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CHAPTER 1

INTRODUCTION

1.1

Introduction

A proportionalintegralderivative controller (PID controller) is a generic control loop feedback mechanism (controller) widely used in industrial control systems.PID is the most commonly used feedback controller. A PID controller calculates an "error" value as the difference between a measured process variable and a desired set point. The controller attempts to minimize the error by adjusting the process control inputs.

The PID controller calculation (algorithm) involves three separate constant parameters, and is accordingly sometimes called three-term control: the proportional, the integral and derivative values, denoted P, I, and D. Heuristically, these values can be interpreted in terms of time: P depends on the present error, I on the accumulation of past errors, and D is a prediction of future errors, based on current rate of change. The weighted sum of these three actions is used to adjust the process via a control element such as the position of a control valve, or the power supplied to a heating element.

In the absence of knowledge of the underlying process, a PID controller is the best controller. By tuning the three parameters in the PID controller algorithm, the controller can provide control action designed for specific process requirements. The response of the controller can be described in terms of the responsiveness of the controller to an error, the degree to which the controller overshoots the set point and the degree of system oscillation. Note that the use of the PID algorithm for control does not guarantee optimal control of the system or system stability.

Some applications may require using only one or two actions to provide the appropriate system control. This is achieved by setting the other parameters to zero. A PID controller will be called a PI, PD, P or I controller in the absence of the respective control actions. PI controllers are fairly common, since derivative action is sensitive to measurement noise, whereas the absence of an integral term may prevent the system from reaching its target value due to the control action.

A typical PID temperature controller application could be to continuously vary a regulator which can alter a process temperature. This may be a pulsed switching device for electrical heaters or by opening and closing a gas valve. A heat only PID temperature controller uses a reverse output action. More power is applied when the temperature is below the set point and less power when above. PID control for injection and extrusion applications often employ additional cooling control outputs and usually require multiple controllers. A PID controller reads the sensor signal, normally from a thermocouple or RTD, and converts the measurement to engineering units e.g. Degrees C. It then subtracts the measurement from a desired set point to determine an error.

The basic function of a controller is to execute an algorithm (electronic controller) based on the control engineer's input (tuning constants), the operators desired operating value (set point) and the current plant process value. The requirement for the controller is to act the process value to the set point as closed as possible.

1.2

Objective The objective of this experiment is to study the gas temperature control using PID control.

CHAPTER 2

LITERATURE REVIEW

2.1

Overview

A PID (Proportional Integral Derivative) controller is a common instrument used in industrial control applications. A PID controller can be used for regulation of speed, temperature, flow, pressure and other process variables. Field mounted PID controllers can be placed close to the sensor or the control regulation device and be monitored centrally using a SCADA system. A typical PID temperature controller application could be to continuously vary a regulator which can alter a process temperature. This may be a pulsed switching device for electrical heaters or by opening and closing a gas valve. A heat only PID temperature controller uses a reverse output action, i.e. more power is applied when the temperature is below the set point and less power when above. PID control for injection and extrusion applications often employ additional cooling control outputs and usually require multiple controllers. A PID controller (sometimes called a three term controller) reads the sensor signal, normally from a thermocouple or RTD, and converts the measurement to engineering units e.g. Degrees C. It then subtracts the measurement from a desired set point to determine an error. The error is acted upon by the three (P, I & D) terms simultaneously:

2.2

PID Controller Theory The following section examines PID controller theory and provides further explanation of the question `how do PID controllers work'.

2.2.1

Proportional (Gain)

The error is multiplied by a negative (for reverse action) proportional constant P, and added to the current output. P represents the band over which a controller's output is proportional to the error of the system. E.g. for a heater, a controller with a proportional band of 10 deg C and a set point of 100 deg C would have an output of 100% up to 90 deg C, 50% at 95 Deg C and 10% at 99 deg C. If the temperature overshoots the set point value, the heating power would be cut back further. Proportional only control can provide a stable process temperature but there will always be an error between the required set point and the actual process temperature.

2.2.2

Integral (Reset)

The error is integrated (averaged) over a period of time, and then multiplied by a constant I, and added to the current control output. I represents the steady state error of the system and will remove set point / measured value errors. For many applications Proportional + Integral control will be satisfactory with good stability and at the desired set point.

2.2.3

Derivative (Rate)

The rate of change of the error is calculated with respect to time, multiplied by another constant D, and added to the output. The derivative term is used to determine a controller's response to a change or disturbance of the process

temperature (e.g. opening an oven door). The larger the derivative term, the more rapidly the controller will respond to changes in the process value.

2.2.4

Tuning of PID Controller Terms

The P, I and D terms need to be "tuned" to suit the dynamics of the process being controlled. Any of the terms described above can cause the process to be unstable, or very slow to control, if not correctly set. These days temperature control using digital PID controllers have automatic auto-tune functions. During the auto-tune period the PID controller controls the power to the process and measures the rate of change, overshoot and response time of the plant. This is often based on the Zeigler-Nichols method of calculating controller term values. Once the auto-tune period is completed the P, I &D values are stored and used by the PID controller. Guibe (1992) developed a Rapid thermal processing system for single wafer processing by combining a parameter estimator and a long-range predictive PID controller. Laczik (1996) showed that the magnitude of the defect etching of the commercial LEC InP wafers could be virtually eliminated by an initial low temperature anneal. The isothermal plate is useful to prevent a Si-based wafer or microstructure cracking, some heat treatments such as annealing or tempering process is necessary. During these processes, how to keep the plate stable in uniform temperature is especially important. Bertran (2001) showed the need to anneal anemometric structures of Si/SiC, C/SiC and C/SiN to improve their mechanical properties. Carpenter, 2006 showed a 26.6% chromium white iron microstructure need the heat treatment cycle, which is similar to a commercially, including an annealing and a tempering process. To make the PID controlled systems more user friendly, effective innovation and more intelligent, many techniques are studied. Anders (1999) presents an interactive tool for rapid system identification by step responses analysis with the graphical user interface.

Krajewski (2004) designed PI controllers with a normalized process model by developing MATLAB programs to find the loci, which can be exploited for tuning purposes and robustness analysis, of constant stability margins and crossover frequency in the parameter space. Ang (2005) presents a modern overview of functionalities and tuning methods including system identification and intelligent techniques in software based PID systems helps automate the entire design and tuning process to a useful degree.

CHAPTER 3

METHODOLOGY

3.1

Experimental Procedure

To start the experiment, firstly the operator workstation was switched on by press the Acknowledge button to silence the alarm buzzer sound. The Gas Temperature Process was selected. Then, the TIC91A and TIC92A were set to PID control. Besides, the TIC91 faceplate was called up. TIC91 was set to manual mode and its output was 0%. The TIC92 faceplate was called up. Then, the TIC92 was set to manual mode and its output was 0%. TIC92 faceplate was called up again. The TIC92 was set to Auto mode and its set point (SP) was 200oC. The subsequent PID trial was set. For gain (100/P), reset (I) and rate (D) are 10, 22 s, 5 s. TIC91 faceplate was called up. Next, the TIC91 was set to Auto mode and its set point (SP) was 80oC. The PID trials value was set. For gain (100/P), reset (I), and rate (D) are 10, 100 s, 25 s. The control response was observed in Process View History until the response was steady at its set point SV1 to within 0.2 to 0.3 OC or showed oscillatory response even after 3 cycles of oscillation. After that, Load Step Disturbance was applied. The controller TIC91 faceplate was switched to Manual mode and the control output MV was increased about 20%. On the other hand, the TIC91 was quickly switched back to Auto mode. The set point SV1 was remains

unchanged at the previous SV1 value. Then, the Set Point Disturbance was applied. The temperature set point SV1 at TIC91 was increased to 100oC. Next, the control response was observed in Process View History until the response was steady at its set point SV1 to within 0.2 to 0.3 OC or showed oscillatory response even after 3 cycles of

oscillation. The procedure number 4 and 5 were repeated. The both temperature on TIC91 and TIC92 were cooling down to room temperature. This process took 30 to 40 minutes. The procedure number 6 was repeated. Then, TIC91 faceplate was called up. The TIC91 was set to Auto mode and the Setpoint to 80C. The second PID trials value

was set. For gain (100/P), reset (I) and rate (D) were 5, 70 s, 18 s. The procedure number 8 to 10 was repeated. Lastly, to shut down the process, the controller TIC91 and TIC92 were switched to the manual mode and MV was reset to 0%.

CHAPTER 4

RESULT & DISCUSSION

4.1

Result

PID

TIC91 Setpoint

Gain (100/P)

Reset (I) Sec

Rate (D)

Observation

Sec

I 80 10 100 25 No offset, no error, decay ratio is small. When the disturbance was made, the response takes about 3 minute to become steady. The overshoot was small. The graph was smooth and less oscillates since PID control was used.

II 80 5 70 18 No offset, no error, no decay ratio. When the disturbance was made, the response takes about 3 minute to become steady. The overshoot is small. The graph was smooth without oscillation.

III 80 3 50 15 No offset, no error, decay ratio is much larger than the first trial since the overshoot is also high. The graph is smooth with oscillation and took about 2 minute to become steady.

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Figure 1: Trial 1

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Figure 2: Trial 2

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Figure 3: Trial 3

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4.2

Discussion

The temperature response is fastest at the third trial because the gain is between the first trial and second trial which their values give slow response but, the overshoot value for the third trial is the highest among the others. Because the rate value for the third trial is the lowest thus, it tends to reduce only the small oscillation and make the response faster. But it different with other trial (Trial 1 & 2), since the reset values is high the rate value cannot make the system response faster. For this experiment, the third trial value is the best PID controller we gained because it gives the faster response.Controller TIC92 didnt achieved their set point because the reset value and rate value are too small thus, the offset occurs. Generally, the gain, reset and the rate value for TIC92 is not suitable. From this experiment, we learned how to tune the controller to make the system give fast response to the disturbance or any change in the system.

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CHAPTER 5

CONCLUSION AND RECOMMENDATION

5.1

Conclusion

After make three trials with various values of gain, reset and rate. There were changes made due to these values: Gain first, second and third values: 10, 10, 5 Reset first, second and third values: 22, 100, 70 Rate first, second and third values: 5, 25, 18 10 ,5 ,3 100, 70, 50 25, 18, 15

Then, the third PID controller values trial shows the good optimization, which faster among others.

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5.2

Recommendation

Only very control of temperature can be achieved by causing heater power to be simply switched on and off according to an under or over temperature condition respectively. Ultimately, the heater power will be regulated to achieve a desired system temperature but refinement can be employed to enhance the control accuracy. To achieve optimum temperature control whether using on-off, P, PD or PID techniques, ensure that the adequate heater power is available, the temperature sensor, be it thermocouple or PRT, is located within reasonable thermal distance of the heaters such that it will respond to changes in heater temperature but will representative of the load temperature. Furthermore, the adequate thermal mass in the system should present to minimize its sensitivity to varying load or ambient conditions, and good thermal transfer between heaters and load.

The controller temperature range and sensor type are suitable try to choose a range that results in a mid-scale set-point.

The other recommendation is the control system performance can be improved by combining the feedback (or closed-loop) control of a PID controller with feed-forward (or open-loop) control. Knowledge about the system (such as the desired acceleration and inertia) can be fed forward and combined with the PID output to improve the overall system performance. The feed-forward value alone can often provide the major portion of the controller output. The PID controller can be used primarily to respond to whatever difference or error remains between the setpoint (SP) and the actual value of the process variable (PV). Since the feed-forward output is not affected by the process feedback, it can never cause the control system to oscillate, thus improving the system response and stability.

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REFERENCES

Araki M., PID Control., CONTROL SYSTEMS, ROBOTICS, AND AUTOMATION Vol. II - PID Control

Astrom K. J., (2002). PID Control., Control System Design

Dr M.J. Willis, (1999). Proportional-Integral-Derivative PID Controls., from www.PAControl.com

PID Control Theory Tutorial. Retrieved on April 14, 2012 from http://www.pacontrol.com/PID.html

PID Temperature Control. Retrieved on April 15, 2012 from http://www.lakeshore.com/pdf_files/Appendices/LSTC_appendixF_l.pdf

PID Controller. Retrieved on April 14, 2012 from

http://www.alistapart.com/articles/cite living