ChE / MET 433

4 Apr 12

Feedback Controller Tuning: (General Approaches)

1) Simple criteria; i.e QAD via ZN I, tr, etc
easy, simple, do on existing process
multiple solutions
2) Time integral performance criteria
ISE integral square error
IAE integral absolute value error
ITAE integral time weighted average error
3) Semi-empirical rules
FOPDT (ZN II)
Cohen-Coon
4) ATV, or Autotuning
5) Trial and error
6) Rules of thumb

Trial and Error (field tuning)*

Select the tuning criterion for the control loop.
Apply filtering to the sensor reading
Determine if the control system is fast or slow responding.
For fast responding, field tune (trail-and-error)
For slow responding, apply ATV-based tuning
Turn off integral and derivative action.
Make initial estimate of Kc based on process knowledge.
Using setpoint changes, increase Kc until tuning criterion is
met

ys

Time

* J.B. Riggs, & M.N. Karim

Chemical and Bio-Process
Control, 3rd ed. (2006)
3

Trial and Error (field tuning)*

Decrease Kc by 10%.
Make initial estimate of I (i.e.,I=5p).
Reduce I until offset is eliminated
Check that proper amount of Kc and I are used.
c

ys

Time
* J.B. Riggs, & M.N. Karim
Chemical and Bio-Process
Control, 3rd ed. (2006)
4

Kc and I
levels good?

Kc

Feedback Controller Tuning: (General Approaches)

1) Simple criteria; i.e QAD via ZN I, tr, etc
easy, simple, do on existing process
multiple solutions
2) Time integral performance criteria
ISE integral square error
IAE integral absolute value error
ITAE integral time weighted average error
3) Semi-empirical rules
FOPDT (ZN II)
Cohen-Coon
4) ATV, or Autotuning
5) Trial and error
6) Rules of thumb

Rules of Thumb
*

sec

**

sec

Flow Loops: typically PI controllers; PB ~ 150; I 0.1 min

Level Loops: PI for tight control; P for multiple tanks in series;
Pressure Loops: can be fast or slow (like P control by controlling condenser)
Temperature Loops: typically moderately slow; typically might use PID
controller; PB fairly low (depends on gains); integral time on order of
process time constant, with faster process I can be smaller
derivative time ~ the process time constant.

* D.A.Coggan, ed., Fundamentals of Industrial

Control, 2nd ed., ISA, NC (2005)

** W.L.Luyben, Process Modeling, Simulation and Control for

7
Chemical Engineers, 2nd ed., McGraw-Hill
(1990)

Higher Order Process

Feedback Controller Tuning: (General Approaches)

1) Simple criteria; i.e QAD via ZN I, tr, etc
easy, simple, do on existing process
multiple solutions
2) Time integral performance criteria
ISE integral square error
IAE integral absolute value error
ITAE integral time weighted average error
3) Semi-empirical rules
FOPDT (ZN II)
Cohen-Coon
4) ATV, or Autotuning
5) Trial and error
6) Rules of thumb

Feedback Control
Design
Disturbances:
Load
Setpoint
Questions:
Type of controller to use?
How select best adjustable parameters?
Performance criteria?
Guidelines:
Define performance.
Obtain best parameters, for K C , I , D
Select controller with best performance.

10

Controller with best performance.

P only if can
PI eliminate offset
PID controllers
PID speed up response of sluggish
Proportional:
systems
Accelerates response
(T, comp, control; multi-capacity
Offset
systems)
Integral:
Eliminates offset
Sluggish responses
If increase Kc, more oscillations -> unstable?

Feed Back Control

Derivative:
Anticipates future error
Stabilizing effect
Noise problem

11

Examples:

12

13

14

15

16

E s

Controllers:
P-Only:

m t m K c r (t ) c(t )

P-I Controller:

P-I-D Controller:

M s
Kc
E ( s)

Gc

Kc
m t m K c e(t )
e(t ) dt

M s
1

K c 1
E (s)
I s

1
d e(t )
m t m K c e(t ) e(t ) dt D

dt
I

Derivative (rate) time [=] time

Chapter 5 ~ p 183

M s

M s
1
K c 1
D s
E ( s)
I s

17

P-I-D Controller:

R (t )

Derivative Action:

1
d e(t )
m t m K c e(t ) e(t ) dt D

dt
I

C (t )

e(t )
C (t )

R (t )

e(t )

t
slope

d e(t )
dt

slope

C (t )

d C (t )
dt

1
d C (t )
m t m K c e(t ) e(t ) dt D

dt
I

18

Derivative Action:
Another potential problem: noise

R (t )

Ds
filter
D s 1

C (t )

e(t )
C (t )

e(t )

t
slope

small
0.05 0.2

19

PID
Derivative action:
Advantages:
Reduces overshoot
Reduces oscillations
Recommended for slow/sluggish processes (speed up control)
Disadvantages:
Susceptible to noise
Filtering (or averaging PV) introduces delay
3rd tuning parameter

20

PID Control
PID Tuning

Tune for PI
Derivative:
Add in D
Minimum response time
D initial = Tu/8
Adjust Kc and I by same factor (%)
Check response has correct level of integral action

PS: Try PID for HE process on Loop Pro Developer

21

Rules of Thumb
*

**

Flow Loops: typically PI controllers; PB ~ 150; I 0.1 min

Level Loops: PI for tight control; P for multiple tanks in series;
Pressure Loops: can be fast or slow (like P control by controlling condenser)
Temperature Loops: typically moderately slow; typically might use PID
controller; PB fairly low (depends on gains); integral time on order of
process time constant, with faster process I can be smaller
derivative time ~ the process time constant.

* D.A.Coggan, ed., Fundamentals of Industrial

Control, 2nd ed., ISA, NC (2005)

** W.L.Luyben, Process Modeling, Simulation and Control for

22 (1990)
Chemical Engineers, 2nd ed., McGraw-Hill

ChE / MET 433

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