Instrumentation and Process Control

Series 3531

Process Control
Temperature

Courseware Sample
86010-F0

A
 INSTRUMENTATION AND PROCESS CONTROL
SERIES 3531

PROCESS CONTROL
Temperature

Courseware Sample

by
the staff
of
Lab-Volt Ltd.

Copyright © 2011 Lab-Volt Ltd.

All rights reserved. No part of this publication may be
reproduced, in any form or by any means, without the prior
written permission of Lab-Volt Ltd.

Printed in Canada
April 2011
 Foreword
Automated process control offers so many advantages over manual control that
the majority of today’s industrial processes use it at least to some extent.
Breweries, wastewater treatment plants, mining facilities, the automotive
industry, and just about every other industry sector use it.

Maintaining process variables such as pressure, flow, level, temperature, and pH

within a desired operating range is of the utmost importance when manufacturing
products with a predictable composition and quality.

The Instrumentation and Process Control Training System, series 353X, is a

state-of-the-art system that faithfully reproduces an industrial environment in
which students can develop their skills in the installation and operation of
equipment used in the process control field. The use of modern, industrial-grade
equipment is instrumental in teaching the theoretical and hands-on knowledge
that is required to work in the process control industry.

The modularity of the system allows the instructor to select the equipment
required to meet the objectives of a specific course. Two versatile, mobile
workstations, on which all of the equipment is installed, form the basis of the
system. Several optional components used in pressure, flow, level, temperature,
and pH control loops are available, as well as various valves, calibration
equipment, controllers, and software.

We hope that your learning experience with the Instrumentation and Process
Control Training System will be the first step toward a successful career in the
process control industry.

A Process Control v
 Table of Contents
Unit 1 Process Characteristics................................................................ 1
Process control system. The study of dynamical systems. The
controller point of view. Dynamics. Types of processes.
Process characteristics.

Ex. 1-1 Determining the Dynamic Characteristics of a

Process ........................................................................... 15
Open-loop method. How to obtain an open-loop
response curve. Preliminary analysis of the open-loop
response curve. Analyzing the response curve.

Unit 2 Feedback Control ........................................................................ 33

Feedback control. On-off control. PID control. Proportional
controller. Proportional and integral controller. Proportional,
integral, and derivative controller. Proportional and derivative
controller. Comparison between the P, PI, and PID control. The
proportional, integral, and derivative action. Structure of
controllers.

Ex. 2-1 Tuning and Control of a Temperature Loop ............... 53

Recapitulation of relevant control schemes. Tuning
with the trial-and-error method. Tuning with the
ultimate-cycle method. Limits of the ultimate-cycle
method. The open-loop Ziegler-Nichols method.

Unit 3 Troubleshooting a Process Control System ............................ 75

Troubleshooting. Plant shutdown.

Ex. 3-1 Guided Process Control Troubleshooting .................. 81

Setting the scene.

Appendix A I.S.A. Standard and Instrument Symbols .................................. 85

Introduction. Function designation symbols. General
instrument symbols. Instrument line symbols. Other component
symbols.
Index .................................................................................................................... 97
Bibliography ......................................................................................................... 99
We Value Your Opinion! .................................................................................... 101

A Process Control vii

Sample Exercise
Extracted from
Student Manual
 Exercise 2-1

Tuning and Control of a Temperature Loop

EXERCISE OBJECTIVE When you have completed this exercise, you will be familiar with three different
methods for tuning your controller and you will have gained experience using at
least one of them on a temperature process.

DISCUSSION OUTLINE The Discussion of this exercise covers the following points:

 Recapitulation of relevant control schemes

 Tuning with the trial-and-error method
 Tuning with the ultimate-cycle method
 Limits of the ultimate-cycle method
 The open-loop Ziegler-Nichols method

This exercise introduces three control schemes and puts them to use in a
DISCUSSION temperature process loop. This allows a comparative analysis of the different
schemes in terms of efficiency, simplicity, and applicability to various situations.
An intuitive method to tune controllers is also presented.

Recapitulation of relevant control schemes

A controller in proportional mode (P mode) outputs a signal ( ( ) – manipulated

variable) which is proportional to the difference between the target value (SP: set
point) and the actual value of the variable ( ( ) – controlled variable). This simple
scheme works well but typically causes an offset. The only parameter to tune is
the controller gain (or the proportional band ( % = 100%/ ) if your
controller uses this parameter instead).

A controller in proportional/integral mode (PI mode) works in a fashion similar to

a controller in P mode, but also integrates the error over time to reduce the
residual error to zero. The integral action tends to respond slowly to a change in
error for large values of the integral time and increases the risks of overshoot
and instability for small values of .Thus, the two parameters which require
tuning for this control method are (or %) and (or the integral gain, defined
as = 1/ ).

A controller in proportional, integral, and derivative mode (PID mode)

incorporates the three control actions into a single polyvalent and powerful
control scheme. The addition of derivative action to the PI mode covered in the
previous exercise results in the capacity to attenuate overshoots to some extent,
but adds the risk of instability if the process is noisy.

Tuning a controller in PID mode requires careful adjustment of the proportional

gain ( ), the integral time ( ), and the derivative time ( ) to properly address
the control requirements of the process. In some circumstances, the controller

A Process Control 53
Ex. 2-1 – Tuning and Control of a Temperature Loop  Discussion

output must not be zero when the error is null. In these cases, a bias ( ), also
known as manual reset, must be set.

The on-off control mode is the simplest control scheme available. It involves
either a 0% or a 100% output signal from the controller based on the sign of the
measured error. The option to add a dead band is available with most controllers
to reduce the oscillation frequency and prevent premature wear of the final
control element. There are no parameters to specify for this mode beyond a set
point and dead band parameters. Note that it is possible to simulate an on-off
mode with a controller in P mode for a large value of (or a very small %).

Tuning with the trial-and-error method

The trial-and-error method of controller tuning is a procedure for adjusting the

P, I, and D parameters until the controller is able to rapidly correct its output in
response to a step change in the error. This correction is to be performed without
excessive overshooting of the controlled variable.

This method is widely used because it does not require the characteristics of the
process to be known, and it is not necessary to bring the process into a
sustained oscillation. Another important aspect of this method is that it is
instrumental in developing an intuition for the effects of each of the tuning
parameters.

However, the trial-and-error method can be daunting to perform for

inexperienced technicians because a change in tuning constant tends to affect
the action of all three controller terms. For example, increasing the integral action
increases the overshooting, which in turn, increases the rate of change of the
error and then increases the derivative action. A structured approach and
experience help in obtaining a good tuning relatively quickly without resorting to
involved calculations.

A good trial-and-error method is to follow a geometrical progression in the search

for optimal parameters. For example, multiplying or dividing one of the tuning
parameters by two at each iteration can help you converge quickly toward an
optimal value of the parameter.

A procedure for the trial-and-error method

The trial-and-error method is performed using the following procedure (also refer
to Figure 2-25 and Figure 2-26 for PI control):

1. Set the controller in the mode you want to use: P, PI, PD, or PID. Follow
the instructions to adjust every parameter relevant to the mode you are
using. Note that, if your controller allows doing so, you can use the PID
mode to perform any of the modes by simply setting the parameters to
appropriate values (e.g. = 0 for PI mode).

Adjusting the P action

2. With the controller in manual mode, turn off the integral and derivative
actions of the controller by setting and respectively to the largest
possible value and 0.

54 Process Control A
Ex. 2-1 – Tuning and Control of a Temperature Loop  Discussion

3. Set the controller gain to an arbitrary, but small, value, such as 1.

The controller gain is
related to the proportional 4. Place the controller in the automatic (closed-loop) mode.
band: % = 100%/ .
5. Make a step change in the set point and observe the response of the
If your controller uses the controlled variable. The set point change should be typical of the
proportional band, start with expected use of the system.
a value of % = 100%,
and replace instructions to Since the controller gain is low, the controlled variable will take a
increase by a factor of relatively long time to stabilize (i.e., the response is likely to be
two by instructions to de- overdamped).
crease % by a factor of
two. 6. Increase by a factor of 2 and make another step change in the set
point to see the effect on the response of the controlled variable.

The objective is to find the value of at which the response becomes

underdamped and oscillatory. This is the ultimate controller gain. Keep
increasing by factors of 2, performing a set point change after each
new attempt, until you observe the oscillatory response.

Once the ultimate controller gain is reached, revert back to the previous
value of by decreasing the controller gain by a factor of 2. The P
action is now set well enough to add another control action if required.

Adjusting the I action

7. Start bringing in integral action by setting the integral time at an

arbitrarily high value. Decrease by factors of 2, making a set point
change after each setting.

Do so until you reach a value of , at which the response of the

controlled variable becomes underdamped and oscillatory. At this point,
revert back to the previous value of by increasing to twice its value.

The I action is now set and you can now proceed to the adjustment of
the D action, if required.

Adjusting the D action

8. Start bringing in derivative action by setting the derivative time at an

arbitrarily low value. Increase by factors of 2, making a set point
change after each setting.

Do so until you reach the value of that gives the fastest response
without amplifying the overshooting or creating oscillation.

The D action is now set.

Fine-tuning of the parameters

9. Fine-tune the controller until the requirements regarding the response

time and overshooting of the controlled variable are satisfied.

A Process Control 55
Ex. 2-1 – Tuning and Control of a Temperature Loop  Discussion

With the controller in manual mode, turn off the integral and derivative
actions. Set the controller gain to 1.0.

Place the controller in automatic mode.

Make a step change in the set point.

Is the process response No Increase the

underdamped and oscillatory? controller gain to
twice its value.

Yes

Set the gain to halfway between the actual gain and the previous gain.

Bring in the integral action by setting the integral time at a high value.

Make a step change in the set point.

Is the process response Decrease the

No
underdamped and oscillatory? integral time by a
factor of 2.

Yes

Set the integral time to halfway between the actual time and the previous time.

Bring in the derivative action by setting the derivative time at a low value.

Make a step change in the set point.

Is the process response No Increase the

longer and is derivative time to
overshooting amplified? twice its value.

Yes

Reduce the derivative time to obtain the fastest response without overshooting amplification.

Fine-tune the controller to meet the response requirements.

Figure 2-25. Trial-and-error tuning method.

56 Process Control A
 Ex. 2-1 – Tuning and Control of a Temperature Loop  Discussion

A complementary approach to trial-and-error tuning

Another, more visual approach is to use Figure 2-26 to assist you in tuning your
controller. The figure presents responses of a PI process to a step change for
different combinations of parameters. A good tuning is shown in the center of the
figure for ‘optimal’ and parameters. The tuning in the center is not
necessarily the most appropriate for the process you want to control; but the
response shown is a good target for a rough first tuning.

The figure also shows responses for detuned parameters (both above and below
the ‘optimal’ and ). Comparing the response you obtain for your system with
the detuned responses in the figure tells you in which direction to change , ,
or both to converge towards the center case. Changing the parameters by a
factor of two at every step until you get very close to the optimal value is a good
method to converge rapidly.
1
2
2

1
2

Figure 2-26. PID tuning chart.

If required, derivative action can then be added to the control scheme by

following step 8 of the trial-and-error method. Then, fine-tune the parameters to
optimize the control and to meet the specific requirements of your process.

Tuning with the ultimate-cycle method

The ultimate-cycle tuning method is one of the first heuristic methods suggested
by Ziegler and Nichols for tuning PID controllers (the method is consequently
sometimes called the closed-loop Ziegler-Nichols method). The ultimate-cycle

A Process Control 57
Ex. 2-1 – Tuning and Control of a Temperature Loop  Discussion

tuning method is designed to produce quarter-amplitude decay in the controlled

variable after a given step change in the set point. This method enables the
operator to calculate the P, I, and D tuning constants required for P, PI, PD, or
PID control of a process using two parameters of the process: the ultimate gain
( ) and the ultimate period ( ).

The ultimate proportional The ultimate gain is the largest value of in P-only control mode such that
band can be used the process is still stable (albeit marginally), i.e., the system is in a continuous,
instead of . It is then sustained oscillation. The ultimate period is the period of the response when
defined as the smallest the gain is set to the ultimate gain.
value of for which the
process is stable.

100%
Controlled Variable

%=

Time
(a) Decreasing oscillation.
Controlled Variable

Time
(b) Increasing oscillation.
Controlled Variable

Time
(c) Sustained oscillation.

Figure 2-27. Types of oscillations and determination of the ultimate period.

58 Process Control A
Ex. 2-1 – Tuning and Control of a Temperature Loop  Discussion

The ultimate-cycle tuning method follows this procedure:

1. With the controller in manual mode, turn off the integral and derivative
actions so as to use only P mode.

2. Set the proportional gain at an arbitrary, but somewhat small, value,

such as 1.

3. Place the controller in automatic (closed-loop) mode.

4. If the process starts to oscillate by itself, go to step 7. Otherwise, create

a step change in the set point. The set point change should be typical of
the expected use of the system.

5. If the process does not oscillate, increase the gain by a factor of 2.

6. Repeat steps 4 and 5 until the response becomes oscillatory.

7. Determine whether the oscillation is sustained—i.e., if it continues at the

same amplitude without increasing or decreasing as in Figure 2-27c. If
not, make small changes in the proportional gain until a sustained
oscillation is achieved.

a Note: It is often necessary to wait for the completion of several oscillations

before it can be determined if the oscillation is sustained.

The proportional gain, at which the sustained oscillation begins without

causing saturation of the controller output, is the ultimate proportional
gain, . Note this value. Then note the period of the oscillation of the
process, as shown in Figure 2-27c. This is the ultimate period, .

8. Using the ultimate proportional gain and ultimate period, calculate the
tuning constants of the controller as follows:

Table 2-2. Control parameters for the ultimate-cycle tuning method.

Mode Controller Gain Integral Time Derivative Time

= 0.5
P - -
( =2 )
= 0.45
PI = ⁄1.2 -
( = 2.2 )
= 0.6
PD - = ⁄8
( = 1.65 )
= 0.6
PID = ⁄2.0 = ⁄8
( = 1.65 )

Once the tuning constants of the controller are adjusted to the calculated
values and the controller is returned in the automatic (closed-loop) mode,
changes in the set point should produce a quarter-amplitude decay
response. Optimization of the controller settings may require further fine-
tuning.

A Process Control 59
Ex. 2-1 – Tuning and Control of a Temperature Loop  Discussion

Quarter-amplitude decay ratio

John G. Ziegler and Nathaniel B. Nichols, who were pioneers in control

engineering, established a criterion to determine if a controller is appropriately
tuned. This criterion is the quarter-amplitude decay ratio. It states that, for two
successive oscillations, the amplitude of the second oscillation should be one
fourth of the amplitude of the first oscillation.
Controlled
variable

= =
4 4

Time

Set point

Figure 2-28. Quarter-amplitude decay ratio.

Presence of a quarter-amplitude decay ratio in a response is a rough

approximation for the optimal tuning of PID controllers. A controller is generally
considered to be reasonably tuned when it satisfies this criterion; but fine-tuning
may be required to adapt the controller response to a specific process control
application.

The quarter-amplitude decay response is a compromise between an

underdamped and an overdamped response. The process response is
overdamped when the controlled variable slowly returns to the set point after the
step change without overshooting it. The response is underdamped when the
controlled variable quickly returns to the set point with one or more overshoots
before stabilizing. An underdamped response often means that the controller
reacts too aggressively to correct the error, thereby overdoing it.

Limits of the ultimate-cycle method

It is important to note that the formulas given above apply only for non-interacting
ideal controllers. Other formulas must be used for series or non-interacting
parallel controllers. Refer to the section entitled Structure of controllers on
page 50 for details.

60 Process Control A
Ex. 2-1 – Tuning and Control of a Temperature Loop  Discussion

It is also important to stress that using the ultimate-cycle tuning method may be
out of the question in processes where bringing the system into continuous
oscillation could be dangerous or might cause damage. Instead, another method
of tuning, such as the trial-and-error method or the open-loop step response
method, should be used. The open-loop step response method is also known as
the open-loop Ziegler-Nichols method.

The open-loop Ziegler-Nichols method

This method of controller tuning was developed in 1942 by John G. Ziegler and
Nathaniel B. Nichols. It enables the operator to calculate the P, I, and D tuning
constants required for P, PI, or PID control of a process based on the open-loop
response of the process to a step change in the set point.

The open-loop step response method is performed according to the following

procedure:

1. With the controller in open-loop mode, create a step change in controller

output. The resulting change in controlled variable should be typical of the
expected use of the system. Note that you can use a calibrator instead of the
controller to create a step change.

2. Based on the response curve of the controlled variable, determine the

process gain , the dead time , and the time constant τ of the process.
Refer to Ex. 1-1 for a discussion about process parameters.

Calculate the value of the parameter κ

τ
κ=
t K

3. Using the process characteristics found in step 2, calculate the tuning

constants of the controller as follows:

Table 2-3. Control parameters for the open-loop Ziegler-Nichols tuning method.

Mode Proportional Gain Integral Time Derivative Time

P = - -

PI = 0.9 = 3.33 -

PID = 1.2 =2 = 0.5

Once the tuning constants of the controller are adjusted to the calculated values
and the controller is returned to the closed-loop mode, a typical change in the set
point should produce the desired quarter-amplitude decay response. The
controller should also be able to correct for load changes rapidly, without
excessive overshooting or oscillation of the controlled variable. Note, however,
that small readjustments of the P, I, and D tuning constants may be required to
obtain the optimum controller setting.

A Process Control 61
Ex. 2-1 – Tuning and Control of a Temperature Loop  Procedure Outline

It is important to note that the formulas given above apply only to non-interacting,
ideal controllers. Other formulas must be used for series or non-interacting
parallel controllers. Refer to the section titled Structure of controllers on page 50
for details.

An advantage of the open-loop step response method is that the process needs
to be disturbed only once to obtain the required process characteristics. On the
other hand, the determination of precise process parameters requires a few
calculations and, often, some adjustments.

PROCEDURE OUTLINE The Procedure is divided into the following sections:

 Setup and connections

 Tuning the controller
 Controlling a temperature process

PROCEDURE Setup and connections

Although a specific tuning

method is proposed in this 1. Verify that the emergency push button is wired so as to be able to cut the
exercise, feel free to try and power in case of emergency. The Familiarization with the Training System
compare the results of other manual covers the security issues related to the use of electricity with the
tuning methods. system as well as the wiring of the emergency push button.

2. Make sure the 3531 system is properly set up to use the Heating/Cooling
unit. The system should also be in its basic setup configuration.

3. Connect the equipment according to the piping and instrumentation

diagram (P&ID) shown in Figure 2-29, and use Figure 2-30 to position the
equipment correctly on the frame of the training system. To set up your
system for this exercise, start with the basic setup presented in the
Familiarization with the Training System manual and add the equipment
listed in Table 2-4. Drives 3 and 4 and pumps 3 and 4 must be connected to
the setup as explained in the Familiarization with the Training System
manual even though they are not shown explicitly in Figure 2-29.

Note how a T-shaped connector is used to split the flow of water from HV2B
between the heat exchanger and the three-way control valve. This setup
allows stopping the flow of cold water in the heat exchanger using the control
valve.

62 Process Control A
Ex. 2-1 – Tuning and Control of a Temperature Loop  Procedure

Table 2-4. Material to add to the basic setup for this exercise.

Name Model Identification

Brazed plate heat exchanger 46905
J-type thermocouple 46916 TE1B
Platinum RTD 46917 TE1A
Temperature transmitter 46940 TIT
Paperless recorder 46972
Controller ---- TIC

Figure 2-29. P&ID – Heat exchanger control.

A Process Control 63
Ex. 2-1 – Tuning and Control of a Temperature Loop  Procedure

Air from the pneumatic unit

(170 kPa (25 psi))

Figure 2-30. Setup – Heat exchanger control.

4. Connect the pneumatic unit to a dry-air source with an output pressure of at

least 700 kPa (100 psi).

5. Connect the I/P converter of the three-way control valve to the pneumatic
unit. Use the low-pressure port to do so.

6. Do not power up the instrumentation workstation yet. Do not turn on the

electrical panel or the heating/cooling unit before your instructor has
validated your setup—that is not before step 11.

64 Process Control A
Ex. 2-1 – Tuning and Control of a Temperature Loop  Procedure

7. To perform control of your process, you must connect the output of your
controller to the control valve and the temperature transmitter to the input of
the controller. You must include the recorder in your connection. On
channel 1 of the recorder, plot the signal from the controller output and on
channel 2, plot the signal from the transmitter output. Be sure to use the
analog input of your controller to connect the temperature transmitter. Refer
to the manual of your controller for details on how to connect it to other
devices.

8. Figure 2-31 shows how to connect the paperless recorder to your system to
plot the control signal from the controller on channel 1 and the controller
input on channel 2.

Analog input

In1 Out1 Ch1 Ch2

24 V

Figure 2-31. Connecting the equipment to the recorder.

9. Before proceeding further, complete the following checklist to make sure you
have set up the system properly. The points on this checklist are crucial
elements for the proper completion of this exercise. This checklist is not
exhaustive, so be sure to follow the instructions in the Familiarization with the
Training System manual as well.

f
 Every piece of equipment used is secured to the station with the
appropriate bolt-and-nut mechanism.
 The heat exchanger is properly installed on the station.
 The hand valves are in the positions shown in the P&ID:
Open valves: HV1A, HV1B, HV2A, HV2B, HV5A, and HV5B.
Closed valves: HV3A, HV3B, HV4A, and HV4B.
 The hand valves under the drip trays are in the positions specified in the
Familiarization with the Training System manual:
Open valves: HV1A, HV1B, HV8A, and HV8B.
Closed valves: HV6A, HV6B, and HV7.
 The L port of the three-way control valve is fully open.
 The pneumatic connections are correct.

A Process Control 65
Ex. 2-1 – Tuning and Control of a Temperature Loop  Procedure

 The controller is properly connected to the temperature transmitter.

 The controller is properly connected to the three-way control valve.
 The paperless recorder is connected correctly to plot the calibrator signal
on channel 1 and the temperature transmitter output on channel 2.

10. Ask your instructor to check and approve your setup.

11. Power up the electrical unit. This starts all electrical devices as well as the
pneumatic devices.

Adjust the pressure at the low-pressure port so 170 kPa (25 psi) is sent to
the I/P converter of the control valve.

12. Start the drives 3 and 4 (pumps P3 and P4). These pumps make the water of
the two tanks flow in the heating/cooling unit. Ensure the process fluid from
each tank is circulating correctly, then power up the heating/cooling unit.
Make sure valve HV7 is closed. Continue with the next steps while the water
in each tank is respectively heating and cooling toward their temperature set
points.

13. Test your system for leaks. Use drives 1 and 2 to make pumps P1 and P2
run at low speed to produce a small flow rate. Progressively increase the
frequency output of drives 1 and 2 up to 30 Hz. Repair any leaks.

Let drives 1 and 2 run at 30 Hz.

14. The temperature in the two tanks should be stable and at their respective set
points by now. If this is not the case, identify the problem or wait until the
temperatures of the tanks stabilize.

15. Test the three-way control valve with your controller in manual mode and
make sure it is fully open on L for a 4 mA signal and fully open on U for
a 20 mA signal.

16. Configure the paperless recorder so it displays and records the control signal
to the three-way control valve on channel 1 and the process temperature on
channel 2.

a The sampling rate of the paperless recorder should be set to 1 s. To do so, go

in the Main Menu ► Setup ► Application ► Signal Group ► Group X (where
X is the number of your active group, typically set to 1) ► Save Cycle ► 1 s.

17. Use the temperature transmitter to display the temperature measured by the
RTD (TE1A) and to send the related 4-20 mA signal to your controller and

66 Process Control A
Ex. 2-1 – Tuning and Control of a Temperature Loop  Procedure

trend recorder. The RTD should be installed at the output of the heat
exchanger, where the cooled water exits.

18. With the controller in manual mode, set the controller output to 100% to
maximize the amount of cold water that circulates in the heat exchanger.
Wait for the temperature to stabilize and record the transmitter output (the
temperature) in percentage below.

TE1A output (100% controller output): ______________%

19. Unplug the RTD from the temperature transmitter. After a few seconds, the
transmitter should display the temperature measured by the thermocouple
and it should send the associated 4-20 ma signal to the trend recorder.
Record the temperature of the cold water output for a 100% controller output
in percentage below:

Cold water temperature (100% controller output): ______________

20. Plug the RTD back in place and be sure the paperless recorder displays the
warm water flow temperature.

21. Set the controller output to 0% to stop the cold water flow in the heat
exchanger. Wait for the temperature to stabilize, and record the transmitter
output (the temperature) in percentage below.

TE1A output (0% controller output): ______________%

22. Again, unplug the RTD from the temperature transmitter. After a few
seconds, the transmitter should display the temperature measured by the
thermocouple. Record the temperature of the cold water output for a 0%
controller output in percentage below:

Cold water temperature (0% controller output): ______________

23. Plug the RTD back in place and be sure the paperless recorder displays the
warm water flow temperature.

A Process Control 67
Ex. 2-1 – Tuning and Control of a Temperature Loop  Procedure

Tuning the controller

24. The temperature process can be controlled using various control schemes
(on-off, P, PI, PD, and PID). However, you are more likely to obtain good
results using a controller set to the PI mode. Set your controller to this mode
and adjust the parameters using the open-loop Ziegler-Nichols method.

Use the process characteristics obtained in the previous exercise for your
calculations and note the parameters entered in the controller:

= ____________

= ____________

25. Switch the controller to the automatic mode and have it maintain a set point
of 70%.

26. Test your settings extensively by creating step changes in the controller set
point (e.g., from 70% to 60%).

27. Does the open-loop Ziegler-Nichols method gives good results without
further tuning of the controller parameters?

28. If the control is not satisfactory, fine-tune the controller parameters manually
using Figure 2-26 to find the best PI parameters. If you had to change the
controller parameters, note the new parameters below:

= ____________

= ____________

Controlling a temperature process

29. Once the controller is properly tuned, erase the internal memory of the
paperless recorder. Wait a few seconds after the recorder is done rebooting,
then perform a set point step change from 70% to 60%.

30. Wait for the value of the process variable to stabilize.

31. Once the system is at steady state, transfer the data from the paperless
recorder to a computer or save it on a USB key. Follow the procedure in the
Familiarization with the Training System manual to do so.

68 Process Control A
Ex. 2-1 – Tuning and Control of a Temperature Loop  Conclusion

32. Stop the system.

33. Plot the process data using a spreadsheet software.

34. Stop drives 1 and 2, and let the water drain out of the hoses.

35. Turn off the heating/cooling unit, then stop drives 3 and 4. Turn off the
pneumatic unit and the electrical unit. Turn off your calibrator if one was
used.

36. Store the equipment adequately, clean up your workspace, and leave the
station ready for the next team.

CONCLUSION This experiment presented the control of a temperature process loop. You
became acquainted with the widely used open-loop Ziegler-Nichols tuning
method.

REVIEW QUESTIONS 1. What is the advantage of adding integral action to a proportional control
scheme?

2. Why is on-off control not efficient in the experiment presented above?

3. Why does the trial-and-error method proceed with a factor of two change at
every iteration?

4. What happens if you increase the parameter in a PI control scheme?

A Process Control 69
Ex. 2-1 – Tuning and Control of a Temperature Loop  Review Questions

5. Which process characteristic determines both the integral time and the
derivative time when using the open-loop Ziegler-Nichols tuning method?

70 Process Control A
 Sample
Extracted from
Instructor Guide
Exercise 2-1 Tuning and Control of a Temperature Loop

Exercise 2-1 Tuning and Control of a Temperature Loop

ANSWERS TO 18. TE1A output (100% controller output): 55% (about 26°C (79°F)).
PROCEDURE STEP
QUESTIONS
19. Cold water temperature (100% controller output): Approximately 58% (about
27°C (80.5°F)).

21. TE1A output (0% controller output): Approximately 78% (about 33°C (91°F)).

22. TE1B output - Cold water temperature (0% controller output) =

Approximately 55% (about 27°C (80°F)).

24. The Ziegler-Nichols method suggests the following relationships to obtain the
parameters in PI mode:

= 0.9 = 3.33 κ=

Using the process characteristics obtained in the previous exercise ( =

−0.575, = 34 s, and = 13 ), we can calculate the parameters. Note that
the results obtained are indicative only and are likely to differ.

= 4.089 = 43.3 s

27. In our case, the results were acceptable. The precision and care invested in
the measurement of process characteristics have a large impact. A fine-
tuning remains almost always advantageous.

A Process Control 3
Exercise 2-1 Tuning and Control of a Temperature Loop

33. The graph obtained as the process underwent a 70-60% step change (past
the 400 s mark) is provided below. Your results may vary.

100

80

Controller
60
Valve position
(%)
%

40 Temperature
Temperature
(%)
20

0
0 100 200 300 400 500 600

Time (s)
Process data for the temperature process.

ANSWERS TO REVIEW 1. A well tuned integral action eliminates the offset typical of P-only control.
QUESTIONS
2. On-off control works well for slow-changing processes with large
capacitance. In the experiment at hand, the temperature varies too quickly to
be controlled by a two-state scheme.

3. This method (geometrical progression) typically converges toward the

solution faster than a fixed increment method (arithmetic progression).

4. The response will have a larger amplitude of oscillation and will take more
time to stabilize.

5. , the dead time of the process

4 Process Control A
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A Process Control 99
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100 Process Control A