Shell Global Solutions

Tuning Workshop

PID Controllers
What is Controller?

Feed flow Outlet temperature

Fuel flow TT
Furnace
TC
Set Value

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CP0420
PID Controller Key Concepts

• The PID control algorithm does not "know" the correct

output to bring the process to the set point.
• It merely continues to move the output in the direction
which should move the process toward the set point.
• The algorithm must have feedback (process
measurement) to perform

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Open Loop / Controller in Manual

e.g. Furnace, TC in MANUAL

TC
Process

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Closed Loop/ Auto Mode

e.g. Furnace, TC in AUTO

TC
Process

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PID Controller Tuning Parameters

• Proportional Band (Controller Gain)

• Integral Action ( Reset)
• Derivative Action

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Proportional action

Controller output varies proportionally

to input :
Dout = G c * Din

G c = Controller Gain
in = deviation or (PV-SV)

Proportional action therefore provides a signal

proportional to the size of the deviation

Also:
100% = Proportional Band (PB)
G c
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CP0520
Proportional-only control

Controller output
( MV )

100%

Output span: 100%

50

Controller input
( PV )
0 20 50 80 100%

0 Input span: 60%

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CP0585
Proportional-only control

Low Gain

Set value

Deviation Offset

Process variable

time

High gain

Set value
Offset
Deviation

time
- smaller offset
- less damping of measured value
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CP0560
 Proportional-only control - Offset

Set value change by operator

Disturbance in feed flow

Set value

Offset
temperature

Offset Desired value

Process variable trend

(if no feedback control)

Process variable (actual measured value)

time

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CP0550
 Proportional action
• Proportional action gives an output signal proportional to the size of the
error.
• Proportional action can be tuned via the Controller Gain (Gc)
• Proportional action will leave an offset between SP and PV.

DOP = K * D 

With:
 = (PVP – SPP)
PVP = PV / “Range” * 100 % = PV / (PVEUHI – PVEULO) * 100 %
SPP = SP / “Range” * 100 % = SP / (PVEUHI – PVEULO) * 100 %

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Integral Action Definition

Dout = 1 0 q(t) dt
ti
Integral action therefore provides a signal which depends the
length of time a deviation has existed.
Integral action time ti is defined as the time taken for the
controller output to change by the same amount from integral
action as that from proportional action.

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CP0570
 Integral action
Deviation

Time
Controller Output

Integral Action Only

Time
Controller Output
Proportional + Integral Action
Proportional Action Only
Change due to the Proportional Action

Time
ti

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Integral action at different Values

Controller Output
Proportional + Integral Action
Proportional Action Only
Change due to the Proportional Action

Time
ti

Proportional + Integral Action

Controller Output

Proportional Action Only

Change due to the Proportional Action

Time
ti

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 Proportional & Integral action
Initial kick in output from proportional action.
After that integral action increases output
Process value reaches set point – no off set due to integration

Proportional & Integral controller

80 100.00

70 90.00
Set point / Process Value

80.00
60
70.00

Output (%)
50 60.00 SP
(EU)

40 50.00 PV
Integral action eliminates the off set
30 40.00 OP
Initial kick from proportional action 30.00
20
20.00
10 10.00
0 0.00
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
Time (minutes)

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Proportional & Integral action

• Proportional action gives an output signal proportional to the

size of the error
• Integral action gives a signal which magnitude depends on the
time the error has been there. The longer the error is present
the higher the contribution of the Integral action to the total
output.

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Proportional + Integral control

Long Integral action time t1

Set value

Deviation

Process Variable

time

Set value Short Integral action time t2

Deviation
Process Variable

time

Integral Action removes offset

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CP0590
 Derivative Action

Deviation

time

Controller output
Derivative action only

time

Controller output
Proportional + Derivative action
Proportional action only
change due to the Proportional action

time
td
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CP0610
Derivative Action Definition

Dout = td
dq
dt
Derivative action therefore provides a signal which depends on
the rate-of-change of deviation

Derivative action therefore provides anticipatory action

Derivative action time td is the time taken for the change in
controller output due to proportional action to equal the same
change as that from derivative action

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CP0600
Proportional & Integral & Derivative action
• Disturbance at t = 10 (min). Initial kick in output from proportional and
derivative action; integral action increases OP further; when PV starts to
move derivative action brings OP quickly back to steady state value.
PI controller - with derivative action
(Kp = 1; Tp = 6; Td = 2; Kc = 2.3; Ti = 6; Tder = 0.6)

80 100.00

70 90.00
80.00
Set point / Process

60
70.00

Output (%)
Value (EU)

50 60.00 SP
40 50.00 PV

30 40.00 OP
30.00
20
20.00
10 Disturbance of - 5 10.00
0 0.00
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
Time (minutes)

PI controller - derivative action removed

(Kp = 1; Tp = 6; Td = 2; Kc = 2.3; Ti = 6; Tder = 0)

80 100.00

70 90.00
80.00
Set point / Process

60
70.00

Output (%)
Value (EU)

50 60.00 SP
40 50.00 PV

30 40.00 OP
30.00
20
20.00
10 Disturbance of - 5 10.00
0 0.00
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40

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Time (minutes)
Proportional & Integral & Derivative action

• Proportional action gives an output signal proportional

to the size of the error
• Integral action gives a signal which magnitude depends
on the time the error has been there
• Derivative action gives a signal proportional to the
change in the PV. It gives sort of “anticipatory” control.
Sensitive to measurement noise !

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Proportional + Integral + Derivative control

P + I action
(without Derivative action)
Set value

Deviation
Process Variable

time

P + I + D action
Set value

Deviation
Process Variable

time

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CP0620
PID controller actions - summary

• Proportional action
Dout = Gc * Din = Gc * Dq
• Integral (reset) action
t

Dout = 
1q(t).dt
ti 0

• Derivative action

Dout = td dq
dt
• P + I + D controller
t

Out = Gc * q +
1  q(t).dt + td dq
i
0
t dt
for a P-only controller Out = Gc * q + 50%
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CP0630
 Controller Responses
Proportional control
Offset
Offset

Low Gain vs. High Gain

Proportional + Integral control

Long Integral action time vs. Short Integral action time

without Derivative action with Derivative action

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CP800
Controller Selection

• P-Only Controllers:
•Used when offset is uncritical (some level
applications).
• PI controllers are used in 95% of the applications:
•When offset is undesirable
• On applications having long dead time and time
constant use PID except if the measurement is noisy.
•Examples

•Large Volume Pressure

•Temperature Control
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 Controller Algorithm Selection
- Type Td < 0.2*Tp 0.2*Tp < Td < Tp Tp < Td < 5*Tp Td > 5*Tp
Dominant first order Dominant dead time

- PI x x x x
- PID x x
- PIT x x x
- I-only x

- Td = process dead time (minutes)

- Tp = process time constant (minutes)
- Use PI as standard
- Use Derivative action (together with P& I action) only as exception; most effective when
0.5*Tp < Td < 5*Tp
- Proportional Integral Time-delay (PIT) controller when dead time exceeds time constant.
Special algorithm and relatively easy to implement in DCS.

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 Desired Response
• Desired behavior or response must be decided upon before loop can be tuned.
• Response below could be in general considered as “good” (fast and well damped).

One Overshoot

Set Value

One Undershoot

Process Variable

Time

Response to a Step Change

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Valve Failure Action
 Spring to Close (Air Failure Close)
(Air to Open)

 Spring to Open (Air Failure Open)

(Air to Close)

Decision Fail Action is taken in

Process/Safeguarding design

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Reverse and Direct Controller Polarity
If the The controller Reverse
measurement output has to
increases be reduced to
counter act
PV↑ OP↓ Reverse

If the The controller Direct

measurement output has to
increases be increased
to counteract
PV ↑ OP ↑ Direct

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Controller Action

Direct-Acting
C-1 Controller

Output
LC

(Air Failure Close)

Pump
increase of PV leads to increase of OP of
controller with constant SP

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Controller action

(Air Failure Close)

C-2

LC
Output

Reverse-Acting Controller

Pump
increase of PV leads to decrease of
OP of controller with constant SP

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Valve Linearity
Valves are usually non-linear.That is, the flow through the valve is not the same as the
valve position. Several types of valves exist:
Linear
Same gain regardless of valve position

Equal Percentage (most commonly used)

Low gain when valve is nearly closed
High gain when valve is nearly open

Quick Opening
High gain when valve is nearly closed
Low gain when valve is nearly open

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Shell Global Solutions

End of The PID Controllers