Tuning Control Loops Page 1 of 7

Tuning Control Loops

Table of Contents TUNING CONTROL LOOPS...................................................................................................1 TUNING CONSTANTS....................................................................................................1 PROPORTIONAL BAND !".......................................................................................1 GAIN !" CALCULATION..........................................................................................1 INT#GRAL or R#S#T T1"..........................................................................................$ D#RI%ATI%# T$".........................................................................................................$ TUNING.............................................................................................................................$ AD&UST PROPORTIONAL BAND..............................................................................$ AD&UST R#S#T INT#GRAL" ACTION....................................................................$ AD&UST D#RI%ATI%# ACTION RAT#"...................................................................' TUNING CONTROLL#RS...................................................................................................' G#N#RAL RUL#S (OR CO))ON LOOPS..................................................................' (LO*.............................................................................................................................' L#%#L...........................................................................................................................' LI+UID PR#SSUR#....................................................................................................., GAS PR#SSUR#..........................................................................................................., T#)P#RATUR#- %APOR PR#SSUR#- AND CO)POSITION................................., CLASSICAL CONTROLL#R TUNING )#T.OD..................................................../ CASCAD# AND OT.#R INT#RACTING CONTROL LOOPS................................/ D#(AULT CONTROLL#R TUNING PARA)#T#RS....................................................0 CONTROL LOOP SCAN RAT#S.................................................................................0 PID ALGORIT.) D#(AULT TUNING CONSTANTS..............................................0

TUNING CONTROL LOOPS

TUNING CONSTANTS PROPORTIONAL BAND (K If Proportional Ban1 is 1223- ea45 per4ent of 45ange at t5e input to t5e 4ontroller 6ill pro1u4e t5e sa7e per4ent of 45ange at t5e 4ontroller8s output. If a Proportional Ban1 is less t5an 1223- ea45 per4ent 45ange of input signal to t5e 4ontroller 6ill pro1u4e a greater per4ent of 45ange at t5e 4ontroller8s output. If a Proportional Ban1 is larger t5an 1223- ea45 per4ent 45ange in input signal to t5e 4ontroller 6ill pro1u4e a s7aller per4ent of 45ange at t5e 4ontroller8s output. T5e Proportional Ban1 t5at is sele4te1 for a parti4ular operating situation 1eter7ines 5o6 7u45 4orre4ti9e signal t5e 4ontroller 4an pro1u4e for ea45 per4ent of 45ange in t5e 9aria:le 4ontrolle1 :; t5e 4ontroller. T5e 4ontroller8s output signal 1eter7ines t5e a7ount of 7o9e7ent t5at 6ill :e pro1u4e1 at t5e 4ontrol 9al9e. GAIN (K CALCULATION Ratio of entire span of 7easure7ent to per4ent span :eing use1 as Proportional Ban1. GAIN < 1223 t5e entire span of 7easure7ent" 3 of span :eing use1 as a proportional :an1

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Tuning Control Loops Page $ of 7 Assu7e GAIN < GAIN < $. /23 proportional :an1- PB < PROPORTIONAL BAND 1223 span" /23 PB" $ .one;6ell uses letter ?!@ to represent GAIN- t5erefore ! <

INT!GRAL OR R!S!T (T" Integral a4tion repeats t5e proportional 4ontrollers initial 4orre4ti9e signal until t5ere is no 1ifferen4e :et6een t5e P% an1 Setpoint. Integral T1 " is eApresse1 in @)inutes per Repeat@ D!RI#ATI#! (T$ C5anges t5e output of a 4ontroller in proportion to t5e @RAT#@ or @SP##D@ at 65i45 t5e 4ontrolle1 9aria:le is 7o9ing to6ar1s or a6a; fro7 t5e setpoint. Deri9ati9e a4tion is eApresse1 in 7inutes. Represents t5e ti7e t5at t5e proportional plus 1eri9ati9e 6ill ta>e to rea45 a 4ertain le9el of output- in a19an4e of t5e ti7e proportional a4tion alone 6oul1 pro1u4e t5e sa7e output. i.eB *5en 1eri9ati9e is applie1 to a t6o 7o1e 4ontroller PI "- to 7a>e it a t5ree 7o1e 4ontroller PID "- it8s a4tion 4onsists of 1e4reasing t5e nu7:er of repeats per 7inute reCuire1 to 1ri9e t5e error :a4> to setpoint.

TUNING AD%UST PROPORTIONAL BAND Al6a;s tune proportional :an1 6it5 9er; little reset a4tion. T5at is- for instan4e 6it5 a spee1 4ontrol loop- al6a;s set t5e reset integral" a1Dust7ent at- sa; t6ent; or t5irt; se4on1s or 7ore :efore a1Dusting t5e proportional :an1. T5en- a1Dust t5e proportional :an1 to a s7aller 9alue 5ig5er gain" until 4;4ling or insta:ilit; :egins. #EA)PL#B Start 6it5 ,23 proportional :an1 a gain of $./"F t5en 5al9e t5e proportional :an1 to $23 a gain of /"F t5en 5al9e t5e proportional :an1 to 123 a gain of 12"F et4. *5en 4;4ling Dust :egins- in4rease t5e proportional :an1 :; /2 per4ent. T5at is- fro7 123 to 1/3F fro7 1G3 to $,3F et4. C;4ling s5oul1 stop. T5e proportional :an1 a1Dust7ent s5oul1 no6 :e properl; set an1 s5oul1 :e left at t5is 9alue. AD%UST R!S!T (INT!GRAL ACTION T5is is 1one :; re1u4ing t5e ti7e 9alue in se4on1s". Sa; t5e reset is at t6ent; se4on1s. T5en re1u4e t5e reset to ten se4on1sF t5en re1u4e t5e reset to fi9e se4on1sF t5en re1u4e t5e reset to t6o se4on1sF et4. *5en 4;4ling or insta:ilit; :egins- in4rease t5e reset a1Dust7ent :; /23.

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Tuning Control Loops Page ' of 7 #Aa7pleB If 4;4ling is o:ser9e1 at t6o se4on1s- in4rease t5e reset to t5ree se4on1s. If 4;4ling is o:ser9e1 at G se4on1s- in4rease t5e reset to 1$ se4on1s- et4. T5e reset a4tion s5oul1 no6 :e properl; a1Duste1 an1 s5oul1 :e left at t5is 9alue. AD%UST D!RI#ATI#! ACTION (RAT! If a 1eri9ati9e a1Dust7ent is felt ne4essar;- a1Dust t5e 1eri9ati9e a4tion :; :eginning at a setting of one se4on1- t5en t6o- t5en t5ree- until i7pro9e7ent is o:ser9e1 an1 see7s to :e opti7al. Nor7all;- 1eri9ati9e a4tion is not nee1e1 an1 1oes not 5elp t5e situation.

TUNING CONTROLL!RS
Sin4e t5ere are a 9er; large nu7:er of 4o7:inations of t5e t6o or so7eti7es t5ree- @>no:s@ pro9i1e1 for 4ontroller tuning- 7an; 7et5o1s 5a9e :een 1e9elope1 o9er t5e ;ears to ai1 in t5eir proper a1Dust7ent. A fe6 reCuire upsetting t5e pro4ess to so7e eAtent- often an una44epta:le pra4ti4e in real life. T5ese notes are inten1e1 to pro9i1e a fe6 si7ple rules to use in tuning 4ontrollers 65i45 6ill 7ini7iHe upsets an1 still get t5e Do: 1one. T&! CONTROLL!R 'UST B! AD%UST!D TO BALANC! T&! PROC!SS. If t5e pro4ess is fast to respon1 i.e. a flo6 loop"- t5en t5e 4ontroller 7ust :e tune1 fast too. (ast or slo6 for a 4ontroller refers to integral or reset". NOT PROPORTIONAL BAND or gain". Do not 4onfuse t5ese a4tions or grief 6ill :e ;our 4onstant 4o7panion 1uring ;our 4ontroller tuning efforts. If t5e pro4ess is slo6 i.e. te7perature 4ontrol of a tra; part 6a; up a 1istillation 4olu7n"- t5en t5e 4ontroller 7ust :e tune1 slo6 TO )ATC. T.# PROC#SS. If ;ou 1o not 5a9e a feel for t5e pro4ess 45ara4teristi4s or 4annot fin1 so7eone to enlig5ten ;ou- lea9e 4ontroller tuning to so7eone else 65o 4an get t5e nee1e1 infor7ation. G!N!RAL RUL!S (OR CO''ON LOOPS (LO) Usuall;- at least 5alf of t5e 4ontrol loops in a plant are flo6 loops. Set integral I" at 2.1 7inutes. A1Dust t5e proportional :an1 so t5at t5e 7easure7ent is not too nois;- usuall; a:out '223 alt5oug5 an o44asional poor 7eter run installation 7a; reCuire as 7u45 as 12223. A loop 65ere a 9al9e positioner 5as :een use1 6ill reCuire a proportional :an1 setting t6o to t5ree ti7es larger t5an for a loop 6it5out a positioner. Slo6 7o9ing or sti4>; 4ontrol 9al9es 7a; reCuire 2.$ or 2.' 7inutes :ut are rare eA4eptions. If t5ese settings 1o not 6or>- inspe4t t5e 9al9e an1 orifi4e installation to fin1 t5e- pro:le7. (iA t5e pro:le7. Do not a1Dust t5e 4ontroller to so7e ri1i4ulous setting su45 as a 12 7inute reset ti7e. Use t5e 4ontroller in 7anual or a 5an1 9al9e if ;ou t5in> a 12 7inute reset ti7e is ne4essar;. I)PORTANT NOT#B No 4ontroller 6ill 6or> 65en t5e 9al9e is al7ost 4lose1 or al7ost 6i1e open. Don8t atte7pt tuning un1er t5ese 4on1itions. .a9e t5e operator open or 4lose a :;pass if one eAists" or 6ait until pro4ess 4on1itions 45ange enoug5 to get t5e 9al9e :a4> 6it5in its operating range fro7 / to I/3 of tra9el as eAtre7e li7its 6it5 12 to I23 as a safer range". Ne9er use 1eri9ati9e a4tion in a flo6 loop. L!#!L
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Tuning Control Loops Page , of 7 T5e neAt 7ost 4o77on loop after flo6 is le9el. DO NOT #%#R US# A S.ORT INT#GRAL %ALU# IN A L#%#L LOOP. If ;ou 1o- ;ou 6ill fin1 t5e loop 6ill al6a;s 4;4le- often 6it5 a perio1 ti7e fro7 t5e pea> of one 4;4le to t5e pea> of t5e neAt" of 12 to 1/ 7inutes. T5e s5orter t5e integral ti7e- t5e longer t5e perio1. Set t5e integral at 12 7inutes. T5is 6ill satisf; G2 to I23 of t5e le9el appli4ations in a plant- if t5e 9essel ti7e 4onstant 9olu7eJflo6" is 1 to $ 7inutes- t5en a s5orter integral ti7e 4an :e use1 :ut re7e7:er t5at a large 9alue is safer. If t5e 9essel is large an1 t5e 4ontrolling flo6 is a tri4>le- t5en a greater 9alue of integral 7ust :e use1. If 4lose 4ontrol of le9el is i7portant- set t5e proportional :an1 to as s7all a 9alue as possi:le $2K/23" 6it5out 4ausing 4;4ling. Use a larger proportional :an1 per5aps 1223" if s7oot5 flo6 4ontrol to a 1o6nstrea7 unit is 7ore i7portant t5an tig5t le9el 4ontrol. Ne9er use 1eri9ati9e a4tion in a le9el loop. Le9el loops 6ill usuall; s5o6 a li7it 4;4le 65en t5e le9el 4ontroller sets a 9al9e- 65i45 is not eCuippe1 6it5 a positioner. A li7it 4;4le loo>s li>e a sa6 :la1e- so7eti7es 6it5 flat :otto7s an1Jor tops Li7it 4;4le 6ill s5o6 a:out /3 45ange. T5ere is a:solutel; not5ing ;ou 4an 1o to tune out su45 a li7it 4;4le. C5anges in tuning 6ill s5orten or lengt5en t5e perio1 :ut onl; a positioner or le9el 4as4a1e1 to a flo6 4ontroller 6ill eli7inate t5e pro:le7. *5en t5e flo6 is use1 to 4ontrol t5e le9el going to tan>age- 4;4ling is usuall; uni7portant. If it is t5e refluA or fee1 to a 1istillation to6er- t5en su45 a li7it 4;4le 7a; :e una44epta:le. Please note t5at a 9al9e 4;4ling al7ost 4lose1 or full; open 6ill also pro1u4e a li7it 4;4le- usuall; of t5e flat :otto7 t;pe 65en al7ost 4lose1" or of t5e flat top t;pe 65en al7ost full; open.

LI*UID PR!SSUR! Tune t5e sa7e- as flo6 loops. Noise s5oul1 not :e as se9ere as for flo6 an1 proportional :an1s 6ill usuall; :e s7aller. GAS PR!SSUR! Tune t5e sa7e as le9el loops using a large integral 9alue. Proportional :an1s 4an :e Cuite s7all un1er 1223 an1 often as s7all as $2K'23.". *ell no6 t5at ;ou89e tune1 o9er I23 of t5e loops in t5e t;pi4al plant- on to t5e 7ore 1iffi4ult 4ontrol tuning appli4ations. T5ese are te7perature- 9apor pressure- an1 4o7position. In4lu1e1 are t5e te7peratures use1 to infer 4o7position for so 7an; 1istillation 4olu7ns. T!'P!RATUR!+ #APOR PR!SSUR!+ AND CO'POSITION T5ere are se9eral 6a;s to tune t5ese 7ore 1iffi4ult loops. T5e first is to use starting settings of 1223 proportional :an1- a / or 12 7inute integral ti7e- an1 no 1eri9ati9e. S6it45 t5e 4ontroller to auto7ati4 65en t5e 7easure7ent is 4lose to t5e 1esire1 set point. If a 4;4le 1e9elops- 7easure t5e ti7e fro7 pea> to pea> 5ig5 to 5ig5 or lo6 to lo6". T5is is t5e perio1 of t5e 4ontrol loop. Di9i1e :; t6o. If t5e starting integral 9alue is less t5an one 5alf of t5e perio1- t5e integral ti7e is too s5ort an1 is 4ausing t5e 4;4le. In4rease t5e integral ti7e. If ea45 pea> is 5ig5er t5an t5e one :efore- in4rease t5e proportional :an1 1ou:le- triple et4." until t5e 4;4les 1a7p out. T5e perio1 6ill get s5orter as t5e integral ti7e is in4rease1. *5en t5e perio1 is a:out t6i4e t5e integral ti7e an1 t5e 4;4les are 1a7pening out- ;ou8re prett;
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Tuning Control Loops Page / of 7 6ell finis5e1. If t5e 7easure7ent is not nois;- set t5e 1eri9ati9e at one Cuarter of t5e integral ti7e. Rea1Dust t5e proportional :an1 if reCuire1 to get a 1a7pe1 os4illation after an upset 6ait for a :u7p or as> t5e operator to 7a>e a s7all set point 45ange in a safe 1ire4tion". If t5e s5ort4ut 7et5o1 1es4ri:e1 a:o9e is unsu44essful or ;ou 6ant to :e a :it 7ore 7et5o1i4al- follo6 t5e pro4e1ure gi9en :elo6. It 6ill al6a;s 6or> an1 6ill lea9e no 1ou:t as to t5e 45ara4teristi4s of t5e 4ontrol loop. CLASSICAL CONTROLL!R TUNING '!T&OD *5en t5e pro4ess is reasona:l; sta:le an1 no plant upsets are eApe4te1- s6it45 t5e 4ontroller to 7anual. T5en set D- 1eri9ati9e or rate on so7e 4ontrollers" to 7ini7u7 if pro9i1e1 on t5e 4ontroller" an1 I- integral or reset on so7e 4ontrollers" to 7aAi7u7. Sele4t a set point eCual to t5e 7easure7ent an1 a1Dust t5e proportional :an1 to 1223 or gain at 1.2" to start. C5ange t5e output a s7all a7ount an1 transfer t5e 4ontroller to auto7ati4. Note t5e starting 9al9e position. If os4illations 1o not 1e9elop- repeat step $ re1u4ing t5e proportional :an1- per5aps to 5alf t5e 9alue trie1 :efore. Continue to re1u4e t5e proportional :an1 until os4illations start. If os4illations of in4reasing a7plitu1e 1e9elop on t5e first tr;- return to 7anual an1 set t5e 9al9e at t5e original position note1 in step $. Dou:le t5e proportional :an1 an1 tr; again until unifor7- or 9er; nearl; so- os4illations 1e9elop. )easure t5e perio1 1efine1 as t5e ti7e for one 4o7plete 4;4le to o44ur". (or a PLI ControllerB Set I < to t5e perio1 A 2.G$. Dou:le t5e proportional :an1. T5e perio1 6ill in4rease :; a:out ,'3. Rea1Dust t5e proportional :an1 if 7ore or less 1a7ping is 1esire1. Set I < to t5e perio1 A O.S. Set D < to t5e perio1 A 2.1$. Dou:le t5e proportional :an1. T5e perio1 6ill 1e4rease :; a:out 1/3. Rea1Dust t5e proportional :an1 if 7ore or less 1a7ping is 1esire1. Re7e7:er- safe 9alues are a large I an1 a s7all D. T5ese instru4tions are for 4ontrollers a1Duste1 in ter7s of 7inutes per repeat. So7e 7anufa4turers use an in9erse relations5ip so large :e4o7es s7all an1 9i4e 9ersa. If t5e 7easure7ent is nois; P5 loops in parti4ular"- 1eri9ati9e 4annot usuall; :e use1F ne9er un1er an; 4ir4u7stan4es set t5e 1eri9ati9e greater t5an t5e integral. CASCAD! AND OT&!R INT!RACTING CONTROL LOOPS Tune t5e se4on1ar; loop first using t5e lo4al set point 7o1e. Re1u4e t5e integral as 7u45 as possi:le. Transfer to re7ote set point an1 tune t5e pri7ar; loop. Ne9er use a pri7ar; 4ontroller integral 9alue less t5an four ti7es t5e integral 9alue use1 for t5e se4on1ar; 4ontroller. T5e sa7e rules 5ol1 true for intera4ting loops su45 as pressure an1 pressure 4o7pensate1 te7perature use1 for a 1istillation to6er. Tune t5e pressure loop representing t5e fastest loop in t5is 4ase" 6it5 a 7ini7u7 integral 9alue- t5en use an integral ti7e at least four ti7es as great for t5e te7perature 4ontroller. To test for intera4tion 65en t6o Kloops 4;4le toget5er at t5e sa7e perio1- pla4e one loop in 7anual. If t5e 4;4le stops- intera4tion is pro:a:l; t5e pro:le7. Rearrange t5e loops or use t5e te45niCue outline1 a:o9e to 7ini7iHe 4;4ling.

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Tuning Control Loops Page 0 of 7 D!(AULT CONTROLL!R TUNING PARA'!T!RS (or t5e startKup of an; plant- t5ere are 1efault tuning para7eters t5at 4an :e entere1 into ea45 4ontroller. T5ese are startKup 9alues onl;- an1 ea45 4ontroller 6ill still reCuire a11itional tuning. T5is tuning 7a; o44ur se9eral ti7es on in1i9i1ual 4ontrollers- 1epen1ing on plant startKup 4on1itions. In fa4t- it 4an :e so7e ti7e t5e plant 5as to sta:iliHe" :efore all 4ontrollers 5a9e t5eir final nor7al operations" tunings. T5ere are no 9alues s5o6n for Deri9ati9e a4tion for startKup 4on1itions- as it 5as not :een s5o6n to :e reCuire1 for t5ose 4on1itions. Deri9ati9e 9alues s5oul1 :e a11e1 in t5e final tunings of t5e appli4a:le 4ontrollers. T5e follo6ing is a list of t;pi4al startKup tuningsB PROC!SS (LO* PR#SSUR# LiCui1" PR#SSUR# Gas" L#%#L GAIN K ./ 1 $ 1 PB $22 122 /2 122 7/ 7/ R!P!ATS,'IN 1$ 1 ./ .$ .' .$ 'INS,R!P!AT T" .2G' or / Se4. 1 )in. $ )in. / )in. './ )in. / )in.

T#)P#RATUR# 1.' ANALMN#RS 1.'

CONTROLL!R INPUT,OUTPUT INDICATION Output to 9al9es 9ie6e1 :; t5e operator s5all in1i4ate 4lose as 23 an1 open as 1223. *5en a 4ontrol 9al9e is trippe1 on a:nor7al 4on1ition Lo6Klo6 le9el- et4."- t5e PID 4ontroller s5all :e 4onfigure1 to s6it45 to 7anual output 7o1e an1 t5e 4ontroller output to t5e failKsafe 4on1ition 9alue. In 4ase of sensing ele7ent failure- a @Ba1 P%@ alar7 6ill :e generate1 an1 if it is a 4ontrol point- 4ontroller s5all s6it45 to 7anual output 7o1e. Controller output to fiel1 1e9i4es s5all :e K0.I3 to 120.I3 to 4o7pensate for 4ali:ration offsets in t5e fiel1 1e9i4e. )aster 4ontroller output in 4as4a1e loops s5all :e 23 to 1223. CONTROL LOOP SCAN RAT!S T5e 4ontrol loops s5all :e 4onfigure1 to a45ie9e t5e fun4tionalit; an1 p5ilosop5; of t5e POIDs. (ollo6ing are t5e :asi4 t;pes of 4ontrol loopsB K Analog In1i4ation Onl; LoopF K Single Control LoopF K Cas4a1e Control LoopF K Co7pleA Control LoopF K Dis4rete 1J2 Loops 6it5in AP) A19an4e1 Pro4ess )anager"- an1 K Dis4rete 1J2 Loops 6it5in L). T5e 4ontrollers AP)" :ase s4an rate 6ill :e 2./ se4on1s. So7e fast loops a44or1ing to #PC 4ontra4tor" 6ill run at 2.$/ se4on1s. PID ALGORIT&' D!(AULT TUNING CONSTANTS

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Tuning Control Loops Page 7 of 7 T5e PID algorit57s 6ill :e 4onfigure1 6it5 t5e follo6ing 1efault 9alues unless ot5er6ise spe4ifie1 :; t5e #PC 4ontra4tor. It is un1erstan1 t5at t5ese are initial 9alues- final loop tuning 6ill :e 1one 1uring plant operationB PID Gain !" 7in. K T1" 2./ 1.2 $.2 1.2 1.' Integral 7in.K T$" 2.2G 1.2 $.2 /.2 '.2 Deri9ati9e 2.2 2.2 2.2 2.2 2.2

(lo6 Pressure LiCui1" Pressure Gas" Le9el Te7perature

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