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Slide 1 Interactive Opportunity Interactive Opportunity Assessment Assessment Demo and Seminar (Deminar) Series for Web Labs – PID Tuning for Self-Regulating Processes June 9, 2010 Sponsored by Emerson, Experitec, and Mynah Created by Greg McMillan and Jack Ahlers www.processcontrollab.com Website - Charlie Schliesser (csdesignco.com

PID Tuning for Self Regulating Processes - Greg McMillan Deminar

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Greg teaches you about Auto Tuning and Adaptive Control of Nonlinear Processes that are self regulating. Recorded video available for viewing at: http://www.screencast.com/t/NDY1NTQx

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Page 1: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

Slide 1

Interactive Opportunity Interactive Opportunity AssessmentAssessmentInteractive Opportunity Interactive Opportunity AssessmentAssessment

Demo and Seminar (Deminar) Series for Web Labs –

PID Tuning for Self-RegulatingProcesses

June 9, 2010Sponsored by Emerson, Experitec, and Mynah

Created byGreg McMillan and Jack Ahlers

www.processcontrollab.com Website - Charlie Schliesser (csdesignco.com)

Page 2: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

[File Name or Event]Emerson Confidential27-Jun-01, Slide 2 Slide 2

WelcomeWelcome WelcomeWelcome Gregory K. McMillan

– Greg is a retired Senior Fellow from Solutia/Monsanto and an ISA Fellow. Presently, Greg contracts as a consultant in DeltaV R&D via CDI Process & Industrial. Greg received the ISA “Kermit Fischer Environmental” Award for pH control in 1991, the Control Magazine “Engineer of the Year” Award for the Process Industry in 1994, was inducted into the Control “Process Automation Hall of Fame” in 2001, and was honored by InTech Magazine in 2003 as one of the most influential innovators in automation. Greg is the author of numerous books on process control, his most recent being Essentials of Modern Measurements and Final Elements for the Process Industry. Greg has been the monthly “Control Talk” columnist for Control magazine since 2002. Greg’s expertise is available on the web site: http://www.modelingandcontrol.com/

Page 3: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

[File Name or Event]Emerson Confidential27-Jun-01, Slide 3 Slide 3

Top Ten Signs a Startup Has Gone WrongTop Ten Signs a Startup Has Gone WrongTop Ten Signs a Startup Has Gone WrongTop Ten Signs a Startup Has Gone Wrong

(10) Product tanks are empty (9) Waste tanks are full (8) The startup team and the DCS has negative free time (7) The entire design team is in the control room (6) The whole research group is in the control room (5) The managers have left the control room (4) The consoles are lit up like a pin ball machine (3) Operators keel over from doughnut overdose (2) A collection is taken for the startup budget

And the Number 1 Sign:

Page 4: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

[File Name or Event]Emerson Confidential27-Jun-01, Slide 4 Slide 4

Top Ten Signs a Startup Has Gone WrongTop Ten Signs a Startup Has Gone WrongTop Ten Signs a Startup Has Gone WrongTop Ten Signs a Startup Has Gone Wrong

(1) The order for souvenir baseball caps is cancelled

Page 5: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

[File Name or Event]Emerson Confidential27-Jun-01, Slide 5 Slide 5

Time (seconds)

% Controlled Variable (CV) or

% Controller Output (CO)

CO

CV

op

Kp = CV CO

CV

CO

CV

self-regulating process time constant

Self-regulating process gain (%/%)

Response to change in controller output with controller in manual

observed process

deadtime

Self-Regulating Process ResponseSelf-Regulating Process ResponseSelf-Regulating Process ResponseSelf-Regulating Process Response

Page 6: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

[File Name or Event]Emerson Confidential27-Jun-01, Slide 6 Slide 6

Conical Tank in MIT Anna University LabConical Tank in MIT Anna University LabConical Tank in MIT Anna University LabConical Tank in MIT Anna University Lab

http://www.controlglobal.com/articles/2010/LevelControl1002.html

Page 7: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

[File Name or Event]Emerson Confidential27-Jun-01, Slide 7 Slide 7

Gravity discharge flow makes the level response self-regulating (increase in level head increases flow through discharge valve)

Increase in cross sectional area with level increases process time constantmaking process response slower

Conical Tank Detail Conical Tank Detail Conical Tank Detail Conical Tank Detail

Page 8: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

[File Name or Event]Emerson Confidential27-Jun-01, Slide 8 Slide 8

Performance of Linear PID Level Controller Performance of Linear PID Level Controller for Conical Tankfor Conical Tank

Performance of Linear PID Level Controller Performance of Linear PID Level Controller for Conical Tankfor Conical Tank

Page 9: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

[File Name or Event]Emerson Confidential27-Jun-01, Slide 9 Slide 9

Process Models Automatically Identified Process Models Automatically Identified for Operating Regionsfor Operating Regions

Process Models Automatically Identified Process Models Automatically Identified for Operating Regionsfor Operating Regions

Page 10: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

[File Name or Event]Emerson Confidential27-Jun-01, Slide 10 Slide 10

Performance of Adaptive PID Level Controller Performance of Adaptive PID Level Controller for Conical Tankfor Conical Tank

Page 11: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

Click on magnifying glass to getdetail view of limits and tuning

Click on Duncan to get DeltaV Insight for “On-Demand” and “Adaptive” tuning

Slide 11

Page 12: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

[File Name or Event]Emerson Confidential27-Jun-01, Slide 12 Slide 12

Control Valve Flow CharacteristicsControl Valve Flow Characteristics

Page 13: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

Equal PercentageFlow Characteristic

Slide 13

Page 14: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

“On-Demand Tuning” automatically identifies dynamics from relay oscillation introduced

click on PID tagand then Tune

Slide 14

Page 15: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

“Adaptive Tuning” automatically identifies dynamics from setpoint or manual output change or injected pulse(For More Info See Emerson Exchange 2009 Presentation on DeltaV Insight for Loop Monitoring and Tuning)

click on PID tagand then Tune

Slide 15

Page 16: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

“Adaptive Control” automatically identifies dynamics in each region

Process gain isapproximatelyproportionalto flow for

equal percentageflow characteristic

Slide 16

Page 17: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

IdentificationOut Limit thatsets deadzoneshould be setapproximatelyequal to valvedeadband and stick-slip near

closed position

Learning Setup (triggers, injection, search, process, initialization, and options for model identification )

Slide 17

Page 18: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

Simulate to show gain and phase margin and load and setpoint response for tuning settings

Slide 18

Page 19: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

[File Name or Event]Emerson Confidential27-Jun-01, Slide 19 Slide 19

Demo of Adaptive ControlDemo of Adaptive ControlDemo of Adaptive ControlDemo of Adaptive Control Objective – Show adaptive control of fast nonlinear self-

regulating processes (Liquid Flow and Liquid Pressure) Activities:

– For Liquid Flow Loop:• Show nonlinear control valve characteristic

• Run “On-Demand Tuner” (0.2Ku and 0.6Tu)

• Run “Adaptive Tuner” (initially SP = 40-35) (Lambda factor = 1 & setpoint trigger = 2%)

• With Adaptive Mode “Off” make setpoint change region 5 (SP = 85-90)

• With Adaptive Mode “Off” make setpoint change region 1 (SP = 5-10)

• Review “Adaptive Control” screen

• Review “Model Viewing” screen

• Review “Learning Setup” screen

• Review “Simulate” screen

• With Adaptive Mode “Partial” make same setpoint changes in region 1 and 5

– For Liquid Pressure Loop:• Show nonlinear process gain

• Repeat above Tuner and Adaptive Control runs and reviews for pressure loop (initially

SP = 50-45, make Adapt mode tests in Region 5 SP = 80-85 and Region 1 SP = 10-15)

Page 20: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

[File Name or Event]Emerson Confidential27-Jun-01, Slide 20 Slide 20

Help Us Improve These Deminars!Help Us Improve These Deminars!Help Us Improve These Deminars!Help Us Improve These Deminars!

WouldYouRecommend.Us/105679s21/

Page 21: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

[File Name or Event]Emerson Confidential27-Jun-01, Slide 21 Slide 21

Join Us June 23, Wednesday Join Us June 23, Wednesday 10:00 am 10:00 am CDTCDTJoin Us June 23, Wednesday Join Us June 23, Wednesday 10:00 am 10:00 am CDTCDT

PID Tuning for Near-Integrating Processes PID Tuning for Near-Integrating Processes (How to Reduce the Tuning Time for Column and Vessel Temperature and Pressure Loops by 90%)

Look for a recording of Today’s Deminar later Look for a recording of Today’s Deminar later this week at:this week at:

www.ModelingAndControl.com

www.EmersonProcessXperts.com

Page 22: PID Tuning for Self Regulating Processes - Greg McMillan Deminar

[File Name or Event]Emerson Confidential27-Jun-01, Slide 22 Slide 22

QUESTIONS? QUESTIONS? QUESTIONS? QUESTIONS?