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The effect of PID module execution time (tx) on integrated error for unmeasured disturbances is:

(Ti + t x + f ) Ei = Eo Ko Kc

(1)

In Lambda tuning for self-regulating processes, the integral time (Ti) is the open loop time constant (o), in Fertik tuning (Tuning Controllers for Noisy Processes, ISA Transactions 14 pages 292-304, 1975) the integral time is proportional to the 63% response time that is the sum of the total loop deadtime (o) and open loop time constant, and in tuning methods to maximize disturbance rejection the integral time is proportional to the total loop deadtime. To prevent more than a 10% increase in the integrated error the max PID execution time should be less than 10% of the integral time less the signal filter time (f):

(2)

To improve the signal to noise ratio, the % process variable rate of change (%PV/t) the PID execution time should be larger than the % quantization error (Eq) or resolution of the measurement divided by this rate of change.

Er % PV / t

(3)

To reduce valve dither that causes premature wear of valve packing the PID execution time should be greater than the period of oscillation (Tn) from noise that causes output fluctuations from proportional and rate action that are greater than the deadband of the final control element (control valve or variable frequency drive). A signal filter can be used to decrease the occurrences of noise in the PID output greater than the deadband. min t x > Tn (4)

The PID execution time increases the total loop deadtime that determines the maximum controller gain and the ultimate limit to loop performance. The additional deadtime (x) to be added to the total loop deadtime can be estimated as half of the PID execution time plus the latency in the availability of the result that is the calculation time (tc), which is time from start of the module execution to when the PID output is computed and sent:

x = 0.5 t x + t c

(5)

Controllers are generally not tuned for maximum performance so the effect of the additional deadtime is not seen in the practical limit to performance. However, in the case

Effect of PID Execution Time Greg McMillan 02-22-2012 of loops with small process time constants and deadtimes and either a variable speed drive or an exceptionally fast control valve, the module execution time affects the tuning and performance from the increase in total loop deadtime. We see the effect of this additional deadtime in the following excerpt from Chapter 14 that I contributed to the PID Control in the third Millennium: Lessons Learned and New Approaches, Editors Ramon Vilanova and Antonio Visioli, Springer 2012 Since a controller cannot compensate for an unmeasured load disturbance before the loop deadtime, the peak error (Ex) (maximum error for a disturbance) is the excursion of the first order response to the step disturbance (Eo) based on the open loop time constant for a time duration of the loop deadtime (Equation 14-1) [2]. The open loop error is the final error seen at the PID from an unmeasured load disturbance if the PID was in manual. The terms open loop and closed loop are used for a response without and with feedback correction, respectively.

E x = [1 e

] Eo

(14-1)

If the total loop deadtime is much larger the open loop time constant, then the peak error is the basically the open loop error. If the deadtime was less than the time constant, then Equation 14-1 can be simplified to Equation 14-2 eliminating the exponential term [2,4].

Ex =

( o + o )

Eo

(14-2)

The minimum integrated error (Ei) can be approximated as the area of two right triangles with the altitude equal to the peak error and the base equal to the deadtime. Taking the area of each triangle as the base multiplied by the altitude we obtain Equation 14-3 where the integrated error is simply the peak error multiplied by the deadtime and consequently proportional to the deadtime squared [2,4]. Ei =

( o + o )

o2

Eo

(14-3)

Equations 14-2 and 14-3 are for the minimum possible errors determined by the open loop process and system automation system dynamics. It is not possible to do better than what is permitted by the dynamics. Thus, these are the ultimate limits to loop performance for unmeasured load disturbances. What is achieved in feedback control depends upon the tuning. In practice controllers are not tuned aggressively enough to achieve the ultimate limit because the response tends to be too oscillatory especially for large setpoint changes and the controller lacks robustness. A 25% increase in loop deadtime or open loop gain or 25% decreases in the open loop time constant can result in oscillations that do not sufficiently decay. We can develop the equations that set the practical limit in terms of controller tuning settings from the equations for the ultimate limit based on open loop dynamics. We will also see that we can independently arrive at

Effect of PID Execution Time Greg McMillan 02-22-2012 the same equation for the integrated error from the response of the PI algorithm to a step disturbance. If we divide through by the deadtime term in Equation 14-2, we have Equation 14-4 where the peak error depends upon the ratio of the open loop time constant to total loop deadtime.

Ex =

(1 + o

Eo

(14-4)

o )

Most tuning methods for maximum disturbance rejection use a controller gain (Kc) that is proportional to the ratio of the open loop time constant to total loop deadtime and inversely proportional to the open loop gain. A detuning factor of about 0.5 is used to provide a smoother response (Kx= 0.5) (Equation 14-5) [2,4,5].

Kc = K x

o Ko

(14-5)

If we solve for the open loop time constant to total deadtime ratio we see this ratio is simply the product of the controller gain and open loop gain (KcKo). If we substitute the product for the ratio in Equation 14-3 we have Equation 14-6, which is the practical limit to the peak error [2,4]. Peter Harriott developed the same form of the equation but with a numerator of 1.5 for the peak error from a proportional only controller tuned for quarter amplitude decaying response [36].

Ex =

1 Eo (1 + K c K o )

(14-6)

For time constant to deadtime ratios that are much larger than one, which is the case for pressure and temperature control of vessels and columns, the product of the controller gain and open loop gain is much greater than one leading to the peak error being simply inversely proportional to the product. Since the controller gain used in practice is about half of the gain for maximum disturbance rejection we end up with Equation 14-7 for the peak error.

Ex =

2 Eo K c Ko

(14-7)

Equation 14-7 corresponds to a peak error reached in about two deadtimes. If we approximate the integrated error as the area of two right triangles each with a base equal to two deadtimes and consider the integral time (Ti) setting as being 4 deadtimes we end up with Equation 14-8 for the integrated error [2,4,5].

Ei =

Ti Eo K c Ko

(14-8)

Resources: 1. Astrom K., Hagglund T. (2006) Advanced PID Control, ISA, Research Triangle Park 2. Blevins T., McMillan G., Wojsznis W., Brown M. (2003) Advanced Control Unleashed, ISA, Research Triangle Park 3. Bohl A., McAvoy T. (1976) Linear feedback vs. time optimal control. II. The regulator problem, Ind. Eng. Chem., Process Des. Dev., Vol. 15, No. 1 4. Boudreau, M. and McMillan, G. (2008) New Directions in Bioprocess Modeling and Control, ISA, Research Triangle Park 5. McMillan, G. (1994) Tuning and Control Loop Performance, ISA, Research Triangle Park 6. McMillan, G. (2003) Advanced pH Measurement and Control, ISA, Research Triangle Park 7. McMillan, G. (2004) Models Unleashed, ISA, Research Triangle Park 8. McMillan, G. (May, 2004) What is your flow control valve telling you, Control Design 9. McMillan G., Sowell M., Wojsznis P. (Sept. 2004) The next generation adaptive control takes a leap forward, Chemical Processing 10. McMillan G. (2005) Good Tuning: A Pocket Guide, ISA, Research Triangle Park 11. McMillan G. (May 2005) Lifes a batch, Control 12. McMillan G. (May 2006) Full throttle batch and startup response, Control 13. McMillan G. (Oct 2007) Improve control loop performance, Chemical Processing 14. McMillan G, (2008) Effect of sample delay on standard PID tuning and loop performance, Advanced Application Note 5, Emerson, Austin http://www.modelingandcontrol.com/repository/AdvancedApplicationNote005.pdf 15. McMillan G. (July 2008) Unlocking the secret profiles of batch reactors, Control 16. McMillan G. (July 2009) Is wireless control ready for prime time?, Control 17. McMillan G. (2010) Essentials of Modern Measurements and Final Elements in the Process Industry - 2nd Edition, ISA, Research Triangle Park 18. McMillan G. (2010), Centrifugal and Axial Compressor Control, Momentum Press, New York 19. McMillan G., Dasani S., Jagadeesan P. (Feb. 2010) Adaptive level control, Control 20. McMillan, G., (July-Aug. 2010) Wireless - Overcoming challenges of PID control & analyzer applications, InTech 21. McMillan G., Baril R. (Aug. 2010) pH measurement and control, Chemical Engineering 22. McMillan G., (Aug. 2010) DeltaV v11 PID enhancements for wireless, Emerson white paper, Austin

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