Tuning interacting PID loops

The end of the era of the

trial and error approach

Desktop and Cloud Application

Introduction
Almost all actuators and instruments in the industry that are part of a control system are controlled by a
PI(D) controller. Although they trace back to the 19th century, PID controllers still form the backbone of
automatic control systems, not only in refineries and petrochemical installations, but also in power plants,
cars, breweries, etc.

The success of PID schemes lies in the simplicity and the ability to understand in an intuitive way, the roles
of the various parameters in the loop. However, there is one key disadvantage of the PID concept, namely
that it is very difficult to optimize PID loops that interact with each other.

A typical approach to dealing with interacting control loops, is to simply assume that
there is no interaction. Each loop is optimally set under the assumption that the rest
of the plant does not exist. Once all “optimal” PID controllers have been put into
“automatic mode” it is possible the complete plant will become less robust, less
stable or even unstable. This is because each PID loop has been tuned in isolation,
not taking into account interactions with other PID loops.

Perhaps the most common strategy is to detune one or several PID controllers.
What to detune, and by how much, is almost impossible to estimate, hence the
detuning is carried out based on the “experience” of the engineer doing the work.
This heuristic approach may result in several iterations depending on the conditions
prevailing in the process, the types of feed, the ambient conditions and so on. It is safe to say that the
resulting tuning will never be optimal.

INCA AptiTune challenges these limited, ad hoc approaches by optimally tuning multiple interacting loops
without the guesswork. For example, it is ideally suited to tune the pressure and top temperature controller
at the top of a distillation column, or several PID controllers on a hydrogen network,
fuel gas network or any other flow network with several PID loops acting on a
single flow source.

Offered as perpetual licencing, annual licencing or pay-as-you go, AptiTune is

available in a package for every tuning workload - whether regular and frequent,
just a few times per year, or to meet the stringent requirements of an audit deadline.
Moreover, AptiTune Go, pay-as-you go, is accessible from any computer through a
web browser without the need to install or download anything making it easy and
convenient.

This article explains in detail the INCA AptiTune work flow, highlighting all the key functions and showing
with real examples how IPCOS’ customers and engineers have benefited.

INCA AptiTune & AptiTune Go, the workflow

INCA AptiTune calculates optimized tuning that can be entered directly in the plant’s existing DCS – in
other words, it facilitates “one shot tuning”. This section presents the INCA AptiTune approach to tuning
interacting PID loops, taking advantage of modern identification methods, advances in optimization theory
and the availability of fast multi-core processors.

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 Figure 1 - The INCA AptiTune & AptiTune Go Workflow

The procedure for developing PID tuning for multivariable systems consists of a predefined workflow.

• Identify the interacting PID loops that could benefit from multivariable tuning and insert these
loops in “Manual mode”.
• Undertake a plant test of the multivariable process and collect process data.
• Identify the process model in the INCA AptiTune software. Model identification features include
the ability to incorporate process knowledge on the model by imposing constraints such as gains,
dead times, relationships between gains, dynamics and so on.
• Carry out constrained optimization to identify optimal PID tuning parameters based on engineering
specifications such as setpoint tracking, disturbance rejection, minimum robustness, maximum
overshoot and so on.
• Simulate the optimized PID loops.
• Insert the optimized PID parameters in the target PID loops and make step changes to confirm the
adequacy of the response.

All the steps from data collection to simulation of PID loops are fasciliated by the INCA AptiTune package.
This allows the user to interactively determine the best tuning for their application based on process safety
and operability considerations, and robustness specifications tailored to the specific DCS.

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A plant test is performed on the various subsystems where PID tuning is desired. Typically, INCA AptiTune
needs just one or two steps to compute good models. The goal is to identify a dynamic model that
accurately captures the input-output behavior of the plant. An accurate model means that the simulated
responses should match the optimal tuning of the actual plant. Extra steps can be performed to increase
the accuracy of the model still further. Well chosen multiple tests can reveal non-linearities - such as
process gains depending on throughput, different static or dynamic behavior when stepping up or down -
and valve issues such as Cv characteristics, valve stiction, backlash, and so on.

Figure 2- Step testing sequence used to generate models in AptiTune

Once a model has been computed using AptiTune (or imported into AptiTune from another common
modeling tool), the next step is to smooth the model (if necessary). the next step is to smooth the model
(if necessary). A default model smoothing is applied and is generally sufficient. The smooth state space
model is then used to determine optimal PID tuning parameters for the closed-loop control system.

Figure 3 - Typical modeling result as is generated by the AptiTune modeling tool

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The user is required to enter instrument ranges and to select the desired PID equation associated with
a particular DCS, the most popular of which are already integrated in the package and include Honeywell
TDC and Experion, Emerson DeltaV, Foxboro I/A,ABB Symphony,Yokogawa and others. Optimal controller
parameters can also can be calculated for P-only, I only, PI and PID options.

Additional specifications and constraints may be specified for the optimization. In particular, unlike other
tuning tools, INCA AptiTune allows parameters such as the maximum allowable overshoot and/or
maximum allowable OP kick to be explicitly specified .This makes tuning a loop much easier as engineering
specifications like overshoot and OP kick are automatically “translated” into tuning parameters (like P, I, and
D). Design cases are logged and the user can analyze the different scenarios in terms of setpoint tracking,
disturbance rejection, and noise attenuation. The integrity of the system when one or more controllers
are placed in “manual” can also be analyzed and the robustness against plant-model mismatch can also be
evaluated and displayed in an easy-to-understand graphical way.

A B

C D

Figure 4 - Simulated behavior of 2 interacting PID controllers. On the diagonal (A,D) the
performance of the PID controllers within its own loop is shown. Off diagonal (B,C) plots
show the interaction with the other PID loop

Recently IPCOS added the functionality to tuning cascading loops in one go. A step test on the output of
the slave controller and the recording of the CV variations on the master and slave produces a 2 x 1 model.
This model is used to tune both master and slave simultaneously. Tuning cascading loops is easy when the
dynamic behavior of the slave is significantly faster compared to the dynamics of the master. However, even
when the dynamic behaviors are less distinct INCA AptiTune is still able to extract the optimal parameters.

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INCA AptiTune, To Go or Not To Go

Offered as perpetual licencing, annual licencing or pay-as-you go, AptiTune is available in a package for every
tuning workload.

Intensive users are advised to purchase a perpetual or term license that will need to be installed on their
computers.This gives them all flexibility to use the software as much as they need. Given that the software
runs on the local computer on site an OPC interface is available to connect AptiTune directly to the DCS.

“Light” users that just want to tune loops a few times per year but still need the most high end tool on the
market can opt for the AptiTune Go platform in the cloud.The tuning capabilities are identical for AptiTune
Go as for AptiTune. The main difference is that the AptiTune Go software runs in the cloud so only a web
browser is needed. No local installations are required and you only pay when you use it from time to time.
The cloud concept however prevents the OPC interface from being used.

The idea behind the AptiTune Go approach is to offer everybody who has some difficult loops to tune the
possibility to use the power of AptiTune, whether it is frequent or un-frequent.

The table below shows the differences between an AptiTune and AptiTune Go platform. Figures 5 and 6
show that the both the desktop and the web based environments are almost identical.

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 Figure 5: Screenshot of the INCA AptiTune desktop application

Figure 6: Screenshot of the same project within the INCA AptiTune Go environment

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Examples
Improved quality from a DIB using INCA AptiTune
The first example shows the typical use of INCA AptiTune on columns. In the refining market, alkylate is a
high value product which is produced from the reaction between isobutane (iC4) and olefins catalysed in
an acidic environment. A distillation column, a so-called de-isobutaniser (DIB), is used to obtain iC4 from
mixed streams also containing high quantities of linear butane (nC4) and other heavier compounds (C5+).
An improvement in the quality of iC4 will result in better yield of alkylates, resulting in significant benefits.
Due to the similar boiling points of iC4 and nC4, DIBs are normally big pieces of equipment with slow
dynamics which operate with high reflux ratios and consume high amounts of energy. Improved operation
of the column will also result in a reduction in energy costs.

Figure 7 - DIB top section control scheme

The separation of the two compounds iC4 and nC4 is very sensitive to the column pressure, which in turn
affects the column temperature profile. In order to achieve finer control of the iC4 top product quality a
pressure compensated temperature (PCT) controller was installed on stage #10 of the DIB column, which
is the sensitive tray for top quality. The temperature controller output is cascaded to the reflux flow set-
point, as shown in figure 7.

INCA AptiTune was used to obtain direct and cross dynamic models connecting the reflux flow and the
pressure valve to tray #10, with temperature and pressure, a step test was carried out with the reflux flow
controller in “automatic” and the pressure controller in “manual”.The models showed that the reflux flow
did not need retuning. Figure 8 shows the models obtained scaled to the typical moves of the independent
variables. Figure 9 compares the simulated behavior of the loops facing typical set-point changes with
the original tuning parameters (red curves) and with the new tuning obtained with INCA AptiTune (blue
curves).

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 Figure 8 - Open loop step test models – scaled to independents typical steps

Figure 9 - 2x2 simulated typical step test response

(red = existing tuning; blue = AptiTune tuning)
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Figure 10 shows the simulation comparison for typical load disturbances.

Figure 10- 2x2 simulated typical load disturbance response

(blue = existing tuning, red = AptiTune tuning)

The two figures below show real data comparing the original tuning with oscillations and the loop
performance after the new tuning implementation for DIB top temperature and pressure. Notice that with
the original tuning (left) the set points were always constant. With the optimal tuning (right) the set point
tracking was much better and the set points themselves were moved in order to optimize the process.The
quality of iC4 extracted using the new tuning enabled more alkylate to be produced, with the associated
financial benefits.

Figure 11- DIB top temperature control: before and after “AptiTuning” it. Notice that the
setpoints on the left picture are constant, while they are moving on the right picture.

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 Figure 12 – DIB top pressure control: before and after “AptiTuning” it. Notice that the set-
points on the left picture are constant, while they are moving on the right picture.

INCA AptiTune improves uptime and process stability at KJO

Another example comes from Al-Khafji Joint Operations (KJO) in the Kingdom of Saudi Arabia. The
company operates a gas processing facility to treat gas associated with the offshore oil production for gas
lift and power generation. Shortly after the plant was revamped in 2014, IPCOS was asked to conduct an
audit and optimize the base control layer to improve production uptime and processing stability.

Figure 13 - Process overview

Following an initial audit IPCOS decided to tune the PID layer within the DCS.This was a highly interactive
process so a multivariable tuning approach was taken for tuning these PID loops. The PID tuning services
for KJO included a review and analysis of all PID loops of the gas plant. Poorly tuned PID loops were
identified, prioritized and tuned using IPCOS’ INCA AptiTune software. The schematic above shows an
overview of the KJO gas processing facility for which PID tuning activities were performed.

It was found during the data analysis that the gas coolers and gas dryers caused temperature and level
fluctuations in the Low Temperature Separator (LTS). The effect of stabilizing the temperature of the gas
cooler is clearly visible in figure 14. It has a stabilizing effect on the level in the LTS as well as the flow out
of the LTS going to the deethanizer and condensate stabilizer.

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During the data analysis and interviews with operators it was observed that the deethanizer flow, level and
temperature fluctuations were caused by:

• Flow coming from the LTS.

• Poor Tuning of Level controller.
• Poor Tuning of the deethanizer hot-oil reboiler.

The effect of the improved tuning is clear in the figure below: after tuning, the temperature, flow and level
of the deethanizer stop oscillating and follow setpoint correctly.

Thus the LTS was stabilized by updating the PID parameters of the gas cooler’s temperature . Due to the
interaction between the different units of the gas plant, the stabilization of the LTS also has a stabilizing
effect on the deethanizer.The different setpoints of the deethanizer level, flow and temperature are better
tracked, as clearly seen in Figure 15. The control of the hot oil outlet temperature was made more robust
and the temperature setpoint tracking was made more accurate.

Figure 14 - Improved tuning LTS

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 Figure 15 - Improved tuning deethanizer

Conclusions
With the introduction of INCA AptiTune the era of tuning interacting loops by trial and error is over.
Iterating endlessly between tuning trials on the plant and analysis in the office has become obsolete.
Translating engineering specifications like maximum allowed overshoot and OP kick into tuning
parameters is no longer an art: instead it is a matter of entering the constraints and running the tuning
optimizer of INCA AptiTune. Based on modeling techniques utilized in Advanced Process Control all
interacting loops on process plants can be tuned in an accurate, optimal, robust and efficient manner.

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About IPCOS
IPCOS is the leading provider of Digital Oil Field and Plant Operations Excellence Solutions. The company
has its headquarters in Leuven (Belgium) and is active worldwide out of a number of regional offices (The
Netherlands, United Kingdom, United States, United Arab Emirates and India). Over the years, IPCOS has
built a strong reputation in various industries such as oil and gas, refining, petrochemical, gas processing
and chemical industries and has become one of the top services provider. Thanks to its upstream and
downstream specialists, IPCOS is able to cover the whole value chain, delivering integrated solutions to
its customers.

Visit our website https://www.ipcos.com/Aptitune to:

Download some AptiTune related Case Studies.

Have a look at AptiTune related Webinars on the IPCOS
YouTube Channel.
Walk through an animated AptiTune Demo on the IPCOS
YouTube Channel.
Ask for a free 2-week license,
Ask for some free hours on the AptiTune Go platform
Let us tune one of your loops for free!

IPCOS Headquarters:

Geldenaaksebaan 329,
B-3001 Leuven, Belgium
tel: 0032 16 39 30 83
[email protected]

Regional Offices:

Boxtel, The Netherlands

Cambridge, UK
Pune, India
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Houston, US

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