PID Basics PICO July92007 PDF

PID Basics With
Pico Controller
Debasish Mukhopadhyay
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Why Closed Loop Control?
Current temperature
Control
Device
Setpoint
¾Temperature
Command
¾ Flow
Position ¾ Speed
to valve ¾ Weight
¾ Level
¾ Pressure
Liquid
Steam ¾PH
Valve
Steam ¾Conductivity
Inlet
Heating
Steam Coil
Return
Temperature
Sensor
Ability to maintain a process variable at a desired state/ value/

setpoint
Why Analog Feedback Control?
• Could control using On/Off strategy

• If Actual>Desired Then ‘Off’
• If Desired<Actual Then ‘On’
Æ Open loop control (non-feedback control) can be used in

systems sufficiently well-characterized as to predict what outputs will
necessarily achieve the desired states. For example, the rotational
velocity of an electric motor may be well enough characterized for the
supplied voltage to make feedback unnecessary.

On-Off Control of Heating System
CONTROLLED
VARIABLE
SET
POINT
OPEN (ON)
FUEL VALVE POSITION
CLOSED (OFF)
TIME

Why Analog Feedback Control?
Need to fix the actuation of the valve to some intermediate position

between 0% and 100% to attain the desired result…
But how to find that position?

Temperature Control
Process
Three Types Of Processes
P
1. Self Regulating- Process that reaches a new
The steady-state when it is driven by a steady change
Feedback in input.
Sensor S O Output
Loop 2. Imbalanced or Integrating Process- Liquid level in
a tank
C
3. Open Loop or Unstable process- Exothermic
ReactorÆexponential change
Control

Tuning Methods
There are Two types of tuning methods used:

•Open Loop
Fast and Simple. Put the PID controller in manual mode. The value of the Control
Variable is stepped by a fixed amount and the performance of the system is observed.
Parameters obtained are K (Process Gain), tp (Process Time Constant), td (Dead Time).
Kp = tp / K* Td , Ti = 5td Td = td / 2
•Close Loop
Instead of changing the output, the setpoint is changed with the PID in Auto mode. The
system behaviors are observed. Some people do this as a fine tuning after doing the Open
Loop tuning. Parameters obtained, KU (Ultimate Gain) & TU (Ultimate Period) are used to
find gain values.
The choice of tuning method depends on the person’s experience and the knowledge of
the process.

Instrumentation and Control Elements Used in
Process Control
• Sensing Element
The components used to measure the process variable. A simple thermocouple is a good example
of a temperature sensor
• Transmitter
Sensors having a sensor and a transmitter both. Flow, Level, Pressure and Temperature
measurement devices are referred to as Transmitters.
• Transducer
Device that has a sensor, some additional circuitry to “polish” the signal (scaling, compensation,
etc), and a transmitter. A pressure transducer can measure pressure, perform some polishing of
the measurement, and transmit a signal on a wire or cable. Transducers are normally mounted
remotely from the conditioning device. An example is a Weight Transmitter connected to remote
Load Cells

Instrumentation
•Most widely used

•Inexpensive
•Wide ranges of temperatures
“J” or “K” type refers to the metals used for the sensor and influences the
range and accuracy of the sensor.
Thermocouples
“Application – Cost – Accuracy – Durability – Reliability”

Instrumentation
Thermistors
Infrared sensors
RTD’s
•Fairly wide Temp. •More accurate than •Expensive

range TC or RTD’s
•Special Applications –High
•More accurate than •Limited Temperature Temp, Moving parts, Non-
Thermocouples range contact surface or large
surfaces

Instrumentation
Pressure Transmitter Flow Transmitter

•Absolute
Level Transmitters
•Mass
•Differential •Discrete
•Volumetric
•Hydrostatic •Continuous
Voltage / Current signal •Velocity
•Inferential
Capacitive and Ultrasonic
CFM – Configurable Technology
Flow Meter for high
speed, high resolution
on calculation and
output

Framework For Understanding
• The contribution of Ziegler and Nichols tuning methods were developed during
1940s
• We will not be concerned about determining settings within 1% (Accuracy
Ballpark)
• Modern controllers perform the same functions as those built around 1940

What Do We Know?
1. PV – Known as Process Variable. Actual measured value which we are trying to control.
Pressure, Temperature, Flow, % Opening etc.
1. Error / Offset - The difference between (Set Point and Process Variable) where we are and
where we want to be.
Measured as SP ~ PV
3. Δt - Knowledge of ‘when’ the PV was observed
4. Control Variable(CV) – Variable adjusted to correct error

PID Æ3 Mode Regulator
• Has the advantages of three components, (P,I, and D)

P Æ Proportional
IÆ Integral
DÆ Derivative
The three put together is called PID
• Most common regulator in the industry
• Very easy to understand the components

• Just like a lead/lag filter Error ÆPID ÆOutput
Simplicity – Versatility- Longevity

PID Equations
Independent
CV = Kp.E% + ΣKi.Δt.E% + Kd (d/dt) E% + S-S Bias. Mostly Bias is ignored.
Dependent
CV = Kp [E% + Σ(1/Ti)Δt.E% + Td(d/dt)E%] + S-S-Bias
Dependent type is a easier operation
There is no “standard” equation or correct PID algorithm. Just stick to one

and go with it.
The Ki and Kd parameters relate only to dynamics of the process, and the Kp
(proportional gain) relates to the gain of the process.

PICO Control Action Parameters
SP - PV (default)
Calculate the Error as Set Point - Process Variable
‘Reverse Acting Loop’
PV - SP
Calculate the Error as Process Variable – Set Point
‘Direct Acting Loop’
PICO GFX supports Reverse Acting control

Controllers and Control Strategies
Disturbances
Controller Output
Final
Algorithm Control
Set Point Σ (Control Law) Element
Process
Process
Measurement

Direct Acting Controller
Controller
Set Point Error / CONTROLLER Output
Σ
Offset
Measurement / Process Variable
Controller Output Increases

when
PV increases
A typical example of a direct-acting system is controlling flow of

cooling water - if the temperature increases, the flow must be
increased to maintain the desired temperature

Reverse Acting Controller
Controller
Set Point Error / CONTROLLER Output
Σ
Offset
Measurement / Process Variable
Increase in PV
Causes
Decrease in Controller Output
A typical example of a reverse-acting system is controlling flow of steam for

heating - if the temperature increases, the flow must be decreased to maintain
the desired temperature

What Does Proportional Do?
Controller output moves in proportion to the error between

Setpoint and Process Variable
• Direct, Linear, Relationship Between the Input and Output
• Determines how fast the regulator reacts to errors
• This action is for dynamics

What Does Proportional Do?
Proportional mode causes an instantaneous response in the controller

output to changes in the error
KC E (where Kc= controller gain, E = error);
Want Proportional Gain as high as possible
Responsible for Disturbance Rejection
System Delays Limit Proportional Gain

Proportional Control
Let the control output be proportional to the difference between ‘Desired’ and ‘Actual’
Output = Kp x Error (Bias is ignored)
Output / Error = Kp (Laplace Transform or Transfer Function)
Kp is dimensionless
When Controller has no automatic reset

Gain =1.0 (integral action), it will usually have a
manual reset (integral) adjustment which
Controller output
Gain =2.0
allows some manual compensation for the
offset or error. Manual reset in a
Gain = 0.5
50 proportional – only controller changes the
fixed relationship between error and
controller output.
Error as % of scale

Error
0 t
Output
Kp = 2.0
Kp = 1.0
Kp = 0.5
0% t

• Will never maintain the desired operating point

• Increasing the multiplier Kp will get you closer to the
desired level but will also create instability
• Any loop will cycle (become unstable) if the gain in
increased far enough

SP oF 80
Offset
OFFSET
Temperature Record of Process With Proportional Control for Two Bottling Machines
Output
Desired
SP oF
80
0
Temperature Record of Process With Proportional Control for One Bottling Machine
Limitation Of Proportional Function
P only is not capable of eliminating offset by itself. P only can be used

if you utilize the BIAS term in the control equation. BIAS can remove
the gap between PV & SP. Having large proportional gains can lead
to system instability for a P only controller
Alternates to proportional control are proportional-integral (PI) control

and proportional - integral - derivative control (PID).PID control is
commonly used to implement closed-loop control.

What Does Integral Function Do?
• Adds or subtracts to the control output when the process value shows a
sustained deviation from setpoint
• Initially manual reset
• Integral action causes the controller output to change at a rate

proportional to the error. The longer the integral time the slower it
changes. Ki = KP / Ti = KP / Big = Small.
• Integral Time or Reset Time is defined as Minutes per Repeat. The

Integral Time is the time to repeat the change that was due to the
proportional action only.

Integral Contribution
I = In-1 + (Ki x Δt x Error)
Note that the result is accumulated and used again

the next time around
Output = Ki x Sum(Error)
Ki units are in inverse time

Integral Contribution
Find the area under a curve by rectangular

approximations
Error
0 t
Δt

Integral Control
PV
SP
Output
100%
0% t
As long as the error is constant the output will continue to accumulate.

How fast it accumulates, depends on the multiplier

What Does Integral Do?
• Eliminates Process Offset (droop)

• Maintains Output at Setpoint
• Is always used with Proportional Control PI or PID, rarely I alone

Proportional Plus Integral
• These two components together are good enough
• Effects of each are ‘interactive’
• Majority of all the loops are “PI” loops
• Proportional function handles the changes in setpoints and the disturbances

whereas Integral function handles the "steady-state” system changes
• Note that Integral needs “time” over which it accumulates. If the Proportional gain
is increased it will effect the overall that the Integral has to react because P is
making error smaller on average therefore increasing the amount of time it takes to
accumulate the same amount of I.
• Change one and it affects the other….balancing act !

Proportional Plus Integral
Error
0 t
Output
‘I’
100%
‘P’
0% t
Proportional and Integral contribute to the output when the error is

constant

What Does Integral Do?
• Integral Action determines S.S. operations
• At S.S. Integral Sum is the PID Output
• Integral Gain determines how fast to react to S.S. operating

point changes

Proportional – Integral Outputs
At SetPoint, Integral output

Proportional Output is needed to maintain SP
100%
O
u
t
p
u
t
0%
T0 TIME T1
Integral Output Contribution

Derivative Control
• In systems where significant delays exist proportional

action produces oscillations…Sluggish systems!
• To offset this effect the rate of change of the system

error was added to allow the controller to ‘pull back’ the
control output based on rate that system changes.

When to Use Derivative Control
• D is largely unnecessary for fast loops (such as flows

and pressures) due to their naturally quick response
times.
• D control is very useful for slow loops and an absolute

must for integrating process such as levels and
insulated temperature loops

What Does Derivative Do?
• Senses the rate of change of the input signal and causes output to
increase or decrease anticipating possible overshoot or undershoot
• Anticipatory type of control by widening the proportional band and

opposing changes in the PV
• Brakes or Gas as needed
• Only functions when error signal is changing

Derivative Contribution
D = K d x (Error(now) - Error(before)) / Δt
A linear slope approximation between two

points. Defined as ’rise’ over ‘run’. Where ‘rise’ is
difference in current and previous errors and
‘run’ is difference in time when the errors were
noted.
Kd units are in time

Derivative Control
Error
0 t
Output
‘P’
100%
‘D’
0% t
A continuously changing error is required to generate

a fixed amount of Derivative…idealistic but not
practical !
Error E
E
E E
ΔError
Out
Out Out Out
Decel
Accel Decel Accel
0 t
Δt
‘D’ Always Opposes Change in ‘PV’

D = d/dt [Error] for Derivative (Error)
D = - d/dt [PV] for Derivative (PV)
Derivative allows Proportional Gain to be larger

The higher the Dead-Time, the more the ‘D’
K d = KP * T d
Can always do without ‘D’ with a smaller ‘P’ ?

• Limits overshoot through anticipation

• Must be used with proportional control
– PID or PD never ID or D
• May not be necessary in many applications with P & I control
action

What P, I, and D Do together?
Proportional and Derivative actions respond to

setpoint changes and dynamic system
disturbances
Integral action responds to changes in steady

state operating point

PID Controls
Output Temperature
Integral
Proportional Derivative
Time Æ

Preparation
• Have some idea of what you are trying to accomplish
• How fast or how far the process is going to respond to the controller output. Restoring stability
with confidence is important
• How much change will you allow In the process and in the controller output ?
• Who is going to adjust controller settings ? How knowledgeable the person is to avoid
confusion or crisis?
• Who is going to switch between Auto and Manual modes and change the setpoint ?
• Knowledge of the safety interlocks and other process related safeties are very important
• Time during and after tuning are important. Process behavioral changes must be closely
monitored and altered accordingly if required.
• Recording of existing settings and controller outputs are important. Especially, when you have
to return to these existing settings. Trending of the parameters should be monitored for
efficient process controls.

Mantras for Process Control
QUARTER WAVE DECAY RATIO A B

B 1
Overshoot ratio
A 4
Quarter decay ratio is usually good compromise between ‘Fast response’ and ‘Stability’
MINIMIZE OVERSHOOT
Critically Damped
Preferred for some applications. However, cannot eliminate deviation as fast as controller
with quarter -decay
MINIMIZE DEVIATION FROM SET POINT
If the controller is tuned to give a quick response to a load upset (one quarter- decay ratio), it may be too
oscillatory when there is a setpoint change

Common PID Myths
• If I go faster, I’ll control better

– Controlling faster
– Resolution effects make control worse
• If I have higher resolution input I can control tighter
– Majority of sensors are less accurate

Closed Loop Ziegler-Nichols tuning method
A controller is tuned with no Integral and Derivative. The Controller gain KC (P

only) is increased while the setpoint is stepped to find the gain at which the
controller begins to oscillate. That gain (ultimate gain=KU) and the period (ultimate
period = TU ) of the oscillation are noted.
Ki= Kp / Ti Kd = Kp * Td
Ki and Kd are calculated from the period. In other words, if the dynamics of the
process changes, using the standard algorithm (Kp affects all terms), Ki and Kd
are changed. If the gain of the process changes, only Kp is changed.
K p = [ CV / PV] * Tp / Td = 1/K * Tp / Td
Where, Tp= Process time constant; Td = Dead Time; K= Process Gain

Common PID Myths
• If I go faster, I’ll control better

– Controlling faster than wastes BW
– Resolution effects make control worse
• If I have higher resolution input I can control tighter
– Majority of sensors are less accurate

Real Life Applications
Cement Plant
Pre - Calcination Tower, Kiln and Kiln Feed

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PID Basics With

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Ability to maintain a process variable at a desired state/ value/

• Could control using On/Off strategy

Æ Open loop control (non-feedback control) can be used in

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

FUEL VALVE POSITION

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Need to fix the actuation of the valve to some intermediate position

But how to find that position?

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

There are Two types of tuning methods used:

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

•Most widely used

“Application – Cost – Accuracy – Durability – Reliability”

•Fairly wide Temp. •More accurate than •Expensive

“Application – Cost – Accuracy – Durability – Reliability”

Pressure Transmitter Flow Transmitter

“Application – Cost – Accuracy – Durability – Reliability”

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

4. Control Variable(CV) – Variable adjusted to correct error

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

• Has the advantages of three components, (P,I, and D)

The three put together is called PID

• Most common regulator in the industry

• Very easy to understand the components

Simplicity – Versatility- Longevity

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

There is no “standard” equation or correct PID algorithm. Just stick to one

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

PICO GFX supports Reverse Acting control

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Measurement / Process Variable

Controller Output Increases

A typical example of a direct-acting system is controlling flow of

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Measurement / Process Variable

A typical example of a reverse-acting system is controlling flow of steam for

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Controller output moves in proportion to the error between

• Direct, Linear, Relationship Between the Input and Output

• Determines how fast the regulator reacts to errors

• This action is for dynamics

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Proportional mode causes an instantaneous response in the controller

KC E (where Kc= controller gain, E = error);

Want Proportional Gain as high as possible

Responsible for Disturbance Rejection

System Delays Limit Proportional Gain

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

When Controller has no automatic reset

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

• Will never maintain the desired operating point

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

P only is not capable of eliminating offset by itself. P only can be used

Alternates to proportional control are proportional-integral (PI) control

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

• Initially manual reset

• Integral action causes the controller output to change at a rate