Process Control

Chapter 1

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What Do You Control?

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Vessel with Level Control

Flow in

Flow out

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FOPDT

First Order plus Dead Time

y t
p
y t0 K p u t p
x

Majority of plant processes have first order

dynamic behaviour
Dead time represents delay in the process
response to a disturbance
Gain represents magnitude of process response
Time constant represents speed of response
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Feedback Control Loop

CONTROLLER
Desired Value
(Set Point)

ERROR

Measured
Variable

PROCESS

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ALGORITHMS

Output

CONTROL
ELEMENT

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Error

Controller error is usually calculated as:

E MV - SP
Where:
E= Error
MV= Measured Variable
SP= Set Point

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Algorithm

When a controller is in automatic:

Algorithm is used to calculate the output in
response to error
can take many forms e.g.: Logic based, On/Off

PID is most commonly used and has three

components:
Proportional (P) Control
Integral (I) Control
Derivative (D) Control
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Proportional Control
Output Kc E

Where:
Kc = Proportional Gain
E = Error Signal

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Proportional Control Only

Offset

Desired Value

Controlled
Variable

Time
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Proportional Band
1
K c
Proportional Band
100
Kc
Proportional Band
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Integral Action

Output Ki Edt

Where:
Ki = Integral Constant
E = Error Signal
t = Time

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Reset or Integral?
Kc
Ki
Ti

Ki KcK r

Integral action often described as reset action

Reset action sometimes uses reset rate or
reset time
Reset time is same as integral time
Reset rate is inverse of integral time
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K-20

Controller Output

Controller Output

Typical P & I Controller

Responses
Ti=1

K-10
K-5

K=5
Ti-5
Ti-2
Ti-1

K-2
Ti-0.5

Time

1
Output K c (E
Ti
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Time

E dt)

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Derivative Action
dy
Output Kd
dt
Where:
Kd = Derivative constant
y = Measured variable
t = Time

Also known as rate action

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Three Term Control

Several forms of PID algorithm

Common form is:

Output Bias Kc.E

Kc t
dy

E dt Kc.Td.

o
Ti
dt
Kc = controller gain
Ti = integral time
Td = derivative time (or rate)
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How are Controllers

Tuned?

Controllers are tuned by manipulating the

three tuning parameters:
Proportional band (gain)
Integral time (reset time or reset rate)
Derivative time (rate)

Adjustments may be:

Trial and error
Model based (formal method) calculations

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Simple PID Tuning

Start with proportional action only:

Minimum gain (maximum proportional band)
Increase gain for desired response

Introduce integral action to remove offset

Maximum integral time (minimum reset rate)
Decrease integral time to remove offset

Stabilise loop:
Add derivative action or reduce gain

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Formal Methods of PID

Tuning

Involve process modelling

Measure process dynamics
Open loop tuning constant calculation:
Reaction curve
Internal Model Control (IMC or LAMBDA tuning)
Integral of Time Weighted Absolute Error (ITAE)

Closed loop cycle tuning (Ziegler Nichols):

Incorporates all elements of loop
Difficult to get permission
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Closed Loop Cycling

Process
Variable

Natural Period, Tu

Setpoint

Amplitude, A

Time

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Ziegler Nichols Method

Control
Action

Performance Criterion

Gain

1/4 decay

0.5 Ku

P1

1/4 decay

0.45 Ku

0.833 Tu

PID

1/4 decay

0.6 Ku

0.5 Tu

0.125 Tu

PID

Some overshoot

0.33 Ku

0.5 Tu

0.33 Tu

PID

No overshoot

0.2 Ku

0.33 Tu

0.15 Tu

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Integral time,
minutes

Derivative time,
minutes

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Reaction Curve Method

Process
Variable

Maximum Slope R1
M Step Change

L
Time, Minutes

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Parameters (Reaction
Curve)
Control
Action

Gain

1
R1 L

PI

0.9
R1 L

PID

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1.2
2
to
R1 L R1 L

Integral time,
minutes

Derivative time,
minutes

3L

2.5L to 2L

0.5L to 0.3L

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Split Range Control

PIC
01

Gas

To vent
Valve 2

Valve 1

Liquid

4Bar A

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ESD Simulation Training

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