Tuning of PID Controllers in

Both Open and Closed Loop

Control Systems

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Tuning of Closed Loop Control Systems

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Why Tune ?
Open loop tuning procedure
Closed loop tuning procedure
Damped oscillation tuning method
Other tuning conditions
Fine tuning of practical control loops

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Objectives of Tuning (1)

1 - Minimize Integral of error

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Objectives of Tuning (2)

2 - Minimize Amplitude of error squared

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Other Aspects of Tuning (3,4,5)

3 - Minimize wear and tear
4 - No overshoot at Start Up
5 - Minimize effect of known disturbances

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Loop Controller and Process

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Steps of Open Loop Tuning

(Reaction Curve)
1. Put controller in
manual mode
2. Make a step change
to the OP value
3. Observe Reaction
Curve
4. Calculate timing
constants

Reaction curve
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Open Loop Tuning Method (2)

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Reaction Curve Calculations

P - Control

KC = OP % ( N L )

PI - Control

KC = 0.9 OP% N L

PID - Control

Tint = 3 L

KC = 12
. OP%

NL

Tint = 2 L
Tder = 0.5 L
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Open Loop Tuning - Exercise #7

Single Loop control with Real PID
Controller mode to manual (F3)
Establish PVE steady at 50% (1000)
Step output from 50% to 65%
Determine L-lag and N-slope values

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Continuous Cycling - Ziegler & Nichols

Find critical value of K for continuous oscillations

Do not use I or D - control
Observe critical frequency for 180 phase shift
Stabilize loop by reducing K and ensure that I & D
control still gives a phase lead

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P-only for Continuous Cycling

Method

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Reaction Curve Method (Ziegler & Nichols)

If we know the exact value of the effective lag
of an industrial process, then we are in the position
to find the frequency matching with the 180 phase
shift (and thence optimum tuning constants).

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Continuous Cycling Method

1. Put controller in P - control only
2. P - control on ERR = (SP - PV)
3. Controller in Auto
4. Step change to SP
5. Double value of K until continuous cycling
6. Calculate tuning constants

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Calculation of Tuning Constants

P - Control

KC = 0.5 KU

PI - Control

KC = 0.45 KU
P
Tint = U 1.2

PID - Control

KC = 0.6 KU
P
Tint = U 2
P
Tder = U 8
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First Order Lag

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First Order Lag Response Curve

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Closed Loop Tuning - Exercise #8

Single Loop control with Real PID
Control to P-only - Tint = 999, Tder = 0
Adjust gain (K) for continuos oscillation
Step SPE from 1000 > 1100
Record gain-K and period for calculations

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Damped Cycling Method

Variation on continuous cycling ....
to avoid danger to process ...
but damped oscillations are acceptable
requires some subjective evaluation

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Damped Oscillation Decay Ratio

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Steps of Damped Cycling Method

1. Put controller in P - control
2. P - control on ERR = (SP - PV)
3. Controller into Auto
4. Double K until oscillations.
5. Terminate immediately
6. Calculate tuning constants
Estimate damping of oscillation
Convert P into Pu using diagram

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Convert P into Pu
using diagram

Estimate damping
of oscillation
(d) ... 0.5 acceptable

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Calculate Tuning Constants

PI - Control

Tint =

PID - Control

Tint =
Tder =

(P

Rd )
1.2

P
Rd = u p

(P R )
d

(P R )
d

K determined by good judgement.....

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Tuning for NO Overshoot on Start-up

Variation of continuous cycling method
When no overshoot even for start-up is
permitted (manual auto)

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Formula for NO Overshoot on Start-up

Same as for continuous cycling
Formula for PID - control

KC = 0.2 KU
Tint =

PU

Tder =

PU

3
2
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Tuning for SOME Overshoot on Start-up

Variation of continuous cycling method

No overshoot during normal modulating
control only

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Formula for Some Overshoot on Start-up

Same as for continuous cycling
Formula for PID - control

K C = 0.33 KU
Tint =

PU

Tder =

PU

2
3
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Choice of Tuning Constant (1)

Level Control
Maintain flow as
constant as possible
to downstream
equipment
Medium response
Tune as slowly as possible without overfilling or emptying
the tank

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Choice of Tuning Constants (2)

Flow Control
Maintain constant flow
Aim for fast response
Small process lag in system
Tune for fast as possible response

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Choice of Tuning Constants (3)

O utlet
Inlet
T2
SP
PV

TC

Temperature Control
Maintain a steady temperature
Major process lag and dead time in the system
Tune as quickly as possible without causing oscillations

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