P9

Pressure Control
List of Experiments:
1. Tuning of Controllers (open Loop)
2. Tuning of Controllers (closed Loop)
3. Tuning of Controllers (Auto tune)

THEORY

Controller Tuning
The three-mode PID controller is the most commonly used feedback controller in
industrial automation. The process of determining the optimal values for its parameters,
based on the complexity and nature of the system, is referred to as loop tuning. These
parameters are chosen to achieve specific objectives, such as minimizing steady-state
error, maintaining robustness against disturbances, and ensuring a desirable transient
response to setpoint changes and external disruptions.
In practice, selecting the proportional band, integral time, and derivative time requires
balancing setpoint tracking and disturbance rejection. If a mathematical model of the
process is available, tuning the controller is relatively straightforward. However, in many
industrial settings, obtaining an accurate model is either challenging or impractical. To
address this, empirical tuning methods have been developed that do not rely on
mathematical models. One of the most widely used techniques was introduced by Ziegler
and Nichols in 1942, offering both open-loop and closed-loop tuning approaches.
1. TUNING OF CONTROLLER (OPEN LOOP METHOD)

Aim: To study tuning of controller using open loop method

Theory (Open loop method (Process reaction curve method))

In open loop method the process is assumed to be model of first order. The step response
i.e. process reaction curve, allows to obtain the approximate values of P, I and D
parameters. With the feedback loop open, a step response is applied to manipulated
variable and the values of P, I and D are estimated.
4
0
30
Variable

Y
20
Controlled

10

L X

0 10 20 30 40
Time

Open loop response for input step change (Process reaction curve)
Where
%𝐶ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑉𝑎𝑟𝑖𝑎𝑏𝑙𝑒𝑠 𝑌
𝑅= =
𝑡𝑖𝑚𝑒 (𝑠𝑒𝑐) 𝑋
Slope R: Slope of line drawn tangent to the point of inflection.
Dead time L: Time between the step change and the point where tangent line crosses the
initial value of the controlled variable (in sec.)
∆P = Step change applied in %

Using these parameters, the empirical equations are used to predict the controller settings
for a decay ratio of 1/4.

For P, PI and PID controller the parameters are calculated as follows.

Mode Proportional band Integral time Derivative time
(in %) (in sec) (in sec)
P 100RL/∆P
P+I 110RL/ ∆P L/0.3
P+I+D 83RL/ ∆P L/0.5 0.5L
Procedure
• Start the set up, adjust the vent valve.
• Select Process Reaction option for control from software. (Click on “Change Expt.”
Button, click on “Change”, Click on “Process Reaction” button.)
• Adjust controller output, so that the process value is maintained at 50%.
• Start data logging.
• With the controller still in manual mode impose a step change apply a 20 - 30 %
change to controller output. (Open the control valve) Record the step response. Wait
for the steady state.
• Stop data logging.
• Plot the step response (Process reaction curve) from stored data. Find out the value of
slope at the point of inflection and time lag.
• Calculate P I D settings for different modes.
• Select PID Mode option for control from software. (Click on “Change Expt.” Button,
click on “Change”, Click on “PID Mode” button.) Switch on the controller to manual
mode and Keep the set point to 50%. Adjust output value so as to match the process
value to set point.
• Set the PID values obtained from the calculations. Switch on the controller to Auto
mode. Apply the step change & observe the response of the system. Allow the system
to reach steady state.

Observations
(Refer theory for formula.)
• Step change to the system ∆P = Initial output - Final output of the controller.
• Plot the graph of process value Vs Time on a graph paper.
From process reaction curve:
• Slope of the process reaction curve R =
• Time lag L=

Calculate P, PI, PID setting from above values.

• Observe response of the system for different PID settings.

2. TUNING OF CONTROLLER (CLOSED LOOP METHOD)

AIM: To study tuning of controller using closed loop method

Theory (Closed loop method (Ultimate gain method))

This method is also called as ultimate gain method. The term ultimate was attached to this
method because its use requires the determination of the ultimate proportional band and
ultimate period. The ultimate proportional band, PBu is the minimum allowable value of
proportional band (for a controller with only proportional mode) for which the system
continuously oscillates at constant amplitude. The ultimate period, Tu is the period of
response with the proportional band set to its ultimate value. To determine the ultimate
proportional band and ultimate period the proportional band of the controller (with all
integral and derivative action turned off) is gradually reduced until the process cycles
continuously.

The process is placed in the closed loop with a proportional controller. The Proportional
band is decreased until the process goes to continuous oscillations. The Corresponding
value of proportional band is called as ultimate proportional band PBu and the period of
oscillation is called the ultimate period Tu. The PID controller parameters are selected
from the following table.

Procedure
• Start the set up, adjust the vent valve.
• Select Close Loop option for control from software. (Click on “Change Expt.” Button,
click on “Change”, Click on “Close Loop” button.)
• Set the proportional band value to maximum (Say 100). Set the controller to manual
mode and adjust the output so that the process is nearly at set point (50%).
• Set controller to auto mode and impose step on the process by moving the set point for
a few seconds & then return to its original value (or apply the step change to the set
point of 5%). Wait for some time & observe the response.
• Decrease the proportional band to the half of previous and impose step on the process
as mentioned above. Wait for some time & observe the response.
• Repeat the above procedure and find out correct value of proportional band for which
 the system just goes unstable i.e. continuous oscillations are observed in the output of
controller.
• Record the ultimate proportional band and ultimate period from the response.
• Calculate the PID values from the table. Select the PID controller and apply the
parameter values obtained from the above steps. Observe the response of the process to
a step change with these settings.

Observations
• Record the ultimate proportional band (Pbu) and ultimate period (Tu) from above
experiment.
• Calculate PID values by referring theory part for different control actions.
• Observe the process response for these settings.
• Compare the values obtained with open loop response method.

3. TUNING OF CONTROLLER (USING AUTO TUNING METHOD)

AIM: To study tuning of controller using AutoTuning method

Procedure
• Start the set up, adjust the vent valve to keep @ 50 % pressure.
• Adjust the set point to 50%
• Select Autotune option for control from software. (Click on “Change Expt.” Button,
click on “Change”, Click on “Autotune” button.)
• Wait Till Autotune is complete. (Blinking of green LED stops).
• Controller automatically finds the PB, IT & DT values.

Observation:
• Find out PID values at different set points /vent valve positions rates.

Results
Open loop Response (Graph)

58
57
56
Control Variable

55
54
53
52
51
50
49
0 20 40 60
Time (in sec)
Closed loop Response (Graph)

50

49

Control Variable
48

47

46

45

44
0 10 20 30 40 50
Time ( in sec )