Interesting and Useful Features of the DeltaV PID Controller

James Beall Emerson Process Management

Introduction

Provide additional information on useful features of the DeltaV PID and related function blocks.
Discuss some common PID function block parameters where the default values can cause poor control.

Provide examples of the use of these features.

Note BOL is DeltaV Books on Line (the embedded, electronic DeltaV documentation)

Topics

PID Form PID Structure Integral Dead Band SP Filter/Rate of Change SP Limits Cascade Features

Gain Scheduler Non-linear Gain Output Characterization (to Valve) Anti-Reset Windup Limits Questions

PID Form

Three Common PID Forms

Parallel Form Standard, aka ISA Form, Series, aka Classical Form.

DeltaV has Choices

Standard (default) Series

PID Form - PID Function Block

DeltaV default is Standard Note that if you choose Nonlinear Gain in FRSPID_OPTS then the FORM becomes Standard More on this later
None Selects equation form (series or standard). If Use Nonlinear Gain Modification is selected in FRSIPID_OPTS, the form automatically becomes standard, regardless of the configured selection of FORM.

FORM

Standard Form of the PID Equation

1 TR s
I

Error = SP - PV
P

OUTPUT = P + I + D

SP +
-

KC
TDS

PV
+
PROCESS

Classical Form of the PID Equation

Error
P

TDS

OUTPUT + +
PROCESS

SP + -

KC

PV

+
1 TR s

PID Form Choice

Prior system experience Personal Preference for Standard or Series Series is identical to Standard form if Derivative action is NOT used Can impact conversion of tuning constants from previous control system

Convert Series (Classical) to Standard

Series is identical to Standard form if Derivative action is NOT used TR should be time/rep & same time units as TD Be sure to convert units after form conversion
KC Standard = KC Series * TR Series ++ TD TSeries Classical D Classical

TR Series Classical 0 0

TR Standard = TR Series

++ TT Series DD Classical

TD Standard =

0 ( TR Series ++ TD TSeries ) ) Classical D Classical

TR Series *T *D TSeries Classical D Classical

PID Function Block Structure Parameter

Used most. Default

PID Function Block Structure Parameter

SP Change on Reactor feed tank level: PI on error, D on PV

Controller Output Flow to reactor

SP

PID Function Block Structure Parameter

SP Change on Reactor feed tank level: I on error, PD on PV

Controller Output Flow to reactor

SP

PID Structure 2 Degrees of Freedom

BETA - determines the degree of proportional action that will be applied to SP changes.
Range = 0-1 BETA=0 means no proportional action is applied to SP change. BETA=1 means full proportional action is applied to SP change.

GAMMA - determines the degree of derivative action that will be applied to SP changes.
Range = 0-1 GAMMA=0 means no derivative action applied to SP change. GAMMA=1 means full derivative action is applied to SP change.

PID Structure 2 Degrees of Freedom

Integral Dead Band

IDEADBAND - When the error gets within IDEADBAND, the integral action stops. The proportional and derivative action continue. Same Engineering Units as PV Scale May be used to reduce the movement of the controller output when the error is less than the IDEADBAND. For example on a level controller that feeds the downstream unit.

Set Points Filter/Rate of Change

SP_FTIME - Time constant (seconds) of the first order SP filter. The Set Point Filter applies in AUTO, CAS and RCAS (not specified in BOL). SP_RATE_DN - Ramp rate at which downward setpoint changes are acted on in Auto mode, in PV units per second. If the ramp rate is set to 0.0, then the setpoint is used immediately. For control blocks, rate limiting applies only in Auto (not CAS or RCAS). SP_RATE_UP - Ramp rate at which upward setpoint changes are acted on in Auto mode, in PV units per second. If the ramp rate is set to 0.0, then the setpoint is used immediately. For control blocks, rate limiting applies only in Auto (not CAS or RCAS).

Set Point Limits

SP_HI_LIM- The highest SP value (EUs) allowed. SP_LO_LIM - The lowest SP value (EUs) allowed. Control Options allow you to specify if SP Limits to be obeyed in CAS and RCAS Can use Output Limits of Master loop in cascade pair to limit SP to Slave loop ONLY in CAS and RCAS

Cascade Features

Column Tray 6
LC 3-2 FC 3-5

Master Loop aka Primary Loop

RSP

Slave Loop aka Secondary Loop

LT 3-2

FT 3-5
Bottoms

Cascade Features

Mode tracking and bumpless transfers are automatically provided through the BKCAL feature Limited conditions in the Slave loop are taken care of through the BKCAL feature Prevent reset windup with external reset by selecting Dynamic Reset Limit in FRSIPID_OPTS on the Master loop Use PV for BKCAL_OUT in CONTROL_OPTS should be selected on Slave loop for use with Dynamic Reset Limit in Master

Enabling PID External Reset

Utilized most often in the primary loop of a cascade Automatically compensates for poor secondary loop response

Gain Scheduler

Proves up to 3 regions of different PID tuning parameters based on a selected state variable (output, PV, error, production rate, etc.) Provides a smooth transition between regions Create PID module using Module Templates: Analog Control/PID_GAINSCHED OR, add function to existing PID module
Expose Gain, Reset and Rate parameters on PID function block Copy all function blocks from template except the PID FB and link as needed.

Gain Scheduler
Module Templates: Analog Control/PID_GAINSCHED

Gain Scheduler

Gain Scheduler Detail Display

FRSIPID_OPTS: Non-linear Gain

Modifies the proportional Gain as a function of the error (PV-SP) Can be used to make the tuning more aggressive as the PV is farther from the set point Can create the error squared PID function

FRSIPID_OPTS: Non-linear Gain

The PID Gain is multiplied by KNL which has a value between 0 and 1 as a function of the error (SP-PV).
Knl Knl=1

Knl=NL_MINMOD e= NL_TBAND NL_GAP NL_HYST

PV-SP

FRSIPID_OPTS: Non-linear Gain

The PID Gain is multiplied by KNL which has a value between 0 and 1 as a function of the error I typically set NL_HYST = 0 Be aware that using this feature on an integrating process, like levels, can cause oscillations at the reduced gain. For these applications, the reset time should be based on Gain*MINMOD which will result in a larger reset time to prevent oscillations. For this affect on integrating processes, consider using the Gain Scheduler

FRSIPID_OPTS: Non-linear Gain Error2

Error squared PID function error*abs(error) Proportional = error*abs(error)*gain = error* (abs(error)*gain) Proportional = error*(Modified Gain) Non-linear Gain Modified Gain = abs(error)*Gain Settings for E2
Modified Gain

Error

Activate NL Gain NL_MINMOD = 0 NL_GAP = 0 NL_TBAND = 100 NL_HYST = 0

Output Characterization to Valve

Use a Signal Characterizer function block to change valve characteristics

Note the best solution is to change valve trim to proper characteristic

SGCR Characterizes IN_1 to OUT_1 Reverse Char. IN_2 to OUT_2

Output Characterization to Valve

See Books On Line for rules for the X and Y curves Set SWAP_2 = TRUE to provide a reverse characterization for the BKCAL signal (The answer in V9.3 and later is Change X by Y axis on IN-2.) BOL: The SWAP_2 parameter swaps the X and Y axes used for OUT_2. When the SWAP_2 parameter is True, IN_2 references the CURVE_Y values and OUT_2 references the CURVE_X values. In addition, the IN_2 units change to Y_UNITS and the OUT_2 units change to X_UNITS.

Anti-Reset Windup Limits

Improves process recovery from saturated conditions On recovery from a saturated condition, when the ARW_HI_LIM and ARW_LO_LIM are set inside the OUT limits, the reset time will automatically be decreased (faster) by 16X until the OUT parameter comes back within the the ARW limits or the control parameter reaches setpoint.

Setting ARW limits

PV

SP

OUT

ARW_LO_LIM OUT_LO_LIM

Setting ARW Limits Important!!!!!

ARW limits are in Engineering Units of the OUT_SCALE. The default is 0-100. If the OUT_SCALE is other than 0-100, be sure to initially set ARW limits to the OUT_SCALE limits.
For example, for the master loop of cascaded loops, the OUT_SCALE is 0-25,000 lbs/hr. Set ARW_HI_LIM = 25,000 and ARW_LO_LIM = 0.

Business Results Achieved

These features can be used to significantly improved the performance of PID control The default ARW limits of 0-100 is a common problems for the master loop in a cascade arrangement. Correcting the ARW limits improves control. These features can be used to customize the response of the PID controller to meet process requirements Difficult process dynamics can be handled Bottom line Better control performance = $$$$

Summary

DeltaV has many useful control features

Watch out for default parameters (ARW limits) that dont match your application Better control performance = $$$$ Questions

Where To Get More Information

Emerson Process Management Education Services

DeltaV Advanced Control Course: # 7201 - CEUs: 3.2 DeltaV Operate Implementation I Course: # 7009 - CEUs: 3.2 EnTech - Process Dynamics, Control and Tuning Course: # 9030 CEUs: 2.8

Emerson Process Management, Advanced Automation Services

http://www.emersonprocess.com/solutions/consulting/advancedautoma tion/index.asp

[email protected] , 903-235-7935

About the Presenter

James Beall is a Principal Process Control Consultant with Emerson Process Management. He has over 26 years experience in process control, including 7 years with Emerson and 19 years with Eastman Chemical Company. He graduated from Texas A&M University with Bachelor of Science degree in Electrical Engineering. His areas of expertise include process instrumentation, control strategy analysis and design, control optimization, DCS configuration and maintenance, control valve performance testing and Advanced Process Control. James is a contributing author to Process/Industrial Instruments and Control Handbook (5th Edition, G.K. McMillan, McGraw-Hill, New York, 1999. He is a member of AIChE and is currently the chairman of ISA Subcommittee 75.25, Control Valve Performance Testing.