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Assume
GAIN =
100% (span)
50% (PB)
2
Honeywell uses letter K" to represent GAIN, therefore K = 2.
GAIN =
PRESSURE
(Liquid)
PRESSURE
(Gas)
Fast.
Most lags are in the control
system.
Linear. Noisy
Single capacity.
No dead time.
Linear, no noise.
Simple process.
P + I Controllers.
Low gain, fast reset, high PB
Derivative hurts.
Linear valves for differential pressure
measurement.
Equal percentage valves for linear
measurement.
Valve is the major dynamic element.
P + I controllers.
Gain near 1, fast reset rate.
Derivative of no value.
Linear valve.
Self acting or high gain proportional
controllers.
Reset seldom necessary.
Derivative unnecessary.
Valve characteristic relatively unimportant
PRESSURE
(Vapor)
LEVEL
TEMPERATURE
COMPOSITION
Dynamics vary.
Dead time possible.
TUNING CONTROLLERS
Since there are a very large number of combinations of the two or sometimes three, "knobs"
provided for controller tuning, many methods have been developed over the years to aid in their
proper adjustment. A few require upsetting the process to some extent, often an unacceptable
practice in real life. These notes are intended to provide a few simple rules to use in tuning
controllers which will minimize upsets and still get the job done.
THE CONTROLLER MUST BE ADJUSTED TO BALANCE THE PROCESS.
If the process is fast to respond (i.e. a flow loop), then the controller must be tuned fast too.
Fast or slow for a controller refers to integral (or reset).
NOT PROPORTIONAL BAND (or gain).
Do not confuse these actions or grief will be your constant companion during your controller
tuning efforts. If the process is slow (i.e. temperature control of a tray part way up a distillation
column), then the controller must be tuned slow TO MATCH THE PROCESS. If you do not have
a feel for the process characteristics or cannot find someone to enlighten you, leave controller
tuning to someone else who can get the needed information.
GENERAL RULES FOR COMMON LOOPS
FLOW
Usually, at least half of the control loops in a plant are flow loops. Set integral (I) at 0.1 minutes.
Adjust the proportional band so that the measurement is not too noisy, usually about 300%
although an occasional poor meter run installation may require as much as 1000%. A loop where
a valve positioner has been used will require a proportional band setting two to three times larger
than for a loop without a positioner. Slow moving or sticky control valves may require 0.2 or 0.3
minutes but are rare exceptions. If these settings do not work, inspect the valve and orifice
installation to find the, problem. Fix the problem. Do not adjust the controller to some ridiculous
setting such as a 10 minute reset time. Use the controller in manual or a hand valve if you think a
10 minute reset time is necessary.
IMPORTANT NOTE: No controller will work when the valve is almost closed or almost wide
open. Don't attempt tuning under these conditions. Have the operator open or close a bypass (if
one exists) or wait until process conditions change enough to get the valve back within its
operating range (from 5 to 95% of travel as extreme limits with 10 to 90% as a safer range).
Never use derivative action in a flow loop.
LEVEL
The next most common loop after flow is level. DO NOT EVER USE A SHORT INTEGRAL
VALUE IN A LEVEL LOOP. If you do, you will find the loop will always cycle, often with a
period (time from the peak of one cycle to the peak of the next) of 10 to 15 minutes. The shorter
the integral time, the longer the period. Set the integral at 10 minutes. This will satisfy 80 to 90%
of the level applications in a plant, if the vessel time constant (volume/flow) is 1 to 2 minutes, then
a shorter integral time can be used but remember that a large value is safer. If the vessel is large
and the controlling flow is a trickle, then a greater value of integral must be used.
GAIN
K
PB
REPEATS/MIN
.5
200
12
PRESSURE
(Liquid)
100
1 Min.
PRESSURE
(Gas)
50
.5
2 Min.
LEVEL
100
.2
5 Min.
TEMPERATURE 1.3
75
.3
3.5 Min.
ANALYZERS
75
.2
5 Min.
FLOW
1.3
MINS/REPEAT
T1
.083 or 5 Sec.
0.5
1.0
2.0
1.0
1.3
Integral
(min. - T1)
0.08
1.0
2.0
5.0
3.0
(min.- T2)
0.0
0.0
0.0
0.0
0.0