Fundamentals of Model Based Loop Tuning

James Beall Principal Control Consultant Emerson Process Management

James Beall

Principal Process Control Consultant, Emerson Process Management 31 Years experience in process control
12 Years Emerson Process Management 19 Years at Eastman Chemical Company

Chairman ISA 75.25 Committee - Control Valve Performance Testing

James.Beall@emerson.com 903-235-7935

2010, Emerson Process Management

PID = Proportional, Integral, Derivative

P = proportional - output contribution is proportional to difference between Set Point and PV (error). Therefore, output contribution is gain times error. Will have offset between Set Point and PV. Integral - output contribution is integration of the difference between Set Point and PV (error). Therefore, always tries to make PV = Set Point (eliminates offset). Derivative - output contribution is based on the derivative (rate of change) of the difference between Set Point and PV. Actually usually based on PV, not error.

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Caution!!!

Controllers have different units for their tuning constants. For this presentation:
Proportional action will be expressed in gain Integral action will be expressed as integral time, Tr, in seconds/repeat Derivative in units of seconds.

Controllers have different forms (Parallel, Series, Standard) of the PID algorithm. This can significantly affect the actual tuning values to achieve the desired response. The tuning rules in this presentation are for Standard and Series.
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Tuning Methods

First tuning method due to Ziegler & Nichols (1942)

Ultimate Gain/Period Reaction Curve

little black books Default tuning (gain=1.0, Reset=1 min) Many people still do not use any method preferring to tune-by-feel
Classical control skills now rare

Most older tuning methods try for as fast as possible Net result is each loop tuned independently
process dynamics not coordinated

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Tuning Procedure

Determine basic process type

Self-regulating Integrating

Determine process dynamics Choose desired closed loop response time, Lambda Calculate tuning constants

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Lambda Tuning - Self Regulating Process Open Loop Response

Controller Output in manual

Process Variable

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Characterize the Process Response

%output

Process Gain = Kp = %PV =1% = 2 %output 0.5% Dead Time = Td = 1.5 sec

Td

Time Constant = Tau = 4 sec 98% of %PV

Tau= T98/4

T98

%PV

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Lambda Tuning Rules - Self Regulating Process

Choose Lambda (), the closed loop time constant

A recommended starting point to ensure robustness is 3 * (larger of Td or Tau). This results in stable tuning if Deadtime and Process Gain double. The closed loop Time to Steady State (T98) (for a set point change) is approximately 4*Lambda (assuming P is on error)

Tr = Reset Time = Tau (units are time/repeat) Kc = Controller Gain = ___Tr____ Kp ( + Td) NOTE Tr stays the same, only Kc changes with Lambda

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Lambda Tuning Example

Choose Lambda = 3 (4 seconds) = 12 seconds Integral Time Tr = Tau = 4 seconds/repeat Kc = Tr / Kp ( + Td) = 4 seconds /(2*(12 seconds + 1.5 seconds)) = 0.148 Lambda 12 sec 8 sec 4 sec 1.5 sec Gain 0.15 0.21 0.36 0.67 Integral Time 4 sec/rep 4 sec/rep 4 sec/rep 4 sec/rep

Faster

Higher Gain

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Response Lambda = 12 sec , 8 sec

Setpoint

Lambda = 12 sec. 48 second Tss

Setpoint

Lambda = 8 sec. 32 second Tss

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Response Lambda = 4 sec , 1.5 sec

Setpoint

Lambda = 4 sec.

Setpoint

Lambda = 1.5 sec.

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Lambda Tuning - Is it slow? Compared to what?

Typical Tune by Feel

Gain = 0.5, Integral = 12 sec/rep

Lambda = 6.6 seconds (normal robustness)

Gain = 0.15, Integral = 2.3 sec/rep

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Integrating Process Identify Open Loop Response

Controller Output

Process Variable

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Lambda Tuning for Integrating Processes Setpoint (Closed Loop) Response

Lambda
13.5% SP PV

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Lambda Tuning for Integrating Processes Load Disturbance Response

Step change in load (inflow) Outflow = inflow

Controller Output changing outflow smoothly! PV

PV Back to SP in 6 x Lambda or 6 x (arrest time)

Change in PV stopped Lambda (arrest time)

Setpoint

LIC

Inflow Outflow

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Characterize the Process Response

%output = -2%

Initial slope = 0%/sec

Final slope = - 0.0024%/sec.

Kp = (final slope - initial slope)/ %output Kp = -.0024%/sec - 0%/sec = 0.0012/sec. - 2%

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Lambda Tuning - Integrating Process

THIS RULE DOES NOT INCLUDE DEAD TIME OR A LAG. Contact the author for applications with dead time or a significant lag. Choose Lambda () (more on this later!) Tr = (2* ) Kc = __Tr___ Kp()2

NOTE Gain AND Reset Time change with Lambda

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Lambda Tuning Rules - Integrating Process

Example Choose Lambda = 10 minutes = 600 sec Tr = (2* ) = (2*600 sec) = 1200 sec/rep Kc = _Tr__ Kp()2 Kc = 2.78
Lambda 600 sec 300 sec
Faster

= 1200 sec/((.0012/sec)*(600sec)2)

Gain 2.78 5.56

Higher Gain

Integral Time 1200 sec/rep 600 sec/rep

Faster (shorter) Reset Time

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Lambda = 10 min. for Integrating Process

Kc = 2.78, Tr = 1200 sec./rep

Step Load Disturbance (10%)

Controller Output Setpoint Process Variable

%PV= 2.8 % =10 min.

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Lambda = 5 min. for Integrating Process

Kc = 5.56, Tr = 600 sec./rep

Step Load Disturbance (10%)

Controller Output Setpoint Process Variable %PV= 1.4 % = 5 min.

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Attenuate Variability with Control/Equipment

Capacity in the process can be used to attenuate or absorb variability Primary source of process capacity is level control To utilize level control as a capacity tune the controller only fast enough to hold the PV within the allowable level deviation (ALD) for a maximum load change
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Utilize Level Control as Variability Sinks

Choose the arrest time (Lambda) slow enough to provide a variability sink yet maintain level within the allowable variation Lambda

__ ALV___ Kp * MLD

ALV = Allowable Level Variation Kp = Integrating process gain MLD = Maximum Load Disturbance (in % of controller output)

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Example of Lambda Calculation

Previous Example Kp= 0.0012/sec Let ALV = +- 15% Let MLD = 25% Lambda = 1333 seconds = 22.2 minutes Tr = 2666 seconds; Kc =1.25

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Example of Lambda Calculation

25% Load disturbance

15% Level Variation

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Results Integrating Process Tuning

As found tuning Gain=6, Reset =15 sec

P-2 Reactor Level Control

Output

100 90 80 70 60 50 40 30 20 10 0

As left tuning Gain=4.7, Reset =2490 sec

Level

Percent

Process Bump Test

Lambda Tuning Increased Reset

11:00 AM 1:00 PM 3:00 PM 5:00 PM 7:00 PM 9:00 PM

9:00 AM

Time - May 15,2003 L02005P.PV % L02005.OP % POLY 2 LEVEL OUTPUT TO SPEED CONTROL

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Process Dynamics *Model Based Tuning May Include Derivative

Pure Gain 1st Order *2nd Order, Over Damped *2nd Order, Under Damped 2nd Order, Lead 2nd Order, Lead with Overshoot 2nd Order, Non-Minimum Phase Integrator *Integrator, 1st Order Lag Integrator, 1st Order Lead Integrator, Non-Minimum Phase
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Summary Tuning Procedure

Determine basic process type

Self-regulating Integrating

Determine process dynamics Choose desired closed loop response time, Lambda Calculate tuning constants NOTE For better load regulation, self-regulation loops with long lags can be tuned as in integrator
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Questions?

James.Beall@Emerson.com 903-235-7935

2010, Emerson Process Management