
aliding stem (glubc) valve 71
n w r t puritimer (see digital tcmprmlure dctccturr 63
thrrmowcll log 29
tilllecol~rtantrraponae 8, 16.
20.27,30-37,40,57,79,
80,85,87
mpnnse timr delay (nee deud time)
moo111 27 lime to rtcady atotc rrrpomc
span 58-62
calibr~tiun11.27, 37 mieclory of arponae 14,29
spell time 69 trmmilw
rpcrifir8tioa m a r l 63.64
valve 66 trallsporntion delay 33, 78,
rpinning(Abera) arntrnl .
7P
,
tutninp 19 trend rccordiny
split range vrlvr 70 uolnprtaaion 95, 101
xplit.nngcd cocolwol 14 update timr 95, 101
xtabiliry 21,24 Iroublrrhootit~gloop 89-101
arai~arer c r p ~ n ~25,c 91 tuning
stlrtup cnnlml tunin) 16 rccuri1cy 1
stltic mixer control tuning adwnccd cuntrol 8, 16,
I9,3b,38 44
xtcady-$tale #ins 30-42, 80
8tcam Irapl 8Y. 91
pruporliond band 9, I I.
70
-"
pulp and paper contrul20
pump curmd 37.39
raw 8, 10, 11,47,58
rcacturco~itml14,16,21,
22,44,48. 51,86, 99
war1 10,11.14,22-35,47
mquwxr ~ v t l l r o 19,
l 44
rtttinga 43,43,51.53
rlwct (web) c o ~ ~ l r19,
ol
20. 24.58
shortcut 75
#laveloup 8,48.70,85-
88
spinuinp (fibers) control
.I'd-
nistup wntrul 16
f l o ~ c o n r m l l Y 38,12.
, n n i c rnixercanlmi 19,
75, 19,85,86 36,38
gain35,47,48,51,52,55, supervirotycontrol7
57,6U, 61.92.99. IUO temperaarc cuntrol 14,
p~ncral.purpoucn~rtbad 24.27.28,29, 35,38.
44-48 4(1,52
he01 cxch~ngrrcontrnl web cu~itrol19,24,58
l9,36, 38 winduw o l ullwnble
Lmbdii 35,38, 57,58- pin^ 22, 47
62. R7.88 ZiegicrNichula 21.48
level 19.20, 21, 24, 25, tuning tnrthoda 1. 16.47-62
29,44,51.52
pH control 27.29,31,36, U
52 update time of d p r i t h m 95.
100.101
upm conrml (tee o h
dirturbancc) 52,53,55,
bU,82,85, Rh, 89.91.95,
97
v vnlvc rprcificalion 66
valve variability 1,2. 16. 19,27.~7
acluul podlion 57 v~rivblr
reluator 66, 71 ~ulltrolicd11.37, 80
ball 66, 71 maoipulutcd 3.9. 11.22,
ilutcrtly I2,36, 66, 71 2Y,31.36.3Y.40
column C O I ~ 70~ ~ I procraa 2,3,8, Y, I I. 14,
eomprcrrnr mntmlb6, 16. LY,27.31,36,40.
70 51, S7,58,60, 78, 10
drnd i h d 2, 19, 20,2y. v h h l c w e d drive (VS0) 3,
33.47.53,60,64,71. 36
LIcIy practicing instrulwu,, process control, an.]
process cnginccr will want to haw thls practical
: ~ n dto tht point pocket guide u n g w d tuning.
Good Zning: A Ackrr Guide ia a porrable, conc
summary of all thc practical consideru~ionsfor
tuning loops. It includrr wp-by-step descriptions
01'1ht three berr field-proven tuning proccdurcs, a
iahle of typical runing settinp, a summary of valve
perf;rmance problems, and ovcr 30 "ruler of
rhumb". Whcrcvcr you have data and tuning
acccss, you can cstimatc thc scttings for configur-
ing new loops to review and improve rhc runing
of cxisting lo up^
ISA
P O Box 12277
Hw,nimh lrlengle Park. NC
2 7 103 USA
848-841 1
Ptmrlo ($3181
Fux (919) 549-8288
t-~rulll mfoOles arg
ISA o n ~ t n owww ma ory