Pi Tops Demo

PITOPS PID/Advanced Control & Dynamics Identification

PITOPS
Powerful and Easy Software for
PID Tuning, Advanced Control &
Multivariable Dynamics Identification
PiControl Solutions Company

Copyright ©
www.picontrolsolutions.com
info@picontrolsolutions.com
PiControl Solutions Company Copyright © www.picontrolsolutions.com 1
Pitops has FOUR Powerful Features
1. PID/Cascade Tuning Optimization

2. Control Valve Stiction Estimation
3. Transfer Function Parameter Identification
4. Advanced Control Implementation in DCS
and PLC (Control Lab on PC)

• Pitops is easy to use for DCS and PLC Technicians,

Control Engineers, Process Operators, Supervisors
• No Need for Advanced College Education
• Value for Everyone, New or Experienced, Both
Technicians and Engineers
PART 1
PID TUNING OPTIMIZATION

PID Control Setpoint Change
Setpoint
Change PV
PID Output
Pitops shows Individual Proportional,

Integral and Derivative Contributions

PID Tuning Optimization
Optimum PID
Optimized
Tuning Parameters
Setpoint Response
Optimized Proportional Kick

Add Noise to Simulate Behavior in Real DCS
Optimized Setpoint Response

In the presence of Random Noise
PID Output

Derivative Action, Noise and Filter

Optimize PV Signal Filtering to Dampen Noise
Optimized PID Tuning

and Filter Constant
PID Output

Optimize Control Action to Reject Disturbances
Unmeasured
Disturbance
PID Output

Custom PID Optimization for SP change
and Typical Disturbances
Custom
Disturbance

Optimally Reject External Sinusoidal Disturbances
Optimized Control Action in presence of

Typical Disturbances in Plant
Optimum PID
Tuning
Sinusoidal
Disturbance

Custom Simulation and Optimization Example
Optimized PID Tuning
Setpoint Change
Custom Simulated Disturbance
Transfer Function
Controller Output Parameters
P, I and D Individual
Contribution

Powerful Multiple Cascade PID Optimizer
Slave Cascade
PID PID
Slave PID Output Cascade PID Output

Individual P, I and D Contributions
Setpoint
Change PV
Pitops shows individual

Proportional, Integral and
PID Output Derivative Contributions. This is
a powerful feature to diagnose
Integral Contribution tuning optimization.
Derivative Contribution
Proportional Contribution
All PID Equations for any DCS or PLC
Control Error Criteria PID Gap Action

Control Valve Characterization Non-Linear Control
for Non-Linearity Using Process Transforms


PART 2
CONTROL VALVE STICTION

Novel Algorithm to Estimate Control Valve Stiction
Pitops reads PID PV
and Valve OP data and
automatically estimates
Stiction. Pitops does
not require step tests.
Pitops Estimates Control

Valve Stiction and then
Optimizes PID Tuning to
Compensate for Stiction
Stiction Plot: Valve Position versus PID Output

Novel Algorithm to Estimate Control Valve Stiction
PID Output
Notice the difference

between PID Output
and Control Valve
Position.
Control Valve does
not move here
because of Stiction
True Control Valve Position with Stiction.

This blue trend is generated by Pitops
PID Tuning Optimization Amidst Valve Stiction
PV
Setpoint
Change
Control Valve
Position Generated
By Pitops
PID OP
Optimized PID
(Output)
Tuning Calculated by
Pitops amidst
Stiction, typical
Simulated Ramp Setpoint Changes and
and Pulse Disturbance Real Disturbances

PART 3
TRANSFER FUNCTION DYNAMICS
IDENTIFICATION

Easy Transfer Function Identification
Measured
Temperature (CV)
Temperature
(Controlled Variable)
Transfer
Function
Model
Notice this is Closed-Loop Data (Controller
in Auto or Cascade). Pitops does not need
Crisp Step Tests.
Identified
Steam Flow Transfer Function
(Manipulated Variable) Parameters

Second Order with Delay Identification
Red=Real Plant Data
(Output Variable)
Blue=Transfer
Function Prediction
Identified by Pitops
Or use Open-Loop
Real Plant Data
Step Tests, to
(Input Variable or Manipulated Variable) Identify Transfer
Functions

Multivariable Input Identification with Closed-Loop Data
Blue Trend Shows a 3-Input Transfer
Function Prediction Identified by Pitops
Red Trend Shows Product Analysis from Online GC
This is a Multivariable
MV #1 Data (Column Feed)
Closed-Loop Transfer
Function Identification
MV #2 using
Data (SideClosed-Loop
Stream Draw) Data
MV #3 Data (Bottoms Reboiler Duty)

Three transfer
functions (2nd Order +
Dead Time)
simultaneously
Identified
Single Click to Identify Transfer Functions
Conduct a “What-If”
Study by typing new
transfer functions
manually and then
click IDENTIFY
button to get the best
transfer function
parameters (see next
slide)

High Accuracy Transfer Function Model
BLUE trend is the

transfer function
model from
PITOPS and red
is the actual plant
data. Notice the
EXCELLENT
PiControl Solutions Company Copyright ©
fit!!!
www.picontrolsolutions.com 29
Proprietary ARTCON 3G Technology
ARTCON’s 3G
Technology
GEOMETRIC provides
unmatched and
GRADIENT unprecedented
ability to
identify multi
GRAVITY input closed-
loop models
amidst complex
Residuals unmeasured
PiControl Solutions Company Copyright ©
disturbances. 30
Multivariable Identification with Closed-Loop Data
Transfer Transfer Transfer

Function #1 Function #2 Function #3
Stiction
Identification &
Control
Optimization

PART 4
ADVANCED CONTROL
IMPLEMENTATION IN DCS OR PLC

Complete Process Control Laboratory on your PC
Customized for Control-Room DCS/PLC Needs

Feedforward Simulation and
Lead, Lag, Gain, Delay Optimization
Slave PID with

Simulated
Disturbance Rejected
Disturbance
Feedforward
Slave Compensation
Output
P, I and D Individual
Contribution

Model-Based Control Simulation
(Empirical, Regressed, IMC, DTC Models)
Long Dead Time

Excellent Control (40 minutes)
Despite Long Dead Time
Slave Output
P, I and D Individual Internal Model

Contribution
Contribution

Simulate Analyzer (GC) Sample Delay
Simulated
Unmeasured
Disturbance
Distillation Product Purity Control
Using Online Gas Chromatograph

Learn to Identify Transfer Functions from Plant Data
186 C
Temperature 182 C
(CV)
180 C
104 lb/hr 178 C
175 C
100 lb/hr Fuel Flow SP (MV)
98 lb/hr
800 lb/hr 805 lb/hr
Feed Flow SP
(disturbance) 790 lb/hr
Time
Transfer Function Delay Gain Time Constant

Fuel -Temperature 3 min 1.5 C/(lb/hr) 10 min
Feed -Temperature 7 min -0.4 C/(lb/hr) 20 min
Learn to Mathematically Implement Optimal
Feedforwards in DCS or PLC
-0.4 e-7s
Feed 20s+1
Flow FEEDFORWD DISTURBANCE
TRANSFER TRANSFER
DISTURBANCE FUNCTION FUNCTION DS
SIGNAL FF (Load)
0.27 (10s+1)e-4s
(20s+1)
SP E
+ Fuel +
Flow PROCESS PV
_ TC TRANSFER
+ CV +
FUNCTION
MV
+ PV OP 1.5 e-3s
10s+1

Learn Internal Model Control and Dead
Time Compensation
Valve Pressure
E
SP PID MV Transfer PV
- (PC) Function Lab
+ Model
Signal,
GC Signal
Signal Process Or
+ +
Model Instrument
Model Signal
Correction - Model
Delay Model can be pure Transfer Function
+ or 1st principles model or Empirical
Model with multi-inputs or anything
capable of predicting the CV

Powerful Industrial Applications
• Online Viscosity Model Predictions
• Polymer Plant Properties – Melt Index, Density
• Online GC Analyzer Control in Distillation Columns
• Any similar Inferential and Model-Based Control
Application.
• Any application where Lab measurement comes
every hour or slower.
• Any application where online measurement is slow –
5 minutes to 60 minutes sample time.

Design and Implement Powerful
Constraint Maximizers
SP 100.0 SP 500.0 SP 10.0
99.7 PID 400.4 PID 2.7 PID

PV #1 PV #2 PV #3
45% 55% 65%
Low Signal
Learn scientific techniques < Selector
to calculate dynamics and
45% SP=180
optimum tuning precisely
Maximize Production Rate
Eliminate FC Minimize Utilities
Improve Product Quality
Guesswork!!!

PART 5
POWERFUL EXCEL AND OPC
CONNECTIVITY TO ANY DCS/PLC

Easy to Read Plant Data Files
AC8711 TFI Dynamic Analysis.XLS
AC8711.P FC5618.SP
V
Excel or
OPC
Format

OPC Server Connection
FC101 COMP11
TC301
LC404
TC309

Live OPC Data Collection Screen
FC1290.PV TC3112.PV LC9812.PV TC4387.PV
TC4387.PV
TC4387.PV

PART 6
PITOPS SERVES ALL
YOUR CONTROL ROOM
PROCESS CONTROL NEEDS

Distillation
PC
Column Control
Condenser
FC 5.3 t/h
Feed
14.1 t/h FC 330
degC Overhead
Product
TC Stream
3.3 t/h
FC
Tune all PIDs, Cascades

Steam
And Feedforwards on
Distillation Columns Bottoms
Reboiler Product
9.1 t/h Stream
Steam Jacket M Motor

Heated Reactor
221 degC
225 degC
2.71 t/h
Raw Material
Feed Streams 0.87 t/h
275 kg/h
Steam to
Steam
Jacket
Condensate
3.4 t/h
Tune all PIDs, Cascades
on any Reactor Product
Stream
10%
Compressor Surge Control
Compressor
15 psig UC Surge
22% Calculation
PT PC
Tune any PID

for any Process
Cooler
3.2 MW
275
Motor psig
Base Load PI
M Gas
Compressor Tune all PIDs, Cascades
1175 RPM
on Compressor
How Pitops Can Increase Plant PROFIT
Average After
Production
Rate Average Before
Improved control after

Process Control Training
and New Control Schemes
Increase in Production
Rate After Improved
Process Control
TIME

PitopsTM will help on the following:
• New Plant Start-ups to come up with

good initial PID values
• Optimize existing plant PID loops
• Train Control Engineers and
Technicians on PID Tuning Skills
• Improve Advanced Control
• Push Production Rates
• Make more Profit
Why Choose PitopsTM?
• Pitops PID has Very Easy User Interface.

TM
• Works wholly in Time Domain which is easy to

learn and understand.
• Competitors work in S (Laplace) or Z(Discrete)
domain but Pitops works entirely in Time Domain.
• Technicians and New Engineers can learn to use
Pitops PID in just half a day!
TM
• Pitops PID works for all types of loops –

TM
millisecond or faster, seconds, minutes, or in

multiples of minutes (any time unit, fast or slow).
PitopsTM PID Applications:
• Compressor Surge Control
• Motor RPM, KW, Amps Control
• Valve Position Control
• Flow Control
• Pressure Control
• Level Control
• Temperature Control
• Distillation Product Purity Control
• Multiple Cascade Control
• Constraint Override Control with Selectors
• Bias Control with Integrated PID Feedforward

PiControl
Technical Support
PiControl provides Free
technical consulting for
all your PID, Primary
Control and Advanced
Control Problems
PiControl Solutions Company

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info@picontrolsolutions.com

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PITOPS PID/Advanced Control & Dynamics Identification

PiControl Solutions Company

1. PID/Cascade Tuning Optimization

PiControl Solutions Company Copyright © www.picontrolsolutions.com 2

• Pitops is easy to use for DCS and PLC Technicians,

PiControl Solutions Company Copyright © www.picontrolsolutions.com 4

Pitops shows Individual Proportional,

PiControl Solutions Company Copyright © www.picontrolsolutions.com 5

Optimized Proportional Kick

PiControl Solutions Company Copyright © www.picontrolsolutions.com 6

Optimized Setpoint Response

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PiControl Solutions Company Copyright © www.picontrolsolutions.com 8

Optimized PID Tuning

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Optimized Control Action in presence of

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Custom Simulated Disturbance

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Slave PID Output Cascade PID Output

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Pitops shows individual

Control Error Criteria PID Gap Action

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Pitops Estimates Control

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Notice the difference

True Control Valve Position with Stiction.

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Red Trend Shows Product Analysis from Online GC

MV #3 Data (Bottoms Reboiler Duty)

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BLUE trend is the

Transfer Transfer Transfer

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Slave PID with

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Long Dead Time

P, I and D Individual Internal Model

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Transfer Function Delay Gain Time Constant

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99.7 PID 400.4 PID 2.7 PID

45% 55% 65%

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AC8711 TFI Dynamic Analysis.XLS

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