PID Control Basics

PID Tuning

Rob Sink
Technical Support Specialist

June 14th, 2016

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What will be covered:
1. Common Process Control Techniques
2. Process Dynamics
3. What is PID
4. PID Control Components
5. How to Tune a PID Loop

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Why do I Need to Understand PID

 Every process is different

 Makes manual tuning easier

 Helps companies save money

 Helps facilities remain safe

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Common Process Control Techniques
ques

 Manual Control

 ON / OFF Control

 Closed Loop Control

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Manual Control

 Operator observes the process error and

adjusts the control output

Set Point

 PID CONTROL

Process
Measurement
(Process Variable)

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ON / OFF Control

 Simplest form of feed back control

 Can be used for processes not requiring extremely tight

control

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Closed Loop Control

 The PID controller measures the process

variable, compares it to the setpoint and then
manipulates the output accordingly.
Set Point

PV

Measurement
(Process Variable) Final Control Element

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Process Dynamics: Dead Time

 Dead time is defined as the time before the process variable

BEGINS to react to a change in the control output

Output

Process
Variable
Lag Time
Dead
Time

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Process Dynamics: Lag Time

 Lag is defined as the time required for the process

variable to adjust to a steady state after an output change
is performed
 Lag time affects the control action

Output

Process
Variable
Lag Time

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Process Dynamics: Output vs. Process Change

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What is PID?

 PID control refers to process control using the

coefficients Proportional, Integral and Derivative
 It is not P&ID which refers to Piping &
Instrumentation Diagram

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PID Control Defined
Temp
(PV)
 PID control can be
described as a set of rules
with which a precise
regulation of a closed-
Temp
loop control system is Setpoint
(SP)
obtained.

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PID Control Terms

 Proportional Band adjusts output amplitude

(reciprocal of Gain)
 Integral eliminates offset error (automatic Reset or
simply Reset)
 Derivative looks at the rate of change of the error
(Rate)

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Proportional Band

 The Proportional Band (P) is defined as the range over

which the control output is adjusted from 0-100%
 Proportional does the heavy lifting getting the temperature
close to the setpoint
 Some manufacturers use Gain instead of Proportional
Band

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Proportional with Manual Reset

 With proportional only control, an offset will be

present between set point and process variable.
 Manual Reset allows a user to bias or shift the
output to compensate for the steady state offset.
1000º

Manual Reset Adjusted Here

500º Proportional
Set Point Band

Time

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Integral

 Integral action is used with proportional to eliminate the

inherent offset
 The integrating term observes how long the error has
existed, summing the error over time
 The sum becomes a value added to the output
Integral Action

Proportional Action
Output

+10%

Error
-10%

Time 200 sec/repeat Integral Time Constant

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Integral – cont.

 Engineering units:
Repeats/minute
Minutes/repeat
Seconds/repeat
 The integral action ceases at a no error condition

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Integral at Work

Setpoint

I I I I

Integral started.

Each time period where the error is not zero,

the output is increased (or decreased) by the
Integral term.

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A Note About Integral Windup

 Integral windup refers to the situation in a PID controller

where the integral, or reset action continues to integrate
(ramp) indefinitely
 This usually occurs when the controller's output can no
longer affect the controlled variable, which in turn can be
caused by controller saturation
 Typical causes of Integral Windup are: The input has been
removed from the process, output device has failed, a
furnace door has been opened keeping the process from
reaching temperature

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Derivative

 Engineering units: minutes or seconds

 Anticipates the error rate and applies the “brakes”
 Derivative has no effect if the error is constant

Derivative Action

Integral Action
Output

+10%

Error
-10%

Time 50 seconds Derivative Time Constant

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P, I and D Working Together

P only P and I PID

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How to Tune a PID Loop

 Manually tuning the loop

 Using the controllers Auto/Self Tune

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Manually Tuning a Loop

 These values are good starting points

 Change only (1) term at a time
 Make small changes observing the result

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Fine-tuning the Proportional Band

 Work from larger to smaller numbers (wider to narrower)

 If cycling appears, the proportional band is too narrow

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Fine Tuning the Integral Time

 The main goal is to reduce the offset

 Adjust from longer to shorter time

 If an oscillation exists at a longer period then the

integral time is too short

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Fine Tuning the Derivative Time
 Adjust from shorter to longer time

 If short-period oscillations develop, the time is to long.

 The larger the Derivative, the stronger the corrective

action and the more likely the output will become
oscillatory

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Tuning Loops with Dead Time

Set P to 5% and the I & D to 0%

Start the process with a setpoint that will allow the

process variable to stabilize

Output

Process
Variable
Lag Time
Dead
Time

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Tuning Fast Reacting Loops

Set P to 100% and the I & D to 0%

Start the process with a setpoint that will allow the

process variable to stabilize

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Using Auto Tune to Determine PID Values

 The output is varied between 0% and 100% three

times (these values may be limited).
 The process variable must ascend and descend
through set point for the output to change state.
 The auto tune algorithm observes the PV response
to these output changes and installs the appropriate
PID terms.

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Ways to Prevent Overshoot

 Limit the working output or enable an output ramp

rate (if available)

 Limit the output range which will have an effect on the

time it takes to get to setpoint

 Ramp the setpoint at a slow rate

 Use fuzzy logic (if available)

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Fuzzy Logic

 Fuzzy logic is used to help reduce setpoint overshoot

 Used in addition to PID control

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Yokogawa Products that Use PID Control

PLC
Single loop controller

Programmable
controller

PLC/RTU DCS

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UTAdvanced Line of controllers

 1-2 loops of control

 Built in ladder sequence control

 Software used in Webinar

 Nuclear qualified

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YS1000 Family of Controllers

 1-2 loops of control

 Nuclear qualified

 Hard manual backup

 Function block programming

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FA-M3 PLC

 Modular PLC design

 4 control loops per PID module

 PID control is not done in ladder logic

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Questions

Questions?
Feel free to email us with further questions
at [email protected].
Please put “PID Webinar” in the subject line.

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Thank you for attending!

Feel free to email us with further questions

at [email protected].
Please put “PID Webinar” in the subject line.

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