Workshop 5 Controller tuning for capacity and dead time processes

A little experience often upsets a lot of theory. Samuel Parks Cadman

Introduction
Prior to attempting this workshop, you should review Chapter 5 in the book. This workshop will illustrate that HYSYS may be used to determine the appropriate parameters for a PI controller that is controlling a capacitive process with signicant dead time. You will learn that controller tuning is determined by the desired load or setpoint response as well as the type of process and the values of the process parameters, which include process gain, time constant, and dead time. A review of the three tuning techniques that are used in this workshop is provided below.

Process reaction curve tuning technique In the process reaction curve method, a process reaction curve is generated in response to a disturbance. This process curve is then used to calculate the controller gain, integral time and derivative time. The method is performed in open loop so that no control action occurs and the process response can be isolated. To generate a process reaction curve, the process is allowed to reach steady state or as close to steady state as possible. Then, in open loop, so that there is no control action, a small step disturbance is introduced and the reaction of the process variable is recorded. Figure W5.1 shows a typical process reaction curve for the process variable (PV) generated using the above method for a generic self-regulating process. The term self-regulating refers to a process where the controlled variable eventually returns to a stable value or levels out without external intervention.

A Real-Time Approach to Process Control, Second Edition W. Y. Svrcek, D. P. Mahoney and B. R. Young 2006 John Wiley & Sons, Ltd. ISBN: 978-0-470-02533-8

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PV

Cp

t
L T

Figure W5.1

Process reaction curve

The process parameters that may be obtained from this process reaction curve are as follows: L T P Cp (%) N= R= Cp T (min) lag time (min) time constant estimate (%) initial step disturbance change in PV in response to step disturbance, (change in PV)/(PV span) 100 (% min1 ) reaction rate

L NL (dimensionless) lag ratio = T Cp

The ZieglerNichols process reaction curve tuning method for a PI controller is as follows: 1 Determine a reasonable value for the step valve change P . This value is arbitrarily chosen, but typically 5 per cent is reasonable. 2 With the controller in manual mode, manually move the valve P per cent. 3 Wait until the PV lines out to the new steady-state value. 4 Determine N and R from the process reaction curve. 5 Perform the following calculations: controller gain K c = 0.9 P /NL controller integral time Ti = 3.33 L 6 Implement these recommendations for the controller settings in the controller. 7 Close the control loop by placing the controller in automatic mode. 8 Test thoroughly, ne-tuning the parameters to obtain the QDR.

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Auto-tune variation tuning technique om is one of a number of techniques The auto-tune variation or ATV technique of Astr used to determine two important system constants called the ultimate period and the ultimate gain. Tuning values for proportional, integral and derivative controller parameters may be determined from these two constants. All methods for determining the ultimate period and ultimate gain involve disturbing the system and using the disturbance response to extract the values of these constants. In the case of the ATV technique, a small limit-cycle disturbance is set up between the manipulated variable (controller output) and the controlled variable (process variable). Figure W5.2 shows the typical ATV response plot with critical parameters dened. It is important to note that the ATV technique is applicable only to processes with dead time. The ultimate period will just equal the sampling period if the dead time is not signicant. The general ATV tuning method for a PI controller is as follows: 1 Determine a reasonable value for the valve change h . This value is arbitrarily chosen, but typically 0.05 is reasonable, i.e. 5 per cent. 2 With the controller in the off position, manually move the valve +h units. 3 Wait until the process variable PV starts to move and then move the valve 2h units. 4 When the process variable crosses the set point, move the valve +2h units. 5 Repeat until a limit cycle is established, as illustrated in Figure W5.2.

Controller Output

Ultimate Period Pu

a
Ultimate Gain 4h Ku = 3.14a

Process Variable

Figure W5.2

ATV critical parameters

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6 Record the value of the amplitude a by picking it off the response graph. 7 Perform the following calculations: ultimate period Pu = period taken from the limit cycle ultimate gain K u = 4h/3.14a controller gain K c = K u /3.2 controller integral time Ti = 2.2 Pu . ZieglerNichols closed-loop tuning technique The closed-loop technique of Ziegler and Nichols is another technique that is commonly used to determine the two important system constants, i.e. ultimate period and ultimate gain. Historically speaking, it was one of the rst tuning techniques to be widely adopted. In ZieglerNichols closed-loop tuning, as for the ATV technique, tuning values for proportional, integral and derivative controller parameters may be determined from the ultimate period and ultimate gain. However, ZieglerNichols closed-loop tuning is done by disturbing the closed-loop system and using the disturbance response to extract the values of these constants. The ZieglerNichols closed-loop tuning method for a PI controller is as follows: 1 Attach a proportional-only controller with a low gain (no integral or derivative action). 2 Place the controller in automatic. 3 Increase proportional gain until a constant-amplitude limit cycle occurs. 4 Perform the following calculations: ultimate period Pu = period taken from limit cycle ultimate gain K u = controller gain that produces the limit cycle controller gain K c = K u /2.2 controller integral time Ti = Pu /1.2.

Key learning objectives

1 Controller tuning is determined by the desired controller response. 2 Controller tuning is determined by the type of process.

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3 Controller tuning is affected by the value of the process gain. 4 Controller tuning is affected by the value of the time constant. 5 Controller tuning is affected by the value of the dead time. 6 The ATV tuning technique is a powerful method for many loops. 7 The ZieglerNichols closed-loop technique is also useful, but more aggressive than ATV. 8 The ZieglerNichols process reaction curve technique is also useful, as it provides estimates for the key process parameters. 9 HYSYS can be used to nd appropriate tuning parameters for a PI controller

Tasks
1 Tuning Controllers

The process used for this workshop is shown in Figure W5.3. A 50/50 feed mixture of water and ethanol (T = 5 C, P = 200 kPa, F = 100 kmol h1 ) is heated in a steam heater to approximately 70 C. The hot stream passes through a dead-time leg before being stored in a tank for future use. Use a PFR unit operation to simulate the dead time with a volume of 3 m3 and a length of 2 m. This was the process you worked on in the latter part of Workshop 3. Set the tank level to 50 per cent with no incoming disturbances. With the temperature controller in manual, adjust the steam valve to get a tank temperature of approximately 70 C. Bring up the temperature controller faceplate. First use the ZieglerNichols process reaction curve technique to determine the controller settings at 50 per cent tank level. Determine the controller settings at two more tank levels (5 and 95 per cent).

Heater PFR
feed hot feed to tank

Tank

steam

TC

TT product

Figure W5.3

Illustrative capacity plus dead time process

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Second, use the ATV technique to determine the controller settings as follows. Set the mode to auto-tune. The controller will bring the process into a limit cycle.

r Determine the period of this limit cycle in minutes. Use this limit cycle to determine
the amplitude of the temperature cycle of the stream exiting the tank and make this dimensionless by dividing by the temperature transmitter span.

r Now determine the fractional amplitude of the controller output h . r Calculate the ultimate gain and use this with the ultimate period to compute the
controller settings.

r Determine the controller settings at two more tank levels (5 and 95 per cent).
Now use the ZieglerNichols closed-loop tuning technique to determine the controller settings at the three tank levels.

r Compare the results of using both the ATV and ZieglerNichols tuning techniques.
2 Controller contributions to attenuation

We have seen in Workshop 3 that the process itself is able to attenuate with no control, i.e. open loop. We have just tuned our feedback controller for various levels of capacitance and can now determine what the process plus control (closed loop) is able to attenuate. By subtracting the open loop attenuation from the total attenuation we can determine what the controller itself contributes to the overall process attenuation.

r Determine the total closed-loop attenuation of the tank operating at the 50 per cent
level for sinusoidal disturbances of periods 10, 20, 30, 40, and 100 min with an amplitude of 25 C.

r Compute the controller contribution to attenuation for these disturbances. r At the 5 per cent level determine the controller attenuation for sinusoidal disturbances
of periods 5, 10, 20, 30, and 50 min and amplitude 25 C.

r At the 95 per cent level determine the controller attenuation for sinusoidal disturbances of periods 10, 20, 30, 40, and 100 min and amplitude 25 C.

r Plot attenuation versus the logarithm of the disturbance period. Compare the curves
using their dead time to time constant ratios that you calculated in Workshop 3. Present your ndings on diskette in a short report using MS-Word. Also include on the disk a copy of the HYSYS les which you used to generate your ndings.