Controller Tuning

PBPLUS OIL AND GAS LEARNING HUB
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PID Controller tuning Topic 8
www.pbplusoilandgas.com
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Controller Tuning
Table of Content
1. Introduction to Controller Tuning
2. Purpose of controller tuning
3. Type of Processes (Self Regulating or Integrating)
4. Controller tuning Parameters
5. The purpose and effect of Proportional action in a control loop
6. The purpose and effect of the Integral or Reset action in a control loop
7. The Purpose and effect of Derivative action in a control loop.
8. Practical illustrations with simulation software
9. The Concept of Direct acting and indirect acting Controllers
10. Assessment quiz
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Learning Objectives
Delegates should be able to:
❖ Identify the need for controller tuning
❖ Highlight the benefit of controller tuning
❖ Understand a self regulating and an integrating processes
❖ Explain the effect of P, I and D in a control loop
❖ Differentiate between the Proportional band and the Gain of a controller
❖ Understand when a controller is using an Integral Gain and Integral Time
❖ Explain direct acting and reverse acting controllers
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Introduction PID Controller Tuning
In our previous lectures we have discussed open loop control,
closed loop control and some other control strategies. In this
lecture we will be referring most of the terms used in the
previous lesson, so you may here me talk about setpoint or the
desired value, PV which is the process variable, the output,
error and the input.
In this lecture we will be looking at the behavior of a simple
close loop control system. The concept of controller tuning is
centered on how the process output respond to a given change
in the input. This change will be in expressed in terms of
quantity (Gain) as well as Time
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The purpose of Controller Tuning
The purpose of tuning a controller is to strike a balance between sensitivity and time of error cancellation
in a process.
A properly tuned controller will bring about the following benefits to the Plant:
1. A more stable and controlled process with a Zero or near zero error
2. Reduction of wear and tear in process equipment.
3. Minimum change in PV (dynamic stability) with changes in load
4. Fast response to setpoint changes (minimum dynamic error)
5. Minimum overshoot/undershoot/oscillation following sudden load or setpoint changes
6. Minimum error (PV − SP) over time
7. Minimum valve velocity (i.e. minimal effect to upstream or downstream processes)
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Type of Processes
It is important to know the type of process you want to
tune before commencement of tuning activities, a process
can be self regulating or integrating, the approach to tune
these processes will entirely be different.
A self Regulating Process: 85% of the process you may
come across in the oil and gas industries are self
regulating processes! What does that mean? A self-
regulating process response to a step input change is
characterized by a change of the process variable, which
moves to and stabilizes (or self-regulates) at a new value.
Many flows, liquid pressures, temperatures, and
composition processes are self-regulating.
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Integrating Processes
Integrating processes are characterized by a
ramping of the process variable in response to a
step-change in the control element value or
load(s). This integration occurs as a result of
either mass flow imbalance or energy flow
imbalance in and out of the process. An
integrating process produces an output that is
proportional to the running total of some input
that the process has been accumulating over
time.
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PID controller Tuning Parameters
There are 3 parameters that may be altered
in the tuning process of a PID controller. It
should also be noted that there are
controllers that exist as Proportional only
controller P, Proportional and Integral (PI)
controller and a PID controller. However,
there exist some controllers with a PD only
control, although they are rare in the
process industry and less common.
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Proportional Only control
The proportional component depends only on the = PV-SP
difference between the set point and the process
variable. In general, increasing the proportional
gain will increase the speed of the control system
response. ... However, if the proportional gain is
too large, the process variable will begin to
oscillate.
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Effects of Proportional Only control
Proportional control is the main form of control, with (P
only) control, the controller attempts to remove existing
error form the process, it does it over and over to eliminate
the error, increasing the Gain a little will reduce the error,
if you keep increasing the Gain a point will reach when no
further error will be reduced, but the process will oscillate
with an offset.
Controller Gain: (KC) = percentage change in controller
output divided by the percentage change in the controller
Input. It tells how sensitive the controller will act on the
process, more gain means more sensitivity, low gain
means lower sensitivity.
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Proportional Band vs Proportional Gain
If for example we make a step change of 20% process input, and we have an increase output of 20%
then our gain becomes
20%/20% (output%/input%) which is equal to 1. Gain is a Unitless number.
Some controller may come with a Proportional Band (PB) setting in the Place of Gain. The
proportional band is the inverse of the controllers Gain, that mean an increased value of the PB will
bring about a low gain and less sensitivity. Proportional Band is given by the formular:
PB= 100%
GAIN
That means if I have a Gain of 2, my proportional band will be set at 50%, if I increase my Gain to 4,
then my will be 25%.
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Integral Action of a controller
The Integral action I of the controller will
be adjusted or tuned to eliminate the offset
left off from the Proportional Controller.
Different controllers manufacturers will
have different unit for Integral Gain.
The Integral action calculates the Previous
errors captured in the process over time
multiplies it by the integral value to the
output as to eliminate the offset.
Too much of an Integral action will cause
instability.
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Derivative Action of a controller
The derivative function is to produce a control
correction sooner than would be possible with
proportional action alone. It is often regarded
as providing an anticipating action. The issue
with derivative action is that it amplifies
process noise. Tuning the PI values in most
controllers will stabilize your process. The
derivative action in most controller will be set
to zero, because they are less commonly used.
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The Concept of Direct & Reverse Acting
Controllers
The knowledge of the controllers action on the
output will be of a great help to the control or
operations perssonel. Some controllers are in
reverse acting mode while others are direct
acting.
Reverse Acting
The diagram shows a controller in the reverse
acting mode. As the PV goes above the
setpoint, the controllers output signal to the
valve decreases and thus reduces the flow of
fluid into the vessel.
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The Concept of Direct & Reverse Acting
Direct Acting
The diagram shows a controller in the Direct acting
mode. As the PV goes above the setpoint, the
controllers output signal to the valve increases and
thus the valve opens more to reduce the level of
liquid in the vessel.
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Tuning Method
The trial and error tuning method is based on guess-and-check. In this method, the
proportional action is the main control, while the integral and derivative actions refine it. The
controller gain, Kc, is adjusted with the integral and derivative actions held at a minimum,
until a desired output is obtained.
The Ziegler–Nichols method. This method starts by zeroing the integral and differential
gains and then raising the proportional gain until the system is unstable. The value of KP at
the point of instability is called KMAX; the frequency of oscillation is f0. The method then
backs off the proportional gain a predetermined amount and sets the integral and differential
gains as a function of f0. The P, I, and D gains are set.
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Pessen Tuning Method (no Overshoot)
This method is a variation of the continuous cycling method. It’s used whenever no overshoot
during normal modulating control is desired, but some overshoot at start-up is acceptable.
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ASSESSMENT: click on the link to take the test!!!

You must Score Above 40%
To Pass this TEST!!!

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