Dr Ahmad Afshar Industrial Control

First Semester
1402-1403 Tuning of PID Controllers

Industrial Control

‫فصل پنجم‬

‫تنظیم پارامترهای کنترل کننده تام‬

PID Controller Tuning
‫‪Dr Ahmad Afshar‬‬ ‫‪Industrial Control‬‬
‫‪First Semester‬‬
‫‪1402-1403‬‬ ‫‪Tuning of PID Controllers‬‬

‫فهرست مطالب‬
‫اهمیت تنظیم پارامترهای کنترل کننده ها‬ ‫‪.1‬‬
‫تنظیم دستی پارامترها‬ ‫‪.2‬‬
‫تنظیم با روش ‪Ziegler–Nichols‬‬ ‫‪.3‬‬
‫تنظیم با روش های مبتنی بر مدل‬ ‫‪.4‬‬
‫تنظیم با روش های بدون مدل‬ ‫‪.5‬‬
Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

‫کتاب مرجع‬
Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

‫اهمیت تنظیم پارامترهای کنترل کننده ها‬

 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

The function of a feedback control system is to ensure that the

closed loop system has desirable dynamic and steady-state
response characteristics.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

The desired performance of closed-loop system

1.The closed-loop system must be stable.
2.The effects of disturbances are minimized, providing good disturbance
rejection.
3.Rapid, smooth responses to set-point changes are obtained, that is, good
set-point tracking.

4. Steady-state error (offset) is eliminated.

5. Excessive control action is avoided.

6.The control system is robust, that is, insensitive to changes in process

conditions and to inaccuracies in the process model.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

The desired performance of closed-loop system

 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Definition
Tuning is the procedure of adjusting the feedback controller parameters to
obtain a specified closed-loop performance.
For operation in a range of operating conditions, a compromise must be
reached in arriving at an acceptable set of tuning parameters.

1 𝑇𝑑 𝑠
𝐶 𝑠 = 𝐾𝑐 (1 + + )
𝑇𝑖 𝑠 1 + 𝜏𝑑 𝑠
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Disturbance input .vs. set point change

One shall make a distinction
between set point changes and
disturbance input when
adjusting PID parameters.

• Disturbances normally does

not cause abrupt changes in
the output

• Set point changes normally

lead to detectable changes
in the output

• Both can have small or

large amplitude
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Design criteria
PID by MATLAB

Consider parallel PID controller with transfer function

𝒌𝒅 𝒔𝟐 + 𝒌𝒑 𝒔 + 𝒌𝒊
𝑮 𝒔 =
𝒔
MATLAB code:
Kp = 1;
Ki = 1;
Kd = 1;
s = tf('s’);
C = Kp + Ki/s + Kd*s or
C = pid(Kp,Ki,Kd)
PID by MATLAB: Open loop step response
m = 1 kg
b = 10 N s/m
k = 20 N/m
F=1N

DC gain is 0.05
Steady-state error IS 0.95
Rise time is about one second
Settling time is about 1.5 seconds
PID by MATLAB: Proportional Control

The plot shows that the proportional

controller reduced both the rise time
and the steady-state error, increased
the overshoot, and decreased the
settling time by a small amount.
PID by MATLAB: PD Control

The plot shows that the

addition of the derivative term
reduced both the overshoot
and the settling time, and had
a negligible effect on the rise
time and the steady-state error.
PID by MATLAB: PI Control

The response shows that the

integral controller eliminated
the steady-state error in this
case.
PID by MATLAB: PID Control

we have a closed-loop
system with no overshoot,
fast rise time, and no
steady-state error.
Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

‫تنظیم دستی پارامترها‬

Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

PID parameters affect system dynamics

 Bode plot of PID controller
Bode plots of ideal
parallel PID controller
and series PID
controller with
derivative filter
• Ideal parallel:
 1 
Gc ( s ) = 2 1 + + 4s 
 10 s 

• Series with
Derivative Filter:

 10 s + 1  4 s + 1 
Gc ( s ) = 2   
 10 s  0.4 s + 1 
Bode plot of PID controller
The PID gain bode plot is shown below illustrating the effect of changing only
the proportional factor (KP). As can be seen, increasing KP not only increases
the mid-frequency range proportional factor, but also lowers the frequency at
which the integration factor ceases effectiveness and raises the frequency at
which the differential factor begins to kick in. The effect of lowering KP is also
illustrated.
Bode plot of PID controller

Proportional band adjustment move notch up and down

Bode plot of PID controller
Changing the integration factor (KI) has the impact shown below. Not only
does it affect the low frequency gain, but it changes the frequency at which the
proportional factor (KP) becomes effective. It would be most desirable to raise
KI as high as possible, but the higher it gets, the more negative a phase shift is
introduced in the proportional range where the servo bandwidth normally
ends up. This reduces the phase margin of the system, causing overshoots and
ringing.
Bode plot of PID controller

Effect of rate and reset adjustments on frequency response

Rate adjustment narrows and widens the The notch can be made high and narrow or
right side of the notch low and wide
Bode plot of PID controller
Increasing the differential gain (KD) lowers the frequency at which it has more
impact than the proportional factor (KP). This introduces positive phase shift
in the proportional range to help offset the negative phase shift from the
integration factor KI, thereby improving the phase margin and reducing the
ringing. It has the undesirable effect, however, of increasing the high
frequency gain, making the system more noise sensitive and encouraging the
undesirable effects of natural resonances.
Bode plot of PID controller

Initial low, wide notch Raising the bottom of the notch

PB Reset Rate

Common 200% 1 RPM 0 min

Systems
Slow 200% 0.1 RPM 0.2 min
Systems

Initial adjustment for PID parameters

Rule of thump Comparing large PB with small PB
Trial and error calculations
Below are some common values of Kc, Ti, and Td used in controlling flow, levels,
pressure or temperature for trial and error calculations.

Flow
P or PI control can be used with low controller gain. Use PI control for more accuracy
with high integration activity. Derivative control is not considered due to the rapid
fluctuations in flow dynamics with lots of noise.
Kc = 0.4-0.65 Ti = 6s

Level
P or PI control can be used, although PI control is more common due to inaccuracies
incurred due to offsets in P-only control. Derivative control is not considered due to the
rapid fluctuations in flow dynamics with lots of noise.
The following P only setting is such that the control valve is fully open when the vessel
is 75% full and fully closed when 25% full, being half open when 50% filled.
Kc = 2 Bias b = 50% Set point = 50%
For PI control:
Kc = 2-20 Ti = 1-5 min
Trial and error calculations
Pressure
Tuning here has a large range of possible values of Kc and Ti for use in PI control,
depending on if the pressure measurement is in liquid or gas phase.
Liquid
Kc = 0.5-2
Ti = 6-15 s
Gas
Kc = 2-10
Ti = 2-10 min

Temperature
Due to the relatively slow response of temperature sensors to dynamic temperature
changes, PID controllers are used.
Kc = 2-10
Ti = 2-10 min
Td = 0-5 min
Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

‫تنظیم پارامترها با روش‬

Ziegler and Nichols
 Ziegler and Nichols second method
Continuous Cycling Method
Ziegler and Nichols (1942) introduced the continuous cycling
method for controller tuning. Also known as Z-N second
method.
Based on the following trial-and-error procedure:

Step 1. After the process has reached steady state (at least
approximately), eliminate the integral and derivative control
action by setting:
TD= zero
TI = the largest possible value
Step 2. Set KP equal to a small value (e.g., 0.5) and
place the controller in the automatic mode.
Step 3. Gradually increase KP in small increments
until continuous cycling occurs. The term continuous
cycling refers to a sustained oscillation with a
constant amplitude.
Ultimate gain, Ku - The numerical value of KP that
produces continuous cycling (for proportional-only
control)
Ultimate period, Pu - The period of the corresponding
sustained oscillation
 Ziegler and Nichols method: Continuous Cycling Method

(a)KP<KU (b)KP=KU

(a)KP>KU (without saturation) (a)KP>KU (with saturation)

 Ziegler and Nichols method: Continuous Cycling Method
Step 4. Calculate the PID controller settings using the Ziegler-
Nichols (Z-N) tuning relations given in Table.

Step 5. Evaluate the Z-N Controll Kp TI TD

controller settings by er type
introducing a small set- P KU/2 - -
point change and
observing the closed-loop PI KU/2.2 PU/1.2 -
response. Fine-tune the
PID KU/1.7 PU/2 PU/8
settings, if necessary.
(series)

PID KU/1.33 PU/1.6 PU/10

(parallel)
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Ultimate frequency in the bode diagram

open loop gain

Open loop phase(deg)

Frequency (rad/min)
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Ziegler and Nichols first method

Quarter Decay Ratio (QDR) response
Also known as Ziegler and Nichols first method, introduced in 1942.

Two steps are involved:

1- The determination of the dynamic characteristics by open loop step test.
2- The estimation of the controller tuning parameters from table.
Not applicable to Integrating and unstable processes.

𝑨𝟐 𝟏
≈
𝑨𝟏 𝟒
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Quarter Decay Ratio (QDR) response

Do a step test:
a. Put the controller in manual and wait for the process to settle out
b. Make a step change in the controller output (CO) of a few percent and wait
for the process variable (PV) to settle out. The size of this step should be
large enough that the PV moves well clear of the process noise/disturbance
level. A total movement of five times more than the peak-to-peak level of the
noise and disturbances on the PV should be sufficient.
c. Determine FOPDT parameters from the reaction curve (step response)
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Quarter Decay Ratio (QDR) response

To determine the FOPDT variables, three methods are available:
1- Tangent method
𝑲𝒆−𝒕𝟎𝑺 𝜟𝑪 𝒄𝒉𝒂𝒏𝒈𝒆 𝒊𝒏 𝒐𝒖𝒕𝒑𝒖𝒕
2- Tangent and point method 𝑮(𝒔) = 𝑲= =
𝟏 + 𝝉𝒔 𝜟𝒎 𝒄𝒉𝒂𝒏𝒈𝒆 𝒊𝒏 𝒊𝒏𝒑𝒖𝒕

3- Two points method

Tangent Method
The time constant is then defined as the distance in the time axis between the point
where the tangent crosses the initial steady state of the output variable and the point
where it crosses the new steady-state value. The dead time is the distance in the time
axis between the occurrence of the input step change and the point where the tangent
line crosses the initial steady state.

t0 𝝉 𝒕𝟏
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Quarter Decay Ratio (QDR) response

Tangent-and-Point Method
The time constant is then the period of time between the point where the tangent line
crosses the initial steady state and the point where the response reaches 63.2% of the
total change. 𝝉 = 𝒕𝟏 − 𝒕𝟎

Two-Points Method
The two-point method makes use of the 63.2% point (t=𝝉) defined in the tangent-and-
point method as well as one other point: where the step response reaches 28.3%
(t=𝝉/𝟑) of its total steady-state change.
𝝉 = 𝟏. 𝟓(𝒕𝟏 − 𝒕𝟐 )
𝒕𝟎 = 𝒕𝟏 − 𝝉
0,632 k

0,283 k

𝒕𝟐 𝒕𝟏
t0 𝝉 𝒕𝟏 t0
Tangent-and-Point Method Two Points Method
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Quarter Decay Ratio (QDR) response :

• Determine controller settings from the Z-N table.
• Close the control loop by placing the controller in automatic mode.
• Test thoroughly, fine-tuning the parameters to obtain the QDR.
KP=Kc
Controller Kc TI TD
type

P 𝝉/Kt0 - -
PI 0.9𝝉/Kt0 o.33t0 -

PID 1. 𝟐𝝉/Kt0 2t0 o.5t0

(series)

PID 1. 𝟐𝝉/Kt0 2.5t0 o.4t0

(parallel)

Tuning Formulas for Quarter-decay Ratio Response

 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Uncontrollability parameter
It also allows us to define the ratio of dead time to time constant as the
uncontrollability parameter of the loop:
𝒕𝟎
𝑷𝒖 =
𝝉
Where:
𝒕𝟎 = process dead time
𝝉 = process time constant

the uncontrollability parameter for digital controllers is as follows:

𝑻
𝒕𝟎 + 𝟐𝒔
𝑷𝒖 =
𝝉
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Example: Temperature control of steam heater

Step test:
0.8 mA (5%) change in controller output causes a SS change in temperature of 5.0 C.

Steam heater control system Step response of steam heater

 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Step Response
0.8 mA change in controller output causes a SS change in temperature of 5.0 C.
Assume the transmitter range for the steam heater is 50°C to 150°C.

Graphical determination of time constant

and dead time from step response
K = 5.0 % T.O. /5.0 % C.O. = 1% T.O. /% C.O.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

FOPDT model parameters

Since the tangent method
1- Tangent method gives the smallest value for
Dead time plus time constant 0.98 𝒎𝒊𝒏 the uncontrollability
Dead time 𝒕𝟎 = 𝟎. 𝟏𝟐 𝒎𝒊𝒏 parameter—that is,
Time constant: 𝝉 = 𝟎. 𝟗𝟖 − 𝟎. 𝟏𝟐 = 𝟎. 𝟖𝟔 𝒎𝒊𝒏 shortest dead time and
longest time constant—it
results in the tightest
2- Tangent and point method
tuning,
𝑻 = 𝟗𝟎. 𝟎 + 𝟎. 𝟔𝟑𝟐 𝟓. 𝟎 = 𝟗𝟑. 𝟐𝒐𝑪
while the two-point
𝒕𝟏 = 𝟎. 𝟕𝟑 𝒎𝒊𝒏
method produces the
Time constant: 𝝉 = 𝟎. 𝟕𝟑 − 𝟎. 𝟏𝟐 = 𝟎. 𝟔𝟏 𝒎𝒊𝒏
highest value for the
uncontrollability
3- Two points method parameter and thus the
𝑻 = 𝟗𝟎. 𝟎 + 𝟎. 𝟐𝟖𝟑 𝟓. 𝟎 = 𝟗𝟏. 𝟒𝒐𝑪 most conservative tuning.
𝒕𝟐 = 𝟎. 𝟑𝟔 𝒎𝒊𝒏
𝝉 = 𝟏. 𝟓(𝟎. 𝟕𝟑 − 𝟎. 𝟑𝟔) = 𝟎. 𝟓𝟔 𝒎𝒊𝒏
𝒕𝟎 = 𝟎. 𝟕𝟑 − 𝟎. 𝟑𝟔 = 𝟎. 𝟏𝟕 𝒎𝒊𝒏
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

ZN second method Example

A 1oC change in set point is used to start the oscillation. System response for the
proportional controller is shown. There is a sustained oscillation for a gain of 15%
C.O./% T.O. which is the ultimate gain.
Ultimate gain: 15.0 % C.O. / % T.O. (=100/15= 6.7 % PB)
Ultimate period: 0.5 min

Using the table equations:

 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers
ZN second method Example
The response of the controller output and of the outlet process temperature to
an increase in process flow for the P and PI controller with the QDR gain of
7.5%C.O./%T.O. and with a gain of 4.0%C.O./%T.O is shown below.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

ZN second method Example

The response of the controller output and of the outlet process temperature to an
increase in process flow for the parallel PID controller with the QDR gain of
11.25%C.O./%T.O. and with a gain of 6.0%C.O./%T.O is shown below.
Relay Auto-Tuning
•Åström and Hägglund (1984) have developed an attractive
alternative to the continuous cycling method.
•In the relay auto-tuning method, a simple experimental test
is used to determine Ku and Pu.
•For this test, the feedback controller is temporarily replaced
by an on-off controller (or relay).
•After the control loop is closed, the controlled variable
exhibits a sustained oscillation that is characteristic of on-off
control. The operation of the relay auto-tuner includes a dead
band as shown in next slide.
•The dead band is used to avoid frequent switching caused
by measurement noise.
Relay Auto-Tuning

𝟐𝒉
Relay Auto-Tuning

•The relay auto-tuning method has several important

advantages compared to the continuous cycling method:

1.Only a single experiment test is required instead of a

trial-and-error procedure.
2.The amplitude of the process output a can be restricted
by adjusting relay amplitude h.
3.The process is not forced to a stability limit.
4.The experimental test is easily automated using
commercial products.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Example
Heat Exchanger Temperature Control: PI versus PID Performance with QDR Tuning.
To tune the proportional-integral (PI) and the proportional-integral-derivative (PID)
controllers for QDR response on the temperature controller, use the process
parameters estimated by the tangent method:
K= 1.0 % C.O. /% T.O. 𝝉= 0.86 min 𝒕𝟎 =0.12 min
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Internal Model Control (IMC) tuning rules

✓ One of the simplest and most effective methods proposed for tuning
feedback controllers. This method has come to be known It was originally
introduced under the name “controller synthesis” by Martin in 1975 and
then further developed by Smith and Corripio.
✓ For the first-order-plus-dead-time process model, the IMC tuning rules
consist of setting the integral time equal to the process time constant and
the derivative time equal to one half the process dead time. The process
gain is then adjusted to obtain the desired response of the loop.
✓ The following formulas are to be used with the series PID controller:
𝑻′𝑰 = 𝝉
𝒕𝟎
𝑻′𝑫 =
𝟐
✓ When the process dead time is very small compared with the process time
constant, the effect of the derivative time is minor, and a PI controller can
be used in which the integral time is equal to the process time constant.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Gain Adjustment
✓ For good response to disturbances, when Pu is between 0.1 and 0.5, use the
formula:
𝟐𝝉
𝑲′𝒄 =
𝑲𝒕𝟎
✓ When Pu is less than 0.1 or greater than 0.5, you should use one half
this gain as the starting value.
✓ For optimum response to changes in set point, when Pu is in the range 0.1 to 0.5
and when using a PI controller, the following formula is appropriate:
𝟎. 𝟔𝝉
𝑲𝒄 =
𝑲𝒕𝟎
✓ For optimum response to changes in set point, when Pu is in the
𝟎.𝟖𝟑𝝉
range 0.1 to 0.5 and using a PID controller, use this formula: 𝑲𝒄 =
𝑲𝒕𝟎

✓ For 5 percent overshoot on set point changes, use the following formula:
𝟎. 𝟓𝝉
𝑲𝒄 =
𝑲𝒕𝟎
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers
Example: Heat Exchanger Temperature Control QDR versus IMC
This example compares the tuning of a PID controller using QDR tuning versus
IMC tuning. The QDR tuning parameters of the PID controller are the same as
previous example.
Recall that these parameters were obtained from the process parameters estimated
by the tangent method. By contrast, the process parameters estimated by the two-
point method are used to tune the IMC controller.
This is because the two-point method is simpler and more reproducible than the
other two methods. The process parameters are as follows:
K= 1.0 % T.O. /% C.O. 𝝉= 0.56 min 𝒕𝟎 =0.17 min
IMC tuning rules
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers
Example: Heat Exchanger Temperature Control QDR versus IMC
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers
Example: Heat Exchanger Temperature Control QDR versus IMC
To compare the performance to set point changes, the IMC gain must be adjusted to
the value recommended for set point changes.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

PID Control of a Controllable Process

Consider a controllable process with the following parameters:
K = 2.0 %T.O./%C.O. , τ = 5 min, t0 = 0.25 min.
The controllability parameter for this process is Pu = 0.25/0.5 = 0.5, which is
below the limits of most tuning correlations. Since the dead time is small, a
PI controller is appropriate for controlling the process. The tuning
parameters for QDR and for IMC are as follows:

Where the gain of the IMC controller has been taken as one half the gain
given for disturbance inputs because the uncontrollability parameter is less
than 0.1. Notice that the gains are rather high, which indicates very tight
control.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

PID Control of a Controllable Process

 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

PID Control of a Process with Low Controllability

Processes that consist of many lags in series, or that exhibit true
dead time, are difficult to control by feedback control alone.
Consider a process with the following parameters:
K = 2.0 %T.O./%C.O. τ = 5 min t0 = 5 min

The uncontrollability parameter is Pu = 5/5 = 1.0, which is high.

Because of this, a PID controller is appropriate. From the QDR
tuning formulas and the IMC formulas, the controller parameters
for this process are as follows:

Notice that in this case the IMC formulas call for a faster integral
time than do the QDR formulas. The IMC gain is half the one
predicted for disturbance inputs because the uncontrollability
parameter is greater than 0.5.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

PID Control of a Process with Low Controllability

 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

PID Control of a Process with Low Controllability

✓ Derivative mode provides superior performance for processes with a
high dead-time-to-time-constant ratio.

✓ Except for controllers that must constantly respond to set point

changes (e.g., slaves in cascade loops), the controller
should be tuned for good performance on disturbance inputs, and
sudden set point changes should be limited in magnitude.

✓ For very controllable processes, high controller gains are possible, but
they should be avoided when large variations in the controller output
may upset the process.

✓ For very uncontrollable processes, even the best attainable response

produced by the tuning formulas is not good. For these processes,
alternatives to simple feedback control should be explored.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers
Practical Controller Tuning Tips
This section presents seven tips that I hope will help you make your
controller tuning task more efficient and satisfying.
1. Tune coarse, not fine.
Realizing that the performance of a feedback controller is not sensitive to
the precise adjustment of its tuning parameters significantly simplifies the
tuning task. You will be satisfied by the large improvements in performance
that can be achieved by coarse. When tuning a controller, I seldom change a
parameter by less than half its current value.
2. Tune with confidence.
One effective approach is to select the integral time first and set the
derivative time to about one-fourth of the integral time, or, if the dead time
is known, to one half the dead time. Then adjust the proportional gain to
obtain tight control of the controlled variable without undue variations in
the manipulated variable. If the response is still too oscillatory, double the
integral and derivative times, or, if the response approaches the set point too
slowly, cut the integral and derivative times in half; then readjust
the gain. When you obtain satisfactory performance, leave it alone.
Do not try to fine-tune it further.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

✓ Practical Controller Tuning Tips

3. Use all of the available information.
You may be able to gather enough information about the process
equipment to estimate the gain, time constant, and dead time of
the process without having to resort to the open-loop step test. You can
also gather information during trial-and-error tuning, which allows you
to estimate the integral and derivative times from the period of
oscillation of the loop or from the total delay around the loop (dead time
plus time constant). The total delay around the loop can be estimated as
the time difference between peaks in the controller output and the
corresponding peaks in the transmitter signal.

✓ 4. Try a longer integral time.

Many times, poor loop response can be the result of trying to bring
the controlled variable back to its set point faster than the process
can respond. In such cases, increasing the integral time allows an
increase in the process gain and an improvement in the response.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers
✓ Practical Controller Tuning Tips
5. Tuning very controllable processes.
Processes with uncontrollability parameters less than 0.1 have very
large ultimate gains, which are difficult to determine using the
closed-loop method. When the uncontrollability parameter is less than 0.1, most
tuning formulas result in very high gains and very fast integral times, both of
which should be used only rarely. In other words, it is a good idea to let your
judgment override the tuning formulas.

✓ 6. Tuning very uncontrollable processes.

For processes with uncontrollability parameters of 1 and higher, it
is important to recognize that even the optimally tuned feedback
controller will result in poor performance, that is, large initial
deviations on disturbance inputs and slow return to set point.

✓ 7. Beware of problems that are not related to tuning.

• Reset windup, which is caused by saturation of the controller output.
• Interaction between loops.
• Processes with inverse or overshoot response,
• Changes in process parameters because of nonlinearities.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Modified Ziegler-Nichols Method

The tuning rules were developed to give good load disturbance rejection, but this
also gives a closed-loop system that is poorly damped and has a poor stability
margins. The Ziegler-Nichols frequency response method can be interpreted as a
method where the identified point of the Nyquist curve is moved to a new position.
With a PI or PID controller a given point on the Nyquist curve can be moved to an
arbitrary position in the complex plane.

1
𝐺𝑐 𝑠 = 𝐾𝑃 (1 + 𝑇𝑑 𝑠 + )
𝑇𝑖 𝑠
𝑗
𝐺𝑐 𝑗𝜔 = 𝐾𝑃 1 + 𝑗𝜔𝑇𝑑 −
𝜔𝑇𝑖
At any frequency 𝜔0
𝑗
𝐺𝑐 𝑗𝜔0 = 𝐾𝑃 1 + 𝑗𝜔0 𝑇𝑑 − = 𝑟𝑐 𝑒 𝑗 𝜋+𝜑𝑐
𝜔0 𝑇 𝑖
At the ultimate frequency
𝐾𝑃 = 0.6𝐾𝑢 , 𝜔𝑢 𝑇𝑖 = 𝜋 , 𝜔𝑢 𝑇𝐷 = 𝜋ൗ4

𝑗
𝐺𝑐 𝑗𝜔𝑢 = 𝐾𝑃 1 + 𝑗𝜔𝑢 𝑇𝑑 − = 0.6𝐾𝑢 (1 + 𝑗(𝜋Τ4- 1Τ𝜋)) = 0.6𝐾𝑢 1 + 𝑗0.407 =
𝜔𝑢 𝑇 𝑖
°
0.6622𝐾𝑢 𝑒 𝑗25
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Modified Ziegler-Nichols Method

Similarly for points a and b on the Nyquist diagram:

Point A: 𝐺 𝑗𝜔0 = 𝑟𝑎 𝑒 𝑗 𝜋+𝜑𝑎

Point B: 𝐺 𝑗𝜔0 = 𝑟𝑏 𝑒 𝑗 𝜋+𝜑𝑏

To move identified point A to a specified position B with a PID controller is

formulated as:
𝑟𝑐 𝑒 𝑗 𝜋+𝜑𝑐 𝑟𝑎 𝑒 𝑗 𝜋+𝜑𝑎 = 𝑟𝑏 𝑒 𝑗 𝜋+𝜑𝑏

Where 𝑟𝑎 𝑒 𝑗 𝜋+𝜑𝑎 describes the

specified position A.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Modified Ziegler-Nichols Method

2
1 𝑟𝑏
𝐾𝑃 1 + 𝜔0 𝑇𝐷 − =
𝜔0 𝑇𝐼 𝑟𝑎

1
𝜔0 𝑇𝐷 − = tan(𝜑𝑏 − 𝜑𝑎 )
𝜔0 𝑇𝐼

By combining the above equations, 𝐾𝑃 is obtained as:

𝑟𝑏
𝐾𝑃 1 + tan2 (𝜑𝑏 − 𝜑𝑎 ) =
𝑟𝑎
𝑟𝑏
𝐾𝑃 = 𝑐𝑜𝑠(𝜑𝑏 − 𝜑𝑎 )
𝑟𝑎
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Modified Ziegler-Nichols Method

To be able to solve 𝑇I and 𝑇𝐷 uniquely, an additional conditions has to be introduced:

𝑇𝐷 = 𝛿𝑇𝐼

Stating that there is a constant ration between 𝑇I and 𝑇𝐷 .

1
𝑇I = (tan 𝜑𝑏 − 𝜑𝑎 + 4𝛿 + tan2 𝜑𝑏 − 𝜑𝑎 )
2𝜔0 𝛿
1
𝑇D = (tan 𝜑𝑏 − 𝜑𝑎 + 4𝛿 + tan2 𝜑𝑏 − 𝜑𝑎 )
2𝜔0

By changing 𝛿, you can decide on the relative effects of integral and derivative terms
based on our previous discussions.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Tuning Formulas for optimal control

𝑡0

𝑡0
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers
EXAMPLE
𝑮𝒂𝒊𝒏 = 𝟏. 𝟎 %𝑻. 𝑶./%𝑪. 𝑶.

Tangent Method 𝑻𝒂𝒏𝒈𝒆𝒏𝒕 𝒂𝒏𝒅 𝑻𝒘𝒐 − 𝒑𝒐𝒊𝒏𝒕

𝑷𝒐𝒊𝒏𝒕 𝑴𝒕𝒉𝒐𝒅 𝑴𝒆𝒕𝒉𝒐𝒅

Time Constant, 0.82 0.62 0.55

min
Dead time, min 0.13 0.13 0.2
Uncontrollability 0.16 0.21 0.36
parameter

QDR with tangent method

𝑲𝒄 %/% 𝑻𝑰 , 𝒎𝒊𝒏 𝑻𝑫 , 𝒎𝒊𝒏

P 6.2 - -
PI 5.5 0.44 -
PID series 7.4 0.27 0.07
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers
Example
Process gain= 1%/%, time constant=0.62 min, dead time= 0.13 min
10oC step increase in process inlet temperature.
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers
Minimum error integral PI tuning for Disturbance inputs

Process gain= 1%/%, time constant=0.62 min, dead time= 0.13 min

𝑲𝒄 %/% 𝑻𝑰 , 𝒎𝒊𝒏

Minimum IAE 4.4 0.34

Minimum ISE 5.7 0.40

Minimum ITAE 3.8 0.32

 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers
Minimum error integral PI tuning for Disturbance inputs
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Compare the performance of a series PID controller tuned by min

IAE on disturbance and set-point inputs.
𝑲𝒄 %/% 𝑻𝑰 , 𝒎𝒊𝒏 𝑻𝑫 , 𝒎𝒊𝒏

Disturbance Tuning 3.8 0.14 0.08

Set point Tuning 3.8 0.81 0.06

 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers
Minimum error integral PI tuning for Disturbance inputs
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Example 1:
Consider a 4th-order system:
𝟏
𝑮 𝒔 =
𝒔(𝒔+𝟏)(𝒔+𝟐)(𝒔+𝟑)
Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Example 2
A 4th-order system with a repeated pole.
𝟏
𝑮 𝒔 =
(𝒔 + 𝟏)𝟒
Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers
 Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers

Calculation of Tuning Parameters for Optimal Controllers

Dr Ahmad Afshar Industrial Control
First Semester
1402-1403 Tuning of PID Controllers