Chapter 1

Process Control

Li Shaoyuan E-mail: syli@sjtu.edu.cn

Basic Concepts

Control of Industrial Process

Temperature control of Steam Heating

Temperature control of Electric Heating

Level Control

Closed-Loop Transfer Functions

R{0 L!0
Set point change, load is constant

R!0

L{0

Load change, constant set point

C ( s) K M GC GV GP ! R ( s ) 1  GC GV GPGM

(s) ! L( s ) 1 

PID Control

Why PID Control

Simple, easy to use Wide Application: Petrochemical, Pharmaceuticals, Food, Chemical, Aerospace and Semiconductor, etc. Robust: Insensitive to changes to plant parameter and disturbance. Over 90% control loops are PID with two exceptions: 1. On/off control for those with low control requirement loops 2. Advanced control for those difficult systems and with high control quality.

Proportional Function
The controller output u is proportional to error signal e:

1 u ! K ce ! e H
where H is proportional band P control has steady state error.

Example
Temperature control of heating system UT obtains temperature of hot water U and sends Uc Uc regulate steam valve to keep constant outlet temperature. load: hot water flow rate Q and outlet temperature U P control, opening of regulating valve Q controller output
C V ste a m T

co n d e n se r w a te r

Integral Function
Controller output is proportional to error e.
t du ! S 0 e u ! S 0 edt 0 dt

Output of I control is constant only e=0, no steady state error. Reduce system stability. I control is always slower than that of P control, Open loop gain is proportional to S0, increase S0 In reduce system stability.

PI Control
P to improve response time and reject disturbance, I to eliminate steady state error.

1 1 u ! K c e  S0 edt ! e  0 H TI
t

0 edt
t

Derivative Function
Output of controller is proportional to the differential of error

de u ! S2 dt

or

dy u !  S2 dt

Prediction: Adjusting the output according to speed of error. D function must be formed to PD or PID controllers. Controller takes no action if rate of change very small, accumulate error.

PD and PID Control

de ! Kc e  u ! ce  S2 dt 1 de ! e  D H dt
D

de dt

u ! K c e  S 0 edt  S 2

Properties 1. Steady state, de/dt=0, PD control has steady state error. 2. D function reduces oscillation, increases system stability. 3. Adding D increase open loop gain, increase response speed. 4. Sensitive to disturbance.

de 0 dt de 1 1 t 1 ! K c e  edt  T ! e  TI 0 dt H TI
t

edt  T

de dt

General rules of Design PID Controller

Use D function, if system has large time constant and time Using PD if the system allows steady state error, otherwise, Use PI, if system has small time constant, small disturbance Use P, if system has small time constant, small disturbance Use more advanced control scheme, if system has large time delay. using PID and requires no steady state error. and allow steady state error. constant, large time delay and disturbance.

Stability of Closed-Loop Systems

Stability Criterion
Denominator of the closed loop transfer function

1 GC GV GPGM ! 0
The roots of the characteristic equation (s pi ) determine responses

Routh Stability Criterion

Characteristic equation

ansn  an1sn  1  a1s  a0 ! 0

y Any coefficients negative or zero, system unstable. y %ll coefficients positive, Routh Array

an " 0

a a a a b! a
n1 n2 n 1 n1 1 n3 1

n3

a a a a b! a
n1 n4 n 2 n1 1 n5 2

n5

ba a b c! b
1

n1 2

ba a b c! b
1

n1 3

L L

Example
8 GP ! G ! ( s  2)3
GV ! GM ! 1

GC ! KC

Characteristic equation Y ( s) 1  GC GV GPGM ! 0 s3  6s 2 12s  8  8KC ! 0 (s)

1 6 6(12)  (1)(8  8KC ) 6 8  8KC

12

72  (8  8 K C ) " 0 K C

8  8 K C " 0 K C " 1

8  8KC 0 0 0 0 0

KC u 8 unstable

Bode stability criterion

Closed-loop system unstable if the FR of the open-loop T.F. has amplitude ratio greater than one at the critical frequency

s ! j[
G( j[ ) ! K  K j 1 2
G ! AR ! K12  K 22

K2 J !G ! arctan K1

Example:
Determine closed-loop stability for proportional control with values of KC =1, KC =4 and KC =20

GP (s) !

(0.5s 1)3 (0.5s 1)3

2 KC

GO (s) !

Controller Design Based on Transient Response Criteria

Desirable Controller Features

Quick responding Adequate disturbance rejection Insensitive to model, measurement errors Avoids excessive controller action Suitable over a wide range of operating conditions

Impossible to satisfy all Alternatives for Controller Design Tuning correlations - limited to lst order and dead time Closed loop transfer function - analysis of stability Repetitive simulation (computer and interactive graphics) Frequency response-stability and performance (computer and graphics) On-line controller cycling (field tuning)

Controller design based on response points

Settling time, % overshoot, rise time, decay ratio 1st order process model
K E s GO ( s ) ! e X s 1

Ziegler-Nichols, Cohen-Coon based on decay ratio

Optimization Methods (minimize integral)

Integral of absolute value of error (IAE) g
IAE ! I (t ) dt
0

I ! I (t )dt

Integral squared error (ISE)

ISE ! I 2 (t ) dt

Integral Time Weighted Absolute Error (ITAE)

ITAE ! t I (t ) dt
0

Integral error (IE)

Example (IAE)

Controller Design Based on Frequency Response Criteria

Advantages and Disadvantage

Applicable to dynamic model of any order Desired closed-loop response characteristics can be specified Information on stability and sensitivity provided. Tends to be iterative and time consuming interactive computer graphics desirable

FR Characteristics of Controllers
a) Proportional Controller

GC (s) ! KC
b) PI Controller
1 GC (s) ! KC 1 XI s

AR ! G( j[ ) ,

J !0

AR ! KC

1 1 2 2 [ XI

1 J ! tan 1  X I[

c) PD Controller

GC (s) ! KC  X D s 1
d) Ideal PID Controller
1 GC (s) ! KC 1 X s XIs
D

AR ! KC [ 2X D 1

J ! tan 1 [X D

1 AR ! KC [X D  1 [X I

1 J ! tan1 [X D  [X I

Example

Ultimate Gain and Ultimate Period

Ultimate Gain: Max Gain value results in a stable closedloop system for proportional-only control
KCU !
1 ARO |[ [

KC ! 1
Ultimate Period:

PU |

2T

[C

Gain and Phase Margins

How close a system is to a stability limit. Gain Margin: [ ! [C AC | ARO Then
GM | 1
AC

GM " 1 stability

Phase Margin:

[ ! [1 ARO ! 1.0
Phase angle:

J1

PM | 180r J1
Rules of Thumb:

1.7 e GM e 2.0 30re GM e 45r

Tuning Relationships
KC decreases as E increases increases X D ! 0.25X I

and X D

X increase as E X

Reduce K c when adding integral action Increase K c , when adding derivative action To reduce oscillation, decrease K c and increase X I