PID TUNING
• Controller tuning is the process of determining the controller parameters
which produce the desired output.
• Controller tuning allows for optimization of a process and minimizes the
error between the variable of the process and its set point.
• Types of controller tuning methods include the trial and error method, and
process reaction curve methods.
• The most common classical controller tuning methods are the Ziegler-
Nichols and Cohen-Coon methods.
• The Ziegler-Nichols method can be used for both closed and open loop
systems
• while Cohen-Coon is typically used for open loop systems.
TRIAL AND ERROR
• 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, K , is adjusted with the integral and derivative actions
held at a minimum, until a desired output is obtained.
For flow control
• P or PI control can be used with low controller gain
• Use PI control for more accuracy with high integration activity.
• Derivative control is not considered due to the rapid fluctuations in flow dynamics with lots of noise.
• Kc = 0.4-0.65 ; Ti = 6s
For Level control
• P or PI control can be used, although PI control is more common due to inaccuracies incurred due to
offsets in P-only control
• Derivative control is not considered due to the rapid fluctuations in flow dynamics with lots of noise.
• The following P only setting is such that the control valve is fully open when the vessel is 75% full and
fully closed when 25% full, being half open when 50% filled.
• Kc = 2 Bias b = 50% Set point = 50%
• For PI control: Kc = 2-20 Ti = 1-5 min
For Pressure control
• Tuning here has a large range of possible values of K and T for use in PI
control, depending on if the pressure measurement is in liquid or gas
phase.
• Liquid :Kc = 0.5-2; Ti = 6-15 s
• Gas: Kc = 2-10; Ti = 2-10 min
For Pressure control
• Due to the relatively slow response of temperature sensors to dynamic
temperature changes, PID controllers are used.
• Kc = 2-10
• Ti = 2-10 min
• Td = 0-5 min
PROCESS REACTION CURVE
• In this method, the variables being measured are those of a system that is already in place.
• A disturbance is introduced into the systemand data can then be obtained from this curve.
• First the system is allowed to reach steady state, and then a disturbance, X, is introduced to it.
• The percentage of disturbance to the system can be introduced by a change in either the set point or process
variable.
• For example, if you have a thermometer in which you can only turn it up or down by 10 degrees, then raising
the temperature by 1degree would be a 10% disturbance to the system. These types of curves are obtained in
open loop systems when there is no control ofthe system, allowing the disturbance to be recorded.
• The process reaction curve method usually produces a response to a step functionchange for which several
parameters may be measured which include: transportation lag or dead time, τ, the time for the responseto
change, τ, and the ultimate value that the response reaches at steady-state, M.
ZIEGLER-NICHOLS CLOSED-LOOP TUNING METHOD
• The Ziegler-Nichols closed-loop tuning method allows you to use the ultimate gain value, K, and
the ultimate period of oscillation,P, to calculate K .
• It is a simple method of tuning PID controllers and can be refined to give better approximations of
the controller.
• These two parameters, Ku and Pw, are used to find the loop-tuning constants of thecontroller (P, PI,
or PID). To find the values of these parameters, and to calculate the tuning constants, use the
following procedure:
• Remove integral and derivative action. Set integral time (Ti) to 999 or its largest value and set the
derivative controller (Td) to zero.
• Create a small disturbance in the loop by changing the set point. Adjust the proportional,
increasing and/or decreasing, the gainuntil the oscillations have constant amplitude.
• Record the gain value (Ku) and period of oscillation (Pu).
Advantages
• Easy experiment; only need to change the P controller
• Includes dynamics of whole process, which gives a more accurate picture of how the system is behaving
Disadvantages
• Experiment can be time consuming
• Can venture into unstable regions while testing the P controller, which could cause the system to become
out of control
COHEN-COON METHOD
• The Cohen-Coon method of controller tuning corrects the slow, steady-state
response given by the Ziegler-Nichols method when thereis a large dead time
(process delay) relative to the open loop time constant; a large process delay is
necessary to make this method practical because otherwise unreasonably large
controller gains will be predicted.
• This method is only used for first-order models with time delay, due to the fact that
the controller does not instantaneously respond to the disturbance (the step
disturbance is progressive instead of instantaneous).
• The Cohen-Coon method is classified as an 'offline' method for tuning, meaning that
a step change can be introduced to the input once it is at steady-state. Then the
output can be measured based on the time constant and the time delay and this
response can be used to evaluate the initial control parameters.
