Chapter 6 Industrial Control Tuning Strategies

Faculty of Chemical Engineering
UiTM Pulau Pinang
CEV544
PROCESS CONTROL AND
INSTRUMENTATIONS
LEARNING OUTCOMES
At the end of this chapter, student should be
able to:
 Identify the process characteristic for

chemical processes.
 Anticipate the change in process upon
changing P,I and D
 Determine the optimum tuning process
controller by using various tuning rules.
Unit 1: Terminology
Terminology
Process response curve: The trend of process measurement.
Rise time
Overshoot
PV
Period
SP2
Undershoot
SP1
Settling time
0 Time
1. Settling time is the period of time taken by the process reach stability.
2. Period is the time interval between two succesive peaks.
3. Overshoot is the process response (PV) surpasses the set point.
4. Undershoot is the process response (PV) goes below the set point.
5. Risetime is the period of time taken by the process to reach the setpoint.
© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)
process responses under automatic control.
Terminology
Ideal response: The desired process response is achieved at an instantaneous time.
Ideal
response
PV2
PV1
SP2
SP1
Time

Terminology
Stable: The process response stabilized at (near) the set point .
Ideal
response
PV2
PV1
SP2
SP1
Time

Terminology
Unstable: The process response could not be stabilized at the set point.
Ideal
PV2 response
PV1
SP2
SP1
Time

Terminology
Quality limits: A range, set values above and below the set point, whereby the process
is allowed to oscillate. Product quality is acceptable within these limits.
PV
Out of spec
UCL
SP2
LCL
Out of spec
SP
1
0 Time
1. LCL = Lower control (quality)
limit.
2. UCL = Upper control (quality)
limit .
Various shapes of process responses under automatic
control.
QAD Oscillatory
Underdamped
Overdamped
Offset

Unit 1: Process settling criteria
Terminologies
Settling criteria: A response curve that meet any of the following criteria (criterion)
is considered settle.
1. Response time
2. Settling time
3. Rise time
4. Quarter Amplitude Damping (QAD)
5. Quality limits (BEST for product quality control)
6. No overshoot or no undershoot (BEST for
temperature and pH control)
7. Minimum IAE, ITSE, etc.

Unit 1: Introduction
Let us look at a simple PID control loop.
Assuming all instrumentations have been configured correctly, the process has
been designed accordingly and installation has been made as per manual /
guidelines.
Characteristics PB, I & D An optimum PB, I & D

Optimum would drive the process
PB, I & D? toward the setpoint.
Fine Tuning

Tuning Rules
RR, Td & Tc
I/P
Openloop Test

Type of response
Common input changes
1. Step Input
A sudden change in a process variable can be approximated by

a step change of magnitude, M:
The step change occurs at an arbitrary time denoted as t = 0.
• Special Case: If M = 1, we have a “unit step change”. We

give it the symbol, S(t).
• Example of a step change: A reactor feedstock is suddenly

switched from one supply to another, causing sudden
changes in feed concentration, flow, etc.
2. Ramp Input
• Industrial processes often experience “drifting
disturbances”, that is, relatively slow changes up or down
for some period of time.
• The rate of change is approximately constant.
We can approximate a drifting disturbance by a ramp input:
3. Rectangular Pulse
It represents a brief, sudden change in a process variable:
URP tw Time, t
h
0
Examples:
1. Reactor feed is shut off for one hour.

2. The fuel gas supply to a furnace is briefly interrupted.
4. Sinusoidal Input
Processes are also subject to periodic, or cyclic, disturbances.
They can be approximated by a sinusoidal disturbance:
0 for t  0
Usin  t   (5-14)
 A sin t  for t  0
where: A = amplitude, ω = angular frequency

A
Usin (s)  2
s  2
Examples:
1. 24 hour variations in cooling water temperature.

Response of first order system
• First order differential equation
dy (t )
a1  a0 y (t )  bx(t )  c
dt
dY (t )
a1  a0Y (t )  bX(t )
dt   a1 / a0
dY (t ) K  b / a0
  Y (t )  KX(t )
dt
• General first order transfer function
 K 
Y (s)    X (s )
s  1
1.Step response
 K 
Y (s)    X (s )
s  1
 K  x
Y (s )   
s  1 s
•All first order systems forced by a step function will have
a response of this same shape.
Step response for first order system

• To calculate the gain and time constant
from the graph
 y
Gain, K 
x
Time constant, – value of t which the response is
63.2% complete
2. Ramp response
 K 
Y (s)    X (s )
s  1
 K  a
Y (s )    s2
s  1
The normalized output
lags the input by exactly
one time constant
Ramp response for first order system

3. Sine input

U ( s)  2
s  2
Kp  0 1s 2
Y(s)   2   2  2
s  1 s   s  1 s   s  2
2 2
By partial fraction decomposition,

K p 2
0  2 2
  1
 K p 
1  2 2
  1
K p
2  2 2
  1
K p   t  Kp
y( t )  2 2 e  sin(t  )
  1   1
2 2
Where   tan1( )
First order response to the sine wave
Response with time delay
X(t)
Y(t)
t=0 t=t0
Θ=Time delay/dead time

1. Step response
 Kest0 
Y (s )    X (s )
 s  1 
First-order-plus-dead-time (FOPDT)
Unit 2: Process characteristics
Process deadtime
Definition by Z-N:
Period of time between the starting of input (load) change and the intersection of tangent line
and old steady state baseline. (Zieglar-Nichols, 1942)
PV ,% new s.s.
old s.s.
Td
time
MV , %
MV
time

Process time constant
estimation
Definition 1 (Z-N): Tangent Definition 2: Tangent and point
A period of time between the cross-section A period of time between the TPV@62.3% and the time at
of old s.s. baseline and tangent line and the cross-section of old s.s. baseline and tangent line.
cross-section of new s.s. baseline and
tangent line. TC,63.2% = TPV@63.2% - Td
PV ,% new s.s. PV ,% new s.s.
PV63.2%
TC,63.2%
old s.s. old s.s. TPV@63.2
Tc %
Td
time time
TPV@63.2%
MV , % MV , %
MV MV
time time
Process time constant
estimation
Definition 3: Two points method
Time constant is 1.5 times the difference between T(PV@63.2%) and
T(PV@28.3%).
PV ,% new s.s.  TC,Cecil = 1.5 (TPV@63.2% -

TPV@28.3%)
PV63.2%
Definition by
Dr. Cecil
Smith does
PV28.3% not depend
TPV@28.32%
on tangent
old s.s. TPV@63.2% line.
time
MV , %
MV
time
Unit 2: Tutorial 2
Estimate Td, TC,Z-N , TC,63.2% , and TC,Cecil .

Summary of result
45
PV, %
Td, s TC,Z-N TC,63.2% TC,Cecil

40 B C
35
TC,Z-N/Td TC,63.2% TC,Cecil /Td
30 /Td
25
20 How much do they differ?

15
A
10
0 20 40 60 80 100
Time, min

Unit 2: Tutorial 2
Estimate Td, TC,Z-N , TC,63.2% , and TC,Cecil . Step by step guide

1. Locate point of max. gradient.
45
PV, %
2. Draw a tangent line at the max. gradient.
40 B C 3. Draw a straight line at Pvoss.

4. Draw a straight line at Pvnss.
35
30
5. Calculate 0.632 (PVnss – PVoss)
6. Calculate 0.283 (PVnss – PVoss)
25
Summary of result
20
Td, s TC,Z-N TC,63.2% TC,Cecil
15
A
10
0 20 40 60 80 100 TC,Z-N/Td TC,63.2% TC,Cecil /Td
Time, min /Td
How much do they differ?

Answer guide.
Step-by-step calculation for TC,Cecil Step-by-step calculation for TC,Z-N
1. Estimate PVnss. 1. Draw a tangent line at max point.

2. Estimate PVoss. 2. Estimate Tnss
3. Calculate PV63.2% 3. Estimate TC
TC  Tnss  Td
PV63.2%  PVoss  0.63 x PVnss  PVoss 
4. Estimate TPV@63%
Step-by-step calculation for TC,63%
5. Calculate PV28.3%
1. Estimate TC,63%
PV28.3%  PVoss  0.283 x PVnss  PVoss 
TC ,63%  TPV @ 63%  Td
6. Calculate TC,Cecil

TC ,Cecil 1.5 TPV @ 63%  TPV @ 28% 

Response of second order system
• Second order differential equation
d 2 y (t ) dy (t )
a2 2
 a1  a0 y (t )  bx(t )  c
dt dt a2

a0
d 2Y (t ) dY (t )
a2 2
 a1  a0Y (t )  bX(t ) 
a1

a1
dt dt 2a0 2 a0 a2
d 2Y (t ) dY (t ) b
K
 2
2
 2  Y (t )  KX(t ) a0
dt dt
• General second order transfer function
 K 
Y (s )   2 2  X (s )
 s  2 s  1
Composed of two first order subsystems (G1 and G2)
K1K 2
Y (s) 
 1s  1 2s  1
K  1 overdamped
G(s) = 2 2
 s  2s  1 0   1 underdamped
  1 2  1 critically damped
1  2 2nd order ODE model

=
2 12 (overdamped)
K
    12 G(s) =
roots: 12s 2 + (1  2 )s + 1

1. Step response
Y (s)  2 2
K K x

 s  2s  1X (s) Y (s) 
 
 2s 2  2s  1 s
Second Order Step Change
a. Overshoot – fraction of the final steady-state change
by which the first peak exceeds this change
a   
os=  exp  
b  1 2 
 
b. time of first maximum-time required for the output
to reach its first maximum value

tp 
1 2
c. decay ratio-ratio which the amplitude of the sine

wave is reduced during one complete cycle
c  2  a 2
 exp   2
a  1 2  b
 
d. period of oscillation, P – time between two
successive peaks of the response.
2
p
1 2
e. Rise time, tr – time taken for the process output to

first reach the new steady state value.
f. Settling time – time it takes for the output to come

within a band of the final steady-state value and
remain in this band
Type of system
• Self-regulating vs. non self-regulating
systems
• Interacting vs. noninteracting systems

Self-regulating vs. non self-regulating
systems
Unit 4: Openloop response 5:45:4
Openloop response: Self regulating process
• A self regulating process (SR) is

process that goes to a new steady PV ,%
new s.s.
level upon a step input made.
• Examples:
Liquid flow, gas pressure, tempe-
rature, mass flow.
old s.s.
time
MV,%
MV
time

Unit 4: Openloop response 5:45:4
Openloop response: Nonself regulating process
• A non self regulating process

runaway
(NSR) is process that keeps on processes
PV ,%
going upon a step input (load
change) made . It will not reach a
new steady state level.
• Examples:
Liquid level, reaction based
processes, batch processes.
old s.s.
• Be alert for runaway or
time
uncontrolable processes.
MV , %
MV
time

Example of non-self regulating system
A pumped tank (non-self regulating process)
– the level in the tank only remains

Feed flow
steady if the discharge flow rate
through the pump equals the feed
rate.
– If the discharge flow rate exceeds
the feed rate, the tank drains until
empty.
– Similarly, the tank fills until
overfilled if the feed rate exceeds
Outlet flow
the discharge flow rate.
pump
Unit 4: Process characteristics determination
Process characteristics
These methods are used to extract the response rate, deadtime and time
constant from openloop response curves.
• Tangent Method1
• Reformulated Tangent Method2
• Numerical Method3
1 J.G. Zieglar & N.J. Nichols, “Optimum Settings for Automatic Controllers”, Trans. ASME (1942)64:759-768
2
Abdul Aziz Ishak & Muhamed Azlan Hussain, “Reformulation of the Tangent Method for PID Controller
Tuning”, TENCON2000 IEEE Asia-Pacific Regional Symposium, 24-27 Sept. 2000, Kuala Lumpur.
3
Abdul Aziz Ishak & Anuar Ahmad, “Application of Numerical Technique in Tangent Analysis of a Discrete
Step Response Data”, SCOReD 2002, UiTM-IEEE Conference, 16-17 July 2002, Shah Alam.

Openloop Test: Tangent Method
OPTION 1
Non self regulating process Sources of data:

PV ,% Chart recorder,
line printer, etc.
t
max. slope
PV ,%
The Tangent Method
old s.s. Response Rate, RR:

PV /  t max. slope
RR  
Td MV MV
time
Dead time, T : d
A period of time between starting point of step

MV , %
input and the intersection of old s.s. baseline
MV
and tangent line.
 Time constant?
time Information not available.
6-Process Charac.
4/17 (61/108)
1. Td = 2.6 s
2. RR = 0.04182 / s
Interacting vs. Noninteracting
Systems
• Consider a process with several invariables and several output
variables. The process is said to be interacting if:
o Each input affects more than one output.
or
o A change in one output affects the other outputs.
Otherwise, the process is called noninteracting.
• In general, transfer functions for interacting processes are more

complicated than those for noninteracting processes.
•As an example, we will consider the two liquid-level
storage systems
A noninteracting system:
two surge tanks in series.
Two tanks in series whose liquid levels interact.

A noninteracting system:
two surge tanks in series.
Noninteracting-the second tank not

influence the level in the first tank
dh1
Mass Balance: A1  qi  q1 (1) (4-48)
dt
1
Valve Relation: q1  h1 (2) (4-49)
R1
Substituting (2) into 1) eliminates q1:

dh1 1
A1  qi  h1 (4-50)
dt R1
Putting (4-49) and (4-50) into deviation variable form gives
dh1 1
A1  qi  h1 (4-51)
dt R1
1
q1  h1 (4-52)
R1
The transfer function relating H1  s  to Q1i  s  is found by

transforming and rearranging above equation to obtain
H1  s  R1 K1
  (4-53)
Qi  s  A1R1s  1 τ1s  1
where K1 = R1 and τ1 = A1R1. Similar procedure is used to obtain

the transfer function relating Q1  s  to H1  s 
Q1  s  1 1
  (4-54)
H1  s  R1 K1
The same procedure leads to the corresponding transfer functions

for Tank 2,
HH22' (ss) R2 K2
  (4-55)
Q12' (ss) A2 R2 s  1 τ2 s  1
Q
Q2  s  1 1
  (4-56)
H 2  s  R2 K2
where K2 = R2 and τ2 = A2 R2. Note that the desired transfer

function relating the level in Tank 2 to the inflow to Tank 1 can
be derived by forming all the transfer function obtained.
H2 (s) H 2 (s ) Q1(s) H1' (s )
=
or Qi (s) Q1(s ) H1(s) Qi ' (s )
H2 (s) = K1 1 K2
Qi (s)  1s  1 K 1  1s  1
which can be simplified to yield
H2 (s) K2

Qi (s) 1s  1 2s  1
a second-order transfer function
Block Diagram for Noninteracting
Surge Tank System
Input-output model for two liquid surge tanks in series.

Dynamic Model of An Interacting Process
interacting-Tank 1 level depends on
Tank 2
Two tanks in series whose liquid levels interact.
1
q1   h1  h2  (6-70)
R1
The transfer functions for the interacting system are:

 R1R2 A2 
R1  R2  s  1
H1 s 
'
 R1  R2 

Q1, s  R1R2 A1A2S 2  R2 A2  R1A1  R2 A1 s  1
R2
H 2' s  R1  R2

H1 s  R1R2 A2 s  1
'
R1  R2
which can be simplified to yield

Model Comparison
• Noninteracting system
H2 (s) K2

Qi (s) 1s  1 2s  1
• Interacting system
Multiple-Input, Multiple Output
(MIMO) Processes
• Most industrial process control applications involved a number
of input (manipulated) and output (controlled) variables.
• These applications often are referred to as multiple-input/
multiple-output (MIMO) systems to distinguish them from the
simpler single-input/single-output (SISO) systems that have
been emphasized so far.
• For example, consider the system illustrated in Figure below
A multi-input, multi-output thermal mixing process.
• Here the level h in the stirred tank and the temperature T are to
be controlled by adjusting the flow rates of the hot and cold
streams wh and wc, respectively.
• The temperatures of the inlet streams Th and Tc represent
potential disturbance variables.
On – off, Proportional, Integral,
Derivative Control modes
(6.3 SELECTION OF
CONTROLLER MODE &
characteristic of PID
controllers)
Topic Covered
• On – off control
• Proportional control
• Proportional-Derivative control
• Proportional-Integral control
• Proportional-Integral-Derivative control
• General tips for designing a PID controller
Topic Outcome
• Able to understand the characteristics of the
each of proportional (P), the integral (I), and
the derivative (D) controls.
• Able to use them to obtain a desired
response.
Introduction
• Consider the following unity feedback system:
• Plant: A system to be controlled
Controller: Provides the excitation for the plant; Designed to
control the overall system behavior
Selection of controller mode
• Three popular modes of control are:
– Proportional only (P)
– Proportional-Integral (P+I)
– Proportional-Integral-Derivative (P+I+D)
• Porportional only control is normally for a

non critical process control e.g wastewater
treatment plant. This mode of control will
result in an off-set process response.
• For more precise control, P+I and P+I+D shall
be used.
• P+I mode of control is used for fast process

response and noisy process e.g flow, pressure
and liquid level control.
• P+I+D mode of control is applied for slow

process response and noise free process e.g
Temperature control
On – off control
• a thermostat is a simple negative-feedback control: when the

temperature (the "measured variable" or MV) goes below a set
point (SP), the heater is switched on.
• Another example could be a pressure-switch on an air
compressor: when the pressure (MV) drops below the threshold
(SP), the pump is powered.
The three-term controller
• Kp = Proportional gain
• Ki = Integral gain
• Kd = Derivative gain
The characteristics of P, I, and D
controllers
CL RESPONSE RISE TIME OVERSHOOT SETTLING TIME S-S ERROR
Kp Decrease Increase Small Change Decrease
Ki Decrease Increase Increase Eliminate
Kd Small Change Decrease Decrease Small Change
The goal of this problem is to show you how each of Kp, Ki and
Kd contributes to obtain:
• Fast rise time

• Minimum overshoot
• No steady-state error
Open-loop step response
Self-regulated
• The rise time is about one
second, and the settling time
is about 1.5 seconds.
• Let's design a controller that
will reduce the rise time,
reduce the settling time, and
eliminates the steady-state
error.
Proportional control
The proportional controller

reduced both the rise time
and the steady-state error,
increased the overshoot,
and decreased the settling
time by small amount.
Proportional-Derivative control
This plot shows that the

derivative controller
reduced both the overshoot
and the settling time, and
had small effect on the rise
time and the steady-state
error.
Proportional-Integral control
• We have reduced the
proportional gain (Kp) because
the integral controller also
reduces the rise time and
increases the overshoot as the
proportional controller does
(double effect).
• The above response shows that
the integral controller eliminated
the steady-state error.
Proportional-Integral-
Derivative control
Now, with PID gain, we have

obtained the system with no
overshoot, fast rise time,
and no steady-state error.
General tips for tuning a PID
controller
• Obtain an open-loop response and determine what needs to be
improved
• Add a proportional control to improve the rise time
• Add a derivative control to improve the overshoot
• Add an integral control to eliminate the steady-state error
• Adjust each of Kp, Ki, and Kd until you obtain a desired overall
response.
You can always refer to the table shown in this "PID Tutorial" page
to find out which controller controls what characteristics.
Summary
• Lastly, please keep in mind that you do not need
to implement all three controllers (proportional,
derivative, and integral) into a single system, if not
necessary. For example, if a PI controller gives a
good enough response (like the above example),
then you don't need to implement derivative
controller to the system. Keep the controller as
simple as possible.
•PID Controller Tuning
• Tuning –adjustment of the controller parameters
to obtain a specified closed-loop response.
• 2 methods:
• On-line or closed-loop tuning
• Step-testing or open-loop tuning
• A number of tuning procedures and formulas – to
aid and insight into the tuning procedure.
76
CLOSE-LOOP OR ONLINE TUNING METHOD
Quarter Decay Ratio Response By Ultimate Gain
• It consists of two steps:
1. The determination of the dynamic
characteristics
2. The estimation of the controller tuning
parameters that produce a desired response for
the dynamic characteristic in first step
• The dynamic characteristics are represented by:
• Ultimate gain of a proportional controller
• Ultimate period of oscillation of the loop.
77
Quarter decay ratio response to disturbance input
and change in the set point
78
• The decay ratio is the ratio of the amplitudes of
two successive oscillations.
• It should be independent of the input to the
system
• It depends only on the roots of the characteristic
equation of the loop.
• First, determine the ultimate gain and period
• Then, calculate the controller tuning parameters
that produce quarter decay ratio responses.
79
Tuning formulas for quarter decay ratio response
Mode Kc I D
- -
P K
Kc  cu
2
PI K T -
K c  cu I  u
2.2 1 .2
PID K cu Tu Tu
K c'   
'
I
 D' 
1.7 2 8
The technique is not widely used because the closed-loop

tends to be oscillatory and sensitive to uncertainty
80
Determine the controller tuning parameters for quarter decay ratio
response by the ultimate gain method
•Process o sensor transmitter

50 C
G(s
Example )  1.0 %TO
30s  1 k g / s H (s ) 
10s  1 oC
•Valve
0.016 k g / s
Gv (s ) 
3s  1 %CO
To (s ) K spGs (s )Gv (s )Gc (s )

To (s ) 1  H(s )Gs (s )Gv (s )Gc (s )
set
•Characteristic equation
1  H(s )Gs (s )Gv (s )Gc (s )  0
1.0 50 0.016
1 Kc  0
10s  1 30s  1 3s 81 1
1.0 the controller
Determine 50 0.016 tuning
1 K c parameters
0 for quarter decay ratio
10s  1 30 s  1 3sby the
response 1 ultimate gain method
•Rearrange into polynomial form
(10s  1)(30s  1)(3s  1)  0.8K c  0
900s 3  420s 2  43s  1 0.8Kc  0
Substitute s=iωu and Kc=Kcu
900i 3u  420i 2u  43iu  1 0.8K c  0

3 2
Substitutei 2  1 and separate real and imaginary part
(420u2  1 0.8Kcu )  i (900u3  43u )  0
82
Obtain two equations, real and imaginary parts
must be zero
 420u2  1 0.8Kcu  0
 900u3  43u  0
u  0.2186rad / s
Kcu  23.8%CO / %TO
2
Tu 
u
2
Tu   28.73s
0.2186
83
a) A proportional controller
K cu %CO
Kc   11.9
2 %TO
b) A proportional-integral (PI) controller

K cu %CO
Kc   10.8
2.2 %TO
Tu
I   23.92s
1 .2
b) A proportional-integral-derivative (PID) controller

K cu %CO Tu
Kc   14 D   3.59s
1.7 %TO 8
Tu
I   14.37s
2
84
• Consider a feedback control system that has the characteristic equation,
1+GOL=0
where
2K c
GOL (s) 
(s  1)(s  2)(s  3)
Determine the ultimate controller gain, Kcu and ultimate period, Tu.
85
OPEN-LOOP OR OFFLINE TUNING METHOD
Many controller tunings method characterize the

process by
a simple first or second order model with dead time
The model characterizes the process by 3 paramete

•the gain, K or response rate, RR
•dead time, t0
•Time constant,τ I
86
Step
testing
Process reaction curve or open loop response
•A step change in the controller output signal is applie

to the process 87
Open loop analysis
Process reaction curve or open loop response

Determine process gain (K), time delay (Td), time
constant (Tc@∆t), response rate (RR)
88
Time delay (Td), time constant (Tc@∆t), response
rate (RR)
• Tangent method
• Reformulated tangent method
• Tangent and point
• Two point method
89
Tangent method
Reformulated tangent method
90
Ziegler-Nichols's tuning
rule
Process reaction curve
91
Ziegler-Nichols's tuning
rule
Mode Kc I P
P - -
PI -
PID
92
Tuning formulas for Cohen-Coon
Mode Kc I P
P - -
PI -
PID
93
Tuning formulas for Cohen-Coon
Mode Kc I P
P 1    - -
1 
 3 
K  
PI -
1     30  3 /  
K 0.9  12 
  9  20 /  
PID 1  16  3 
 32  6 /   4
K   12 
13  8 /   11 2 /  
94
Unit 4: Tutorial 4
Process: Pressure loop

Openloop: Double step method

Unit 4: Numerical Technique
Numerical Analysis on openloop step response data
Sources of data:
MV  18.1%
Time, s PV, %
FT FC Sources of data:
0 57.2
1 57.2 Paperless
2 57.7
Flow recorder,
3 61.8
4 65.1 DCS,
5 67.8
6 69.6 SCADA, etc.
7 71.1
8 72.5
?
9 73.2
10 73.9
11 74.5 Response rate, RR
12 74.9
13 75.1 Dead time, Td
14 75.3 Time constant, Tc
15 75.6
16 75.7
17 75.8
18 76.1
19 76
20 76.1
21 76.2
22 76.2

Numerical Analysis on openloop process response data
Numerical formulation for response rate,

RR:
tangent line approx.
by central difference Based on 3-point central difference
response
formula, the slope at (to , PVo) :
PV1 curve
PV1  PV1
PVo slope 
2h
Therefore, the response rate
PV-1 becomes:
slope PV1  PV1
= data RR  
points MV 2  h MV
h h
t-1 to t1

Numerical formulation for dead time, Td:

3-point central difference
slope estimation
response
Based on the fact that any point along
curve a straight line has similar slope’s
PV1 value; hence,
PVo
slopeat (Td , PVoss )  slopeat (t1 , PV1 )
PV1  PVoss PV1  PV1

PV-1 
old s.s.
t1  Td 2h
base line
*(T  PV  PVoss 
PVOSS d ., PVoss) = data
Td  t1  2  h  1 
points  1
PV  PV1 
Td h h
t-1 to t1

Numerical formulation for
time constant, Tc:
(Tnss ,
New s.s. base line
PVnss)
* Based on the fact that any point along
a straight line has similar slope’s
PV1 value; hence,
PVo slopeat (Tnss , PVnss )  slopeat (t1 , PV1 )
PVnss  PVoss PV1  PV1

PV-1 
Tnss  Td t1  t1
old s.s.
base line
Tc  PV  PVoss 
PVoss
TC  2 h  nss 
 PV  PV1 
h
h 1
Td Tnss
t-1 to t1
= data points

Example of numerical analysis
MV  18.1%    Calculation steps:
Time, s PV, % RR, 1/s Td, s Tc, s PB, % I, s
0 57.2
Spreadsheet was used to perform the calcu
1 57.2 0.0138
2 57.7 0.1271
PV1  PV1
3 61.8 0.2044 1.9 5.1 42.4 6.2
4 65.1 0.1657
 RRmax 
5
6
67.8
69.6
0.1243
0.0912
2  h MV
7 71.1 0.0801
8 72.5 0.0580  PV1  PVoss 
9 73.2 0.0387
 Td  t1  2  h  
10
11
73.9
74.5
0.0359
0.0276  1
PV  PV1 
12 74.9 0.0166
13 75.1 0.0110  PVnss  PVoss 
14 75.3 0.0138  C
T  2 h  
15 75.6 0.0110
 PV1  PV 1 
16 75.7 0.0055
17 75.8 0.0110
18 76.1 0.0055
19 76.0 0.0000
20 76.1 0.0055
21 76.2 0.0028
22 76.2
0.2044

Unit 4: Tutorial 4
Process FlowInc
MV1, % = 0
MV2, % = 65 Z-N Z-N Z-N C-C C-C C-C
Time, s PV, % RR, 1/s Td, s Tc, s u PB, % Kc I PB, % Kc I
0 26.8
5 26.8
10 26.8
15 26.9
20 27.2
25 27.8
30 28.9
35 30
40 31.5
45 32.9
50 34.4
55 35.9
60 37
65 38.3
70 39.4
75 40.4
80 40.4
85 40.4

Fine Tuning Techniques
• Practical controller tuning tips

Unit 5: Fine Tuning Strategies
Practical Controller Tuning Tips
Armando B. Corripio, Tuning of Industrial Control Systems, 1990, pp78-81
1. Tune coarse, not fine. The performance of a feedback controller is not
sensitive to the precise adjustment of its tuning parameters significantly.
Example
Pressure control loop Pressure control loop
Calculated optimum: Calculated optimum:
PB = 58.3% PB = 60%
I = 5.75 s I=6s
2. Tune with confidence. Select the integral time first, set the derivitive time
to about one fourth of the integral time, and then adjust the proportional
gain to obtain tight control.
D = 0.25 x I
3. Trial-and-error tuning: Fix one parameter while adjusting the other.

Derivitive, D, follows integral, I, by 0.25 x I.
© Abdul Aziz Ishak, Universiti Teknologi MARA (2007)

Armando B. Corripio, Tuning of Industrial Control Systems, 1990
4. Try a longer integral time. Not to force the process reaches the set point
faster than the process can respond.
Example
Pressure control loop Pressure control loop
PB = 60% PB = 60%
I=6s I = 12 s
5. Based on the characterictics of PIDs (plus experience), increase PB, I or

D: not more
than twice, while decrease PB, I or D: not less than half.
Increase: PBnew = 2 x PBold or Inew = 2 x Iold
Decrease: PBnew = 0.5 x PBold or Inew = 0.5 x Iold
D = 0.25 x I

Armando B. Corripio, Tuning of Industrial Control Systems, 1990
6. Tuning very controllable process (dead time < 0.1 x time constant): Use
own judgement when calculated optimum PIDs reccommends lower PB
(fast action) and lower I (fast action).
Example
Flow control loop Flow control loop
PB = 15% PB = 30%
I=3s I=9s
7. On-line tuning (depending on your controller): Keep changing the desired

parameter (P, I or D) until the process becomes stable. The set of PIDs
obtained may not be the best. Must perform set point change to see
whether this set of PIDs will produce stabilty.

Fine tuning techniques
D > Dcalc
I < Icalc
SP2
PB < PBcalc
PB > PBcalc
SP1

Unit 5: Tutorial 5
Effect of proportional band, PB
The response curve below is the result of a set point change from 50% to
60%. The PB is 30, 100 and 200% and I is 6 s. Assume that the process is of
linear characteristic and a linear control valve had been installed.
a. On the response curve, label the PB’s accordingly. Justify your answer.
b. You are to make a set point change from 50 to 60%. Sketch the expected
responses for
i) PB =15% and I = 6 s
ii) PB = 400% and I = 6 s
70
Automatic Response of Level Control
PB = 30, 100, 200%, I = 6 s
60
Level, %
50
0 50 100 150 200 250
Time, s
Unit 5: Tutorial 5
Effect of integral time, I
The response curve below is the result of a set point change from 50
to 60%. The PB is 100 and I is 12 s. If you were to change the integral
a. 12 Ito
time, 20 s
from
b. 12 to 6 s
how would the process response curve be? Justify your answer.
I = 12 s
Level, %
SP
50 100Time, s 150 200

•PID Controller Tuning Based
•Integral Error Criteria
109
Integral Error Criteria
Alternative approach for the closed-loop tuning
• Controller design based on performance index
• Tuning relationship are intended to minimize the
integral of the error.
• Three popular performance indices are:
•Integral of the absolute value of error (IAE)

IAE   et dt
0
•Integral of the squared error (ISE)

 e(t ) dt

IAE 
2
0
•Integral of the time weighted absolute error

(ITAE) 
IAE   t et dt
0
110
M
u
k
a
s
u
r
a
t
Definition of error integrals for disturbances

and set point
111 changes
Minimum IAE formulas for disturbance inputs
Mode Kc I D
0.985
P 0.902  t 0  - -
 
K  
0.986
PI 0.984  t 0    t0 
0.707
-
   
K    0.608   
0.921 0.749 1.137
PID 1.435  t 0    t0  t
0.482  0


   
K   0.878     
Minimum IAE formulas for set point changes

Mode Kc I P
0.861 
PI 0.758  t 0  -
  t 
K    1.02  0.323 0 
 
0.869  0.914
PID 1.086  t 0  t 
  t  0.348  0 
K  112
0.740  0.130 0   
 
Minimum ITAE performance index for disturbance inputs
Controller
τ
Mode A B
I
PI P 0.859 -0.977
I 0.674 -0.680
PID P 1.357 -0.947
I 0.842 -0.738
D 0.381 0.995
Y  At 0 /  
B
Proportional mode Y= KKc

Integral mode τI τ
Y= I
Derivative mode τI τ
Y= DI
113
Minimum ITAE performance index for set point changes
Controller Mode A B
PI P 0.586 -0.916
I 1.03 -0.165
PID P 0.965 -0.85
I 0.796 -0.1465
D 0.308 0.929
Y  At 0 /  
B
For proportional and derivative
Y  A  Bt 0 /   mode
For integral mode

Y= I
Y= DI
114
•Example
– Find the PI controller setting for a process with transfer function for
load changes :
•
Controller Mode A B
• PI P 0.859 -0.977
I 0.674 -0.680
PID P 1.357 -0.947
I 0.842 -0.738
D 0.381 0.995

Y  At 0 /  
B
Y= I
Y= D
I
=0.169
=1.85
115
•For the process model,
4e 3.5s
G(s) 
7s  1
Determine PI controller setting based on the IAE

tuning relations for set-point changes.
116

Chapter 6 Industrial Control Tuning Strategies

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Faculty of Chemical Engineering

UiTM Pulau Pinang

 Identify the process characteristic for

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Characteristics PB, I & D An optimum PB, I & D

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

A sudden change in a process variable can be approximated by

The step change occurs at an arbitrary time denoted as t = 0.

• Special Case: If M = 1, we have a “unit step change”. We

• Example of a step change: A reactor feedstock is suddenly

1. Reactor feed is shut off for one hour.

where: A = amplitude, ω = angular frequency

1. 24 hour variations in cooling water temperature.

Step response for first order system

Ramp response for first order system

By partial fraction decomposition,

Θ=Time delay/dead time

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

PV ,% new s.s. PV ,% new s.s.

PV ,% new s.s.  TC,Cecil = 1.5 (TPV@63.2% -

Estimate Td, TC,Z-N , TC,63.2% , and TC,Cecil .

Td, s TC,Z-N TC,63.2% TC,Cecil

20 How much do they differ?

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Estimate Td, TC,Z-N , TC,63.2% , and TC,Cecil . Step by step guide

2. Draw a tangent line at the max. gradient.

40 B C 3. Draw a straight line at Pvoss.

How much do they differ?

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Step-by-step calculation for TC,Cecil Step-by-step calculation for TC,Z-N

1. Estimate PVnss. 1. Draw a tangent line at max point.

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

1  2 2nd order ODE model

c. decay ratio-ratio which the amplitude of the sine

e. Rise time, tr – time taken for the process output to

f. Settling time – time it takes for the output to come

• Interacting vs. noninteracting systems

• A self regulating process (SR) is

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

• A non self regulating process

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

A pumped tank (non-self regulating process)

– the level in the tank only remains

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Non self regulating process Sources of data:

old s.s. Response Rate, RR:

A period of time between starting point of step

Otherwise, the process is called noninteracting.

• In general, transfer functions for interacting processes are more

Two tanks in series whose liquid levels interact.

Noninteracting-the second tank not

Substituting (2) into 1) eliminates q1:

The transfer function relating H1  s  to Q1i  s  is found by

where K1 = R1 and τ1 = A1R1. Similar procedure is used to obtain

The same procedure leads to the corresponding transfer functions

where K2 = R2 and τ2 = A2 R2. Note that the desired transfer

which can be simplified to yield

Input-output model for two liquid surge tanks in series.

Two tanks in series whose liquid levels interact.

The transfer functions for the interacting system are: