PID CONTROL

now available with

NuFlo™ Scanner® 2000 microEFM
and NuFlo™ Scanner® 2200 EFM

Part No. 9A-30165032, Rev. 01

Introduction to PID Control
Industry has been using PID controllers for automatic process control since the early 1940s because unlike on-off controllers, PID
controllers can consistently produce more stabilized control, which improves application results.

The PID controller compares a user defined setpoint (SP) to the current process value (PV) and adjusts the 4-20 mA analog output
in an attempt to make the PV equal the SP. The 4-20mA output is used to position a final control element which is usually a valve
coupled to a current-to-pneumatic (I/P) converter.

The controller acts on the difference between the PV and the SP based on the combined settings for three tuning factors:

• a proportional constant which is the controller gain (Kp)

• an integral constant (Ki)
• a derivative constant (Kd)
Proportional Constant (Kp) or “Gain”
The proportional control action (or “proportional band”) is referred to as gain in the ModWorX™ Pro software interface. Gain is
fundamental to a PID controller and the controller cannot operate without it. To determine the output value, the controller multi-
plies the error by the gain factor.

The Scanner scales or “normalizes” the process variable operating range to a range of 0 to 1, so the gain values used with the Scan-
ner PID controller may be significantly smaller than those used with a controller that is not normalized.

Both a gain and an integral value must be entered if the process variable is to achieve the user-specified setpoint. In some cases,
the use of a gain alone can result in an offset between the setpoint and process variable that cannot be resolved without an
integral adjustment.

Integral Constant (Ki)

The integral setting eliminates the offset between the setpoint and the process variable. While the gain acts only on the current
error, the integral value acts on the sum of the current error and the previous error (the error that existed at the previous execution
period). The controller will read the error between SP and PV each execution period, sum the existing error and the previous error,
and multiply the sum by the integral value to determine the integral action on the output.

The integral value is typically very small, well below 1, and should be used in combination with a proportional constant.

Derivative Constant (Kd)

The derivative action of a controller reacts to the rate at which the process variable is approaching setpoint or the rate of change
in the error and adjusts the output accordingly. A derivative component is used only in slow-responding processes like tempera-
ture control where a significant amount of time is required for a fluid to heat or cool. It should not be used in applications where
noise is likely to effect the process variable measurement. When a derivative adjustment is not required, the derivative value
should be set to zero (default).

Understanding Gain: A Sample Calculation

For the sake of simple calculations, To determine the output value, the If the gain were 2.0, the controller
we assume a gain value of 1 in this controller multiplies the error by the would respond with a 20% output
example. Actual gain values used with gain factor. change to 10% variable error.
the Scanner® 2000 or Scanner® 2200
PID controller will be much smaller, If the gain were set to 1.0, the control- The direction of change in the output
due to normalization of the process ler will adjust the output by 10%. (increase or decrease) varies, depend-
variable operating range. ing on the action setting selected for
60 - 50 = 10 (% variable error) the controller. See page 6 for informa-
10 x 1 (gain) = 10 (% output change) tion on direct and reverse controller
Setpoint = 50%
action.
Process Variable = 60%
Gain = 1.0

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Scanner Solution
The integrated PID control of the Scanner® 2000 and Scanner® 2200 and the configuration and tuning controls built into the Mod-
WorX™ Pro software provide a powerful solution for a variety of control applications. The control valve position is regulated via a
4-20 mA output, as shown in the illustration below. The analog output is standard on the Scanner® 2200, and is available on an
optional expansion board for the Scanner® 2000.

When purchased with the PID control option, the

Scanner can be used to control parameters such as

• static pressure (from integrated MVT or external

analog input)
• differential pressure (from integrated MVT or
external analog input)
• temperature (from integrated RTD or external
analog input)
• flow rate (mass, volume or energy) based on a
DP or turbine input

The tuning values selected for the controller will deter-

mine if the process control is effective and stable.

All installations must be tuned and this task is nearly

impossible by observing numeric values alone. Com-
petitive products often require that the user observe
the mechanical movement of the control valve indica-
tor in response to an upset condition to validate the
tuning process. In many installations, this is a two-
person job. Without a partner to validate the valve’s
movement, an operator’s tuning success may be
marginal.

The tuning tools within ModWorX™ Pro eliminate the need for a partner to monitor the valve indicator. The software plots the
process variable, setpoint and valve position in an easy-to-read, scaleable graph and updates the output in realtime so a single
operator can monitor the impact of every tuning change and determine when an optimum response is achieved.

Important: Operators must configure and tune PID control settings to operate in accordance with their specific application. As
with any automated control system, operators are advised to take safety precautions to guard against control changes that could
cause personal injury or property damage.

4-20 mA output
3/4” conduit

H L

RTD
assembly

H L Flow

Control valve
Orifice flange or cone meter

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ModWorX™ Pro
ModWorX™ Pro, the software interface for the Scanner®
2000 and Scanner® 2200 , allows the user to configure,
tune and maintain a PID controller.

When ModWorX™ Pro is used to connect to a PID-

enabled Scanner, the Configuration menu will include
a “PID Control” button in the Outputs section of the
screen. This button opens a dialog that guides a user
through the configuration of the PID controller.

A “Manage PID” button also appears at the top of the

main screen. This button opens a maintenance dialog
which allows the user to change the control mode and
control setpoint only. All other configuration settings
are protected, if security settings are enabled.

To configure a controller, the user selects the control

method to be used, mode of operation, the process pa-
rameter to control, and the range of operation required
for the control parameter.

Then, using the tuning dialog, the user can change the
tuning parameters and observe the system response.
The user can switch between manual and automatic
operating modes and observe the system’s response to
changes in valve position and the controller’s response
to changes in tuning values. A user can even view the
progression of the controller response in a time-scale
graph and pause the graph as necessary to make tun-
ing adjustments.

Two Control Methods

From the Configuration menu, users can choose either
of two control methods:

• simple single-variable PID control

• PID control (for flow) with secondary
pressure control
When configured with the second method, the Scanner
can provide flow rate control and maintain static pres-
sure below a user-configured setpoint. This is essential for industrial applications that require monitoring of two process variables
and the flexibility to switch from one to the other as the primary control parameter.

For example, when a new gas well or zone is introduced in a field of old wells, the new well often produces at a higher pressure
and delivers a higher volume of gas than the old wells. If the new well is tied into an existing production facility, it will dominate
and prevent the old wells from flowing into the production system. The new well may also have a shut-in pressure that exceeds
the older production system. To limit the flow and the pressure, a single control valve is installed.

In this example, the user would configure the Scanner for PID with secondary pressure control. The user would enter two setpoints,
one for the flow rate desired and one for the maximum pressure desired. The Scanner would control the valve in accordance with
the flow rate setpoint until the pressure reached its limit, at which time the controller would throttle the valve to quickly bring the
pressure back to the acceptable range. Once the pressure is in check, the controller would transition back to flow control.

Unlike the primary controller that is used to control flow in accordance with a fixed setpoint, the secondary pressure controller
does not require a balance of gain and integral values. Because the secondary controller is concerned only with reducing pressure
quickly, gain is the only tuning value required.

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Configuring the Controller
Simple PID Controller
1. From the Configure PID Control screen, change the controller type to Simple PID
Controller.
2. Select the type of controller action desired
(direct or reverse).
3. From the Process Variable section, select
the parameter that you want to control. If
the parameter you wish to control is based
on an analog input, you must configure the
input before configuring the PID Controller.
See the ModWorX™ Pro manual for details.
The execution period of the controller is
automatically set to match the sampling
and/or calculation period of the process
variable being controlled.
4. Enter the Range Low and Range High values
for the process variable you will control (for
example, 0 to 200 In. H2O, as shown).
5. Enter the desired setpoint.
6. In the Control Loop section, you may enter tuning values, if known. Otherwise,
use the tuning dialog (step 8) to discover the appropriate values.
7. Click Apply to save the settings. The 4 to 20 mA output will automatically be
configured for PID control.
8. Click on the Tune button in the Control Loop section of the screen. See Tuning
the Controller, page 7, for tuning instructions.

Flow Controller with Pressure Override

When configured for this type of control, the Scanner can provide flow rate control
and maintain static pressure below a user-configured setpoint.

1. From the Configure PID Control screen,

change the controller type to Flow
Controller with Pressure Override.
2. Enter the settings described above in steps
2 through 6.
3. In the Pressure Override section, select the
static pressure source. (When the pressure
source is the integral MVT, the setting will
be Integrated Static Pressure).
4. Enter the Range Low and Range High
values to establish the range of the pressure
source.
5. Enter the setpoint for the pressure override
in the Max. Pressure Test Value field. Should
the pressure exceed this value, the con-
troller will actuate the valve to reduce the
pressure.
6. Enter a value for Gain to control how quickly
the valve responds to a pressure override.
7. Click Apply to save the settings.

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Configuring the Controller (cont’d)
Controller Action: Direct or Reverse?
To configure the PID controller, the user must define the type of controller action desired. The action setting answers the question
“what type of change in the controller output (increase or decrease) is required to bring the process variable in line with the con-
trol setpoint?”. If an improper action setting is selected, the controller will respond in a manner opposite the intended response
(increasing temperature, rather than decreasing it, for example).

Direct action causes the output value to change in the same direction as the change in PV (increase in PV ► increase in controller
output).

Reverse action causes the output value to change in the opposite direction as the change in PV (increase in PV ► decrease in
controller output).

Controller Output: Increased or Decreased?

How do you know if an increased or decreased controller output is needed for a particular application? The answer depends heav-
ily on two variables:
• the configuration of the valve (air-operated valves are referred to as “fail open” or “fail close”)
• how a change in valve position will affect the process variable (in some installations, opening a valve will increase the process
value; in others, opening a valve will decrease the process value)
The following examples show how valve configuration can affect the action setting. In both cases, the process is designed such
that when the valve opens, the process value will decrease. In the first example, an increased output is required to actuate a “fail
close” valve. In the second example, a decreased output is required to actuate a “fail open” valve. With the proper action setting,
either valve configuration can be used to achieve the desired result.

Direct Acting
The control valve will fail in the closed
position. An increased controller output
opens the valve, and decreases the SETPOINT SCANNER INCREASED VALVE
CONTROL PROCESS
process value. 2000 OPENS
OUTPUT VALVE VARIABLE
CONTROLLER
In this example, the error is initially
FAIL CLOSE
positive (PV - SP>0). The positive error is
counteracted by an increased control-
PROCESS ERROR DECREASED
ler output; therefore, this controller is
direct-acting.

Reverse Acting
The control valve will fail in the open
position. A decreased controller output
opens the valve and decreases the SETPOINT SCANNER DECREASED VALVE
CONTROL PROCESS
process value. 2000 OUTPUT VALVE OPENS VARIABLE
CONTROLLER
In this example, the error is initially
FAIL OPEN
positive (PV - SP>0). The positive error
is counteracted by a decreased control-
PROCESS ERROR DECREASED
ler output; therefore, this controller is
reverse-acting.

Independent Controls for Flow and Pressure

When configuring a Scanner for PID with secondary pressure control, the user must choose two controller action settings—one
for the primary flow controller and one for the secondary pressure controller. The controllers operate independently to control the
position of a single control valve. A single application may require increased controller output to control flow, and decreased out-
put to relieve pressure on the system. With dual controller action settings, each controller is configured to do the job it is designed
to do.

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Tuning the Controller
Press the Tune button on the
Configure PID Control screen to
open the Tune PID Control dialog.
From this screen, an operator can
observe the system’s response to
changes in tuning values, valve
position and setpoint. When the
process variable tracks to the set-
point in a stable trend, the control-
ler is properly tuned.

Because control parameters are

unique to each application, the
tuning values for achieving an opti-
mum response vary widely.

The Scanner controller has been

normalized to a range of zero to 1.
Therefore, tuning values may be
significantly lower than those used
with a system that is not normal-
ized.

Configuring the
Display
Main Graph. The graph display allows the user to monitor the system’s response to changes in valve position, setpoint and tuning
values. The x axis displays time, the left y axis displays valve position in percentage, and the right y axis displays the range of the
controller in the engineering units associated with the process variable being controlled. The progression of the graph can be
paused for observation while data continues to be gathered, and then unpaused to display the accummulated data.

Strip Graph. The small graph at the top of the screen scales the viewing area of the main graph. By moving the slider bar left and
right, the user controls how much of the data collected is visible on the screen.

Setpoint Control. The setpoint can be changed two ways: by moving the slider bar or by entering a value in the field below the
bar. The setpoint can be entered in engineering units or a percentage; to change the format, click on the Setpoint Scale field and
change the selection in the dropdown menu. To plot the setpoint on the graph, make sure the Plot checkbox beneath the slider
bar is checked. Changes will not become effective until you press Apply.

Valve Position. The valve position is displayed as a percentage. In automatic mode, the controller sets the valve position via the 4
to 20 mA output; in manual mode, the user can change the valve position by moving the slider bar or entering a value in the field
below the slider bar. To plot the setpoint on the graph, make sure the Plot checkbox beneath the slider bar is checked. Changes
will not become effective until you press Apply.

PID Control Loop. The control constants (Kp, Ki and Kd ) can be changed using the arrows or by selecting the existing value with
the mouse and re-entering a new value. Changes will not become effective until you press Apply.

In manual mode, the user can adjust the valve position and observe the system’s response.
1. To place the controller in Manual mode, click on Output Mode and select Manual from the dropdown menu.
2. Change the valve position (type value or move slider bar).
3. Observe the response in the trend graph. With this information, tuning algorithms (such as Ziegler-Nichols) can be used to
estimate appropriate tuning values.
In auto mode, the user can adjust the setpoint and observe the system’s response.
1. To place the controller in Auto mode, click on Output Mode and select Auto from the dropdown menu.
2. Enter a new setpoint (type value or move slider bar).
3. Observe the response on the graph. With this information, tuning algorithms (such as Ziegler-Nichols) can be used to estimate
appropriate tuning values.

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Maintaining the Controller
The field operator can modify the setpoint and override the valve position setting from the Manage PID Controller screen without
affecting the controller’s configuration, which remains secure and inaccessible to those without security access.

To access the Manage PID Controller screen, click Manage PID from the menu buttons at the top of the ModWorX™ Pro main
screen.

From the Manage PID Controller screen, the

user can:

• change the setpoint

• change the mode of operation (auto or
manual)
• change the units for displaying the setpoint
• change the valve position (manual mode
only)
The setpoint and valve position can be
changed two ways: by moving the slider bar or
by entering a value in the field below the bar.
Changes will not become effective until you
press Apply.

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Configuring the Valve Control Signal (Analog Output)
The analog output provides the control signal for opening and closing the valve. An analog output is standard on the Scanner®
2200 EFM, and is easily added to the Scanner® 2000 with an optional expansion board.

When a PID controller is configured, the analog

ouput is automatically configured for tracking
the PID controller.

To view the analog output setting, navigate to

the Scanner Configuration Menu, and click the
Analog Outputs button.

The Configure Analog Outputs screen is dis-

played.

The Change button near the Output Mode

field near the top of the screen allows users to
configure the analog output for other uses.

To test or calibrate the analog output signal,

see Analog Output Testing, page 10.

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Testing the Analog Output
ModWorX™ Pro gives users quick and
easy tools for calibrating and testing the
4 to 20 mA output signal, which can be a
timesaver in troubleshooting operating
issues.

Before calibrating and testing the output,

ensure that the following tasks have been
completed:

• A current meter must be connected

to the Scanner.
• The Scanner must be powered by an
external power supply. Wiring dia-
grams are provided in the applicable
Scanner hardware manuals, in the
Scanner® 2000 Expansion Board
Quick Start Guide, and in the
Scanner® 2200 Quick Start Guide.

Caution: Before performing a 4-20 mA

calibration or test, verify that the posi-
tion of the automated valve or control is
as desired for continued operations and
disable the controlled device if neces-
sary. Calibrating and testing the 4-20 mA
output with peripheral equipment in
operation may change the position of the
valve, causing false alarms or unexpected
changes in operations.

4-to-20 mA Calibration
To calibrate the analog output, navigate to the Configure Analog Output
screen perform the following steps:

1. Under New Output Calibration, click on the 4 mA Setting button to

send a 4 mA signal to the receiving device.
2. Enter the output value as read by the receiving device, in the Zero Ad-
justment screen and click OK. The adjustment will appear in the Active
Output Calibration section. Click Apply.
3. Repeat the steps for the 20 mA setting.

4-to-20 mA Testing
To test the analog output following adjustments, click the Test Output button at the bottom of the Configure Analog Output
screen. A Test Analog Output dialog box will appear.

Enter the output value (in milliamps) you wish to apply and click Apply. The Scanner will send the signal to the receiving device.
If everything in the loop is properly connected and calibrated, the readout of the receiving device should match the test value
entered in the Test Analog Output screen.

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Frequently Asked Questions
Does the Scanner PID controller “bump” when you switch from “auto” to “manual” mode?

In some process control systems, the switch from manual to automatic mode can result in a sudden change in the output, which
then settles back to the setpoint. The Scanner PID controller eliminates this “bump” in the output by implementing what is com-
monly called “bumpless transfer” between manual and automatic modes.

Does the PID controller handle problems with integral windup?

When a controller receives an error signal, the integral term of the controller will increase with each execution period. Normally,
this integral action will result in a change in the output. However, when the valve has reached an absolute limit (fully open or fully
closed), the integral action can no longer change the valve position, and the integral term continues to act on the unresolved er-
ror. This is referred to as “integral windup.”

Integral windup can also occur when a system override is applied, such as the secondary pressure control in the Scanner. When
the secondary controller takes control of the system, the original controller is not switched off, so it still receives an error signal,
which over time “winds-up” the integral term.

Integral windup can cause oscillation and numeric overflow and result in significant control inefficiencies. The Scanner PID con-
troller is designed to prevent problems associated with integral windup.

My controller is running in auto mode, but it appears to be stuck in the 100% (or 0%) valve position. Why?

This response may be caused by an improper controller action setting (for example, a setting which may be telling a fully closed
valve to close). Verify that the controller is configured for the correct action (direct or reverse). See page 6 for more information.

I am controlling the flow rate and the update in the controller output seems very slow. Why?

The execution period for the PID controller is the same as the calculation period for the flow run. The default setting for flow run
calculation is 60 seconds. At this default value, the system response may be too slow for optimal control. The flow run calculation
period (execution period) can be changed on the ModWorX Pro Flow Run Configuration screen.

To avoid computational delay entirely, consider using the raw differential pressure or pulse meter measurement for control rather
than the computed flow run values.

Technical Support Contact Information

Cameron
Measurement Systems Division
14450 John F. Kennedy Blvd.
Houston, TX 77032
Phone: 1-800-654-3760; 281-582-9500
Fax: 281-582-9599

NuFlo and ModWorX are trademarks of Cameron International Corporation (“Cameron”).

Scanner is a registered trademark of Cameron.

© 2010 Cameron International Corporation (“Cameron”). All information contained in this publication is confidential and propri-
etary property of Cameron. Any reproduction or use of these instructions, drawings, or photographs without the express written
permission of an officer of Cameron is forbidden.

All Rights Reserved.

Printed in the United States of America.

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[email protected]

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