Chapter 14

PID Implementation Issues

Overall Course Objectives
Develop the skills necessary to function as
an industrial process control engineer.
Skills
Tuning loops
Control loop design
Control loop troubleshooting
Command of the terminology
Fundamental understanding
Process dynamics
Feedback control
Reset Windup for PID Controllers
Windup results when the manipulated
variable is not able to control to the setpoint
resulting in sustained offset causing the
integral of the error from setpoint to
accumulate.
When control returns, accumulated error
causes an upset.
Windup can occur when a control valve
saturates or when a control loop is not being
used (e.g., select control).
Reset Windup
Time
y
y
sp
c
A
Note that controller output saturates causing area
A to accumulate by the integral action.
After the disturbance returns to its normal level,
the controller output remains saturated for a period
of time causing an upset in y.
Anti-Reset Windup
Time
y
y
sp
c
When the manipulated variable saturates, the
integral is not allowed to accumulate.
When control returns, the controller takes
immediate action and the process returns smoothly
to the setpoint.
Methods for Anti-Reset Windup
Turn off the integral when a valve saturates
or a control loop is not in use.
Clamp the controller output to be greater
than 0% and less than 100%.
Apply internal reset feedback
Apply external reset feedback
Industrial Approach
External reset feedback
Controller output clamping
Digitally turn-off integral calculation
Internal Reset Feedback
K
c
1/(t
I
s+1)
E(s) C(s)
+
+
F(s)
(

+ =
+
=
+

=
=
+
+
s
s E K s C
s
s
s E K
s
s E K
s C
s C
s
s C
s E K
I
c
I
I
c
I
c
I
c
t
t
t
t
t
1
1 ) ( ) (
1
) (
1
1
1
) (
) (
) (
1
) (
) (
Conventional PI Controller
K
c
1/t
I
s E(s) C(s)
+
+
Therefore, internal reset feedback is equivalent to
a conventional PI controller.
It still has windup, but controller output can be
clamped.
(

+ =
s
s E K s C
I
c
t
1
1 ) ( ) (
External Reset Feedback
K
c
E(s) C(s)
+
+
1/(t
I
s+1) U
meas
(s)
F(s)
An extension of internal reset feedback, therefore,
it is equivalent to a conventional PI controller.
When u saturates, windup will cease preventing
windup.
Less windup than clamping, but requires u
meas
.

Bumpless Transfer
When a control loop is turned on without
bumpless transfer, the process can become
unduly upset.
With bumpless transfer, an internal setpoint
is used for the controller and the internal
setpoint is ramped at a slow rate from the
initial conditions to the actual desired
setpoint to order to provide a smooth startup
of a control loop.
Comparison of True and Internal
Setpoints
Time
Internal Setpoint
True Setpoint
Control Performance With and
Without Bumpless Transfer
Time
w/o bumpless transfer
w/ bumpless transfer
Split Range Flow Control
In certain applications, a single flow control
loop cannot provide accurate flow metering
over the full range of operation.
Split range flow control uses two flow
controllers (one with a small control valve and
one with a large control valve) in parallel.
At low flow rates, the large valve is closed and
the small valve provides accurate flow control.
At large flow rates, both valve are open.
Split Range Flow Controller
FT
FT
FC
FC
Coordination of Control Valves
for Split Range Flow Control
Total Flow Rate
S
i
g
n
a
l

t
o

C
o
n
t
r
o
l

V
a
l
v
e

(
%
)
Larger Control
Valve
Smaller Control
Valve
Example for Split Range Flow
Control
Acid
Wastewater
NaOH
Solution
Effluent
FT
FT
FC
pHT
pHC
RSP

Titration Curve for a Strong

Acid-Strong Base System
0
2
4
6
8
10
12
14
0 0.002 0.004 0.006 0.008 0.01
Base to Acid Ratio
p
H
Therefore, for accurate pH control for a wide
range of flow rates for acid wastewater, a split
range flow controller for the NaOH is required.
Other Split-Range Flow Control
Examples
When the controlled flow rate has a turn
down ratio greater than 9
See value sizing examples in Chapter 2
Split Range Temperature Control
TT
Cooling
Water
Steam
Split-Range
Temperature
Controller
TT TC
RSP
Split Range Temperature Control
0
20
40
60
80
100
Error from Setpoint for Jacket Temperature
S
i
g
n
a
l

t
o

C
o
n
t
r
o
l

V
a
l
v
e

(
%
)
Steam Cooling
Water
Overview
All controllers that employ integral action
should have anti-reset windup applied.
Bumpless transfer provides a means for
smooth startup of a control loop.
When accurate metering of a flow over a
very wide flow rate range is called for, use
split range flow control.