PID Tuning, Advanced Control & Multivariable Dynamics

PITOPSPID/Advanced Control & Dynamics Identification

www.picontrolsolutions.com

PITOPS

PiControl Solutions Company Copyright © 1

PiControl Solutions Company

Copyright ©


[email protected]

PID Tuning, Advanced Control &

Multivariable Dynamics Identification

Powerful and Easy Software for



Pitops has FOUR Powerful Features

1. PID/Cascade Tuning Optimization

2. Control Valve Stiction Estimation

3. Transfer Function Parameter Identification

4. Advanced Control Implementation in DCS

and PLC (Control Lab on PC)



www.picontrolsolutions.comPiControl Solutions Company Copyright © 3

• Pitops is easy to use for DCS and PLC Technicians,

Control Engineers, Process Operators, Supervisors

• No Need for Advanced College Education

• Value for Everyone, New or Experienced, Both

Technicians and Engineers



PART 1PID TUNING OPTIMIZATION




PID Control Setpoint Change


Setpoint

Change PV

PID Output

Pitops shows Individual Proportional,

Integral and Derivative Contributions



PID Tuning Optimization


Optimized Proportional Kick

Optimized

Setpoint Response

Optimum PID

Tuning Parameters



Add Noise to Simulate Behavior in Real DCS


Optimized Setpoint Response

In the presence of Random Noise

PID Output



Derivative Action, Noise and Filter




Optimize PV Signal Filtering to Dampen Noise


Optimized PID Tuning

and Filter Constant

PID Output



Optimize Control Action to Reject Disturbances


Unmeasured

Disturbance

PID Output



Custom PID Optimization for SP change and Typical Disturbances


Custom

Disturbance



Optimally Reject External Sinusoidal Disturbances


Sinusoidal

Disturbance

Optimized Control Action in presence of

Typical Disturbances in Plant

Optimum PID

Tuning



Custom Simulation and Optimization Example


Setpoint Change

Controller Output

Custom Simulated Disturbance

P, I and D Individual

Contribution

Optimized PID Tuning

Transfer Function

Parameters



Powerful Multiple Cascade PID Optimizer


Slave

PID

Cascade

PID

Slave PID Output Cascade PID Output



Individual P, I and D Contributions


Setpoint

Change PV

PID Output

Pitops shows individual

Proportional, Integral and

Derivative Contributions. This is

a powerful feature to diagnose

tuning optimization.

Proportional Contribution

Integral Contribution

Derivative Contribution



All PID Equations for any DCS or PLC

PID Gap ActionControl Error Criteria



Control Valve Characterization

for Non-LinearityNon-Linear Control

Using Process Transforms





PART 2CONTROL VALVE STICTION




Novel Algorithm to Estimate Control Valve Stiction

Pitops Estimates Control

Valve Stiction and then

Optimizes PID Tuning to

Compensate for Stiction

Pitops reads PID PV

and Valve OP data and

automatically estimates

Stiction. Pitops does

not require step tests.



Stiction Plot: Valve Position versus PID Output



Novel Algorithm to Estimate Control Valve Stiction

PID Output

True Control Valve Position with Stiction.

This blue trend is generated by Pitops

Control Valve does

not move here

because of Stiction

Notice the difference

between PID Output

and Control Valve

Position.



PID Tuning Optimization Amidst Valve Stiction

PV

Setpoint

Change

PID OP

(Output)

Control Valve

Position Generated

By Pitops

Simulated Ramp

and Pulse Disturbance

Optimized PID

Tuning Calculated by

Pitops amidst

Stiction, typical

Setpoint Changes and

Real Disturbances



PART 3TRANSFER FUNCTION DYNAMICS

IDENTIFICATION




Easy Transfer Function Identification


Steam Flow

(Manipulated Variable)

Temperature

(Controlled Variable)

Transfer

Function

Model

Identified

Transfer Function

Parameters

Notice this is Closed-Loop Data (Controller

in Auto or Cascade). Pitops does not need

Crisp Step Tests.

Measured

Temperature (CV)



Or use Open-Loop

Step Tests, to

Identify Transfer

Functions

Red=Real Plant Data

(Output Variable)

Real Plant Data

(Input Variable or Manipulated Variable)

Blue=Transfer

Function Prediction

Identified by Pitops

Second Order with Delay Identification



Multivariable Input Identification with Closed-Loop Data

Red Trend Shows Product Analysis from Online GC

MV #1 Data (Column Feed)

MV #2 Data (Side Stream Draw)

MV #3 Data (Bottoms Reboiler Duty)Three transfer

functions (2nd Order +

Dead Time)

simultaneously

Identified

Blue Trend Shows a 3-Input Transfer

Function Prediction Identified by Pitops

This is a Multivariable

Closed-Loop Transfer

Function Identification

using Closed-Loop Data



Single Click to Identify Transfer Functions


Conduct a “What-If”

Study by typing new

transfer functions

manually and then

click IDENTIFY

button to get the best

transfer function

parameters (see next

slide)



High Accuracy Transfer Function Model


BLUE trend is the

transfer function

model from

PITOPS and red

is the actual plant

data. Notice the

EXCELLENT

fit!!!



Proprietary ARTCON 3G Technology


GEOMETRIC

GRADIENT

GRAVITY

Residuals

ARTCON’s 3G

Technology

provides

unmatched and

unprecedented

ability to

identify multi

input closed-

loop models

amidst complex

unmeasured

disturbances.



Multivariable Identification with Closed-Loop Data

Transfer

Function #1

Transfer

Function #2

Transfer

Function #3

Stiction

Identification &

Control

Optimization



PART 4ADVANCED CONTROL

IMPLEMENTATION IN DCS OR PLC




Complete Process Control Laboratory on your PCCustomized for Control-Room DCS/PLC Needs



Feedforward Simulation and Lead, Lag, Gain, Delay Optimization


Slave PID with

Disturbance Rejected

Slave

Output


Contribution

Simulated

Disturbance

Feedforward

Compensation



Model-Based Control Simulation(Empirical, Regressed, IMC, DTC Models)


Excellent Control

Despite Long Dead Time

Slave Output


Contribution

Long Dead Time

(40 minutes)

Internal Model

Contribution



Simulate Analyzer (GC) Sample Delay


Distillation Product Purity Control

Using Online Gas Chromatograph

Simulated

Unmeasured

Disturbance



100 lb/hr

175 C

Temperature

(CV)

Fuel Flow SP (MV)

Feed Flow SP

(disturbance)

104 lb/hr

98 lb/hr

180 C

186 C

178 C

800 lb/hr

790 lb/hr

805 lb/hr

182 C

Transfer Function Delay Gain Time Constant

Fuel -Temperature 3 min 1.5 C/(lb/hr) 10 min

Feed -Temperature 7 min -0.4 C/(lb/hr) 20 min

Time

Learn to Identify Transfer Functions from Plant Data



FEEDFORWD

TRANSFER

FUNCTION

SP E

PV

_

+ OP

TC

++

+ +

PROCESS

TRANSFER

FUNCTION

DISTURBANCE

TRANSFER

FUNCTION

PV

DISTURBANCE

SIGNAL FF

MV CV

DS

(Load)0.27 (10s+1)e-4s

(20s+1)

-0.4 e-7s

20s+1

1.5 e-3s10s+1

Fuel

Flow

Feed

Flow

Learn to Mathematically Implement Optimal Feedforwards in DCS or PLC



Learn Internal Model Control and Dead Time Compensation

Lab

Signal,

GC Signal

Or

Instrument

Signal

ESP

-+

Valve

MV

Pressure

PVPID

(PC)

Transfer

Function

Process

Model

Model

Signal

Model

Delay

Model

Correction

Model can be pure Transfer Function

or 1st principles model or Empirical

Model with multi-inputs or anything

capable of predicting the CV

+ +

+

-



Powerful Industrial Applications

• Online Viscosity Model Predictions

• Polymer Plant Properties – Melt Index, Density

• Online GC Analyzer Control in Distillation Columns

• Any similar Inferential and Model-Based Control

Application.

• Any application where Lab measurement comes

every hour or slower.

• Any application where online measurement is slow –

5 minutes to 60 minutes sample time.




Design and Implement Powerful Constraint Maximizers

Learn scientific techniques

to calculate dynamics and

optimum tuning precisely

Eliminate

Guesswork!!!

PID

#1

<

FC

Low Signal

Selector

PID

#2

PID

#3

SP SPSP

PV PVPV

55% 65%45%

45% SP=180

100.0

99.7 400.4

500.0 10.0

2.7

Maximize Production Rate

Minimize Utilities

Improve Product Quality



PART 5POWERFUL EXCEL AND OPC

CONNECTIVITY TO ANY DCS/PLC




Easy to Read Plant Data Files


AC8711 TFI Dynamic Analysis.XLS

AC8711.P

V

FC5618.SP

Excel or OPCFormat



OPC Server Connection


COMP11FC101TC301LC404TC309



Live OPC Data Collection Screen


FC1290.PV TC3112.PV LC9812.PV TC4387.PV

TC4387.PV

TC4387.PV



PART 6PITOPS SERVES ALL

YOUR CONTROL ROOMPROCESS CONTROL NEEDS




FC

FC

PC

Reboiler

Condenser

Overhead

Product

Stream

Bottoms

Product

Stream

FC

TC

Steam

Feed

14.1 t/h

5.3 t/h

9.1 t/h

3.3 t/h

330

degC

Distillation

Column Control

Tune all PIDs, Cascades

And Feedforwards on

Distillation Columns



M MotorSteam Jacket

Heated Reactor

Raw Material

Feed Streams

Product

Stream

Steam to

JacketSteam

Condensate

225 degC

275 kg/h

221 degC

2.71 t/h

0.87 t/h

3.4 t/hTune all PIDs, Cascades

on any Reactor



Compressor Surge Control10%

M

UC

PCPT

Compressor

Surge

Calculation

PIBase Load

Gas

Compressor

Cooler

Motor

15 psig

275

psig

22%

3.2 MW

1175 RPMTune all PIDs, Cascades

on Compressor

Tune any PID

for any Process



How Pitops Can Increase Plant PROFIT

Increase in Production

Rate After Improved

Process Control

Improved control after

Process Control Training

and New Control Schemes

Average Before

TIME

Rate

Production

Average After



PitopsTM will help on the following:

• New Plant Start-ups to come up with

good initial PID values

• Optimize existing plant PID loops

• Train Control Engineers and

Technicians on PID Tuning Skills

• Improve Advanced Control

• Push Production Rates

• Make more ProfitPiControl Solutions Company Copyright © 51



• PitopsTM PID has Very Easy User Interface.

• Works wholly in Time Domain which is easy to

learn and understand.

• Competitors work in S (Laplace) or Z(Discrete)

domain but Pitops works entirely in Time Domain.

• Technicians and New Engineers can learn to use

PitopsTM PID in just half a day!

• PitopsTM PID works for all types of loops –

millisecond or faster, seconds, minutes, or in

multiples of minutes (any time unit, fast or slow).


Why Choose PitopsTM?



• Compressor Surge Control

• Motor RPM, KW, Amps Control

• Valve Position Control

• Flow Control

• Pressure Control

• Level Control

• Temperature Control

• Distillation Product Purity Control

• Multiple Cascade Control

• Constraint Override Control with Selectors

• Bias Control with Integrated PID Feedforward


PitopsTM PID Applications:



PiControl Technical Support

PiControl provides Free

technical consulting for

all your PID, Primary

Control and Advanced

Control Problems


PiControl Solutions Company

Copyright ©


[email protected]

Documents

PID Tuning, Advanced Control & Multivariable Dynamics