Dyn-005H Revised: Nov 16, 2012

Controller Parameter Tuning with Aspen HYSYS® V8.0

1. Lesson Objective:
 Use Ziegler-Nichols, Cohen-Coon, and time integral tuning methods to determine the optimal
controller tuning parameters
 To understand basics of dynamic simulation in Aspen HYSYS

2. Prerequisites
 Aspen HYSYS V8.0
 File Dyn-005H_Controller_Tuning_Start.hsc

3. Background
There are several methods for tuning a controller, including Ziegler-Nichols, Cohen-Coon, and the ITAE tuning
method. In this tutorial, we will utilize these methods to determine the tuning parameters for a second order
system. Most processes can be well approximated by a first order response with time delay. Analysis of this
response can then be used to determine tuning parameters for the process.

A process reaction curve can be obtained from the controlled process with the controller disconnected. From
the process reaction curve, one can acquire values of K, τ, and α, which allows approximation of the process
reaction curve via a first-order system with time delay:

( )

Given this, several tuning methods can be used to obtain approximate tuning parameters. In this tutorial, we will
use a PID controller, which has the following tuning rules:

Tuning Method

Ziegler-Nichols
( )

( )( ( )) ( )
Cohen-Coon [ ] [ ]
( ) ( )

ITAE
( ) ( )
[ ( )]

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The examples presented are solely intended to illustrate specific concepts and principles. They may not
reflect an industrial application or real situation.

4. Problem Statement and Solution

Problem Statement
There are two tanks in series with water flowing into and out of each tank. There are two water streams being
fed into the first tank, a hot water stream and a cold water stream. We would like to control the temperature of
the second tank by varying the flowrate of the hot and cold streams flowing into the first tank. This setup is
shown below.

In this flowsheet we have several controllers. Each tank has a controller to keep its liquid level constant. The
cold water stream has a controller that maintains a constant combined water stream flowrate. So, if the hot
water valve opens, the cold water valve will close accordingly. We have installed a controller attached to the
hot water valve that we wish to use to control the temperature of the second tank. In this lesson we will
determine the tuning parameters for this controller.

In order to determine the tuning parameters for the temperature controller, we must first obtain a process
reaction curve. We have disconnected the controller from the valve and implemented a 15% increase in the
valve opening. We have recorded the resulting response in the temperature of the second tank. This plot is
shown below.

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Vessel Temperature % Change 14

12

10

0
0 100 200 300 400 500 600
Time (seconds)

A tangent line can be drawn at the inflextion point on the curve and the values for the key paramters can be
estimated from the graph:


 α =20 seconds = 0.33 minutes
 τ = 200 seconds = 3.33 minutes

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14
Vessel Temperature % Change

12

10

0
0 100 200 300 400 500 600
Time (seconds)

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Using the Zieglar-Nichols PID tuning rules we can obtain the following tuning parameters:

( )

( )

( )

Using the Cohen-Coon PID tuning rules we can obtain the following tuning parameters:

( )( ( ))

( )
[ ]
( )

[ ]
( )

Using the Minimum ITAE PID tuning rules we can obtain the following tuning parameters:

( )

[ ( )]

( )( )

We can then use a simulator such as Aspen HYSYS to model the process and determine the optimal tuning
parameters for this system.

Aspen HYSYS Solution

4.01. Start Aspen HYSYS V8.0. Open Dyn-005_Controller_Tuning_Start.hsc.

4.02. On the face plate for the temperature controller (TIC-100), select Auto to activate the controller.

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4.03. In the Dynamics tab in the ribbon, click the Strip Charts button. This will open the StripChart window.
Click Display.

4.04. The DataLogger1 window will appear. Close the StripChart window.

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4.05. Click the Run button from the Dynamic tab of the ribbon.

4.06. You will see two lines on the strip chart. The blue line is the controller set point and the purple line is
the vessel temperature. You should notice immediately that there is an offset between the set point
and the actual value. This is because the controller is currently only acting as a proportional controller.
If you click the Tuning button on the temperature controller you will see the tuning parameters.

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4.07. Change the set point (SP) for the temperature controller to 60°C.

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4.08. You should see the following response on the strip chart. Notice that there are oscillations and a
significant steady state offset.

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4.09. Change the set point (SP) to 75°C. The response should look like the following.

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4.10. Click the Stop button in the Dynamics tab of the ribbon.

4.11. We will now enter the tuning parameters that we calculated using the Ziegler-Nichols tuning rules. Click
the Tuning button on the temperature control face plate. Enter the new tuning parameters as shown
below.

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4.12. Change the set point (SP) to 65°C and click the Run button in the ribbon. The response should look like
the strip chart shown below. You can see that the new tuning parameters have eliminated the steady
state offset, however we still have significant oscillations. The Ziegler-Nichols tuning method often leads
to very aggressive parameters, which would explain the large overshoot seen in the response.

4.13. Change the tuning parameters to the values calculated using the Cohen-Coon tuning method.

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4.14. Run the dynamic simulation again. Starting from 75°C, change the set point to 65°C. The response
should look like the strip chart below. These tuning parameters are also quite aggressive and lead to a
large overshoot of the set point.

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4.15. Lastly, change the tuning parameters to the values calculated using the ITAE method. Note that these
particular correlations for the tuning parameters are designed for a set-point response and are meant to
be less aggressive than other methods.

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4.16. Run the simulation in dynamic mode and make a set point change to 65°C starting from a temperature
of 75°C. The response should look like the strip chart below. You can see that with these parameters
the tank reaches the set point very quickly with little overshoot and oscillations.

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5. Conclusion
In this lesson we learned how to determine tuning parameters using three different methods. Using Aspen
HYSYS we could observe how the system responds to different tuning parameters and controller step changes.
Tuning parameters found from the methods used in this lesson are often a starting point which is followed by
manual tuning. Manual tuning allows the operator to modify the tuning parameters as is needed, but often
requires experience to know how to manipulate the controller correctly. Aspen HYSYS allows users to
manipulate tuning parameters to observe how the system responds to changes.

6. Copyright

Copyright © 2012 by Aspen Technology, Inc. (“AspenTech”). All rights reserved. This work may not be
reproduced or distributed in any form or by any means without the prior written consent of
AspenTech. ASPENTECH MAKES NO WARRANTY OR REPRESENTATION, EITHER EXPRESSED OR IMPLIED, WITH
RESPECT TO THIS WORK and assumes no liability for any errors or omissions. In no event will AspenTech be
liable to you for damages, including any loss of profits, lost savings, or other incidental or consequential
damages arising out of the use of the information contained in, or the digital files supplied with or for use with,
this work. This work and its contents are provided for educational purposes only.

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