6.

Tuning Methods of
PID Controller

Hamid

1
Session Outlines & Objectives
Outlines
 :
◦ Ziegler-Nichols Open-loop
◦ Coon-Cohen Open-loop
◦ Ziegler-Nichols Closed-loop
◦ Lambda Tuning
◦ Visual Loop Tuning
◦ Autotuning

Objectives
 Know the meaning of controller tuning
 Be able to use several PID tuning methods and
choose the right tuning methods for specific
process control application 2
Introduction (1)
Controller tuning
 A systematic-adjusting procedure of the

controller parameters to obtain a desired

performance of the control system
PID control tuning
 It is a matter of selecting the right mix of P, I,

and D action to achieve a desired

performance

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Introduction (2)
Performance criteria for closed-loop systems
 Stable
 Minimal effect of disturbance

 Rapid, smooth response to set point change

 No offset

 No excessive control action

 Robust to plant-model mismatch

Trade-offs in control problems

 Set point tracking vs. disturbance rejection

 Robustness vs. performance

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Introduction (3)
How do we know when it’s tuned?
 The process didn’t blow up 
 The process variable value (=measurements)

stay close enough to the setpoint

 Boss says OK, and you can go home   
 You not buy a new controller which has

different PID algorithm?

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Introduction (4)
The Problem
 We have the knowledge about the effect of each PID
modes to closed-loop response
 But, from what values of P, I and D modes we would
pick to start to tune?
The Solutions
 If you have tuned the process before, use slightly
different values of the old PID controller parameter
 If the results are still not satisfy you, use a PID
controller tuning method that we will learn just in a
moment that is most suit to your process control
application. Keep watch on …

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Introduction (5)
General Tuning Procedure
◦ Before tuning, FAMILIARIZE with the OPERATION RISK
◦ Get help with experienced operators, explain your
work to him and tell him that NO PERMISSION IS
REQUIRED if their intervention is NECESSARY to save
the loop if things go wrong

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Introduction (6)
Precaution:
All kinds of tuning method should be used for
initial setting and fine tuning should be done!!!

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Cohen-Coon Open-loop Tuning Method (1)
 Proposed in 1953 by G. H.
Cohen and G. A. Coon1
CO
 Main principles:

◦ The process output is affected

not only by the dynamics of
the main process but also by time
the dynamics of the
measuring sensor and final PV
control element
◦ They observed that the
response of most processing
time
unit to an input change had a
sigmoidal shape
G. H. Cohen and G. A. Coon, Theoretical Consideration of Retarded Control , Trans. ASME,Vol. 75,
1)

pp. 827, 1953.

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Cohen-Coon Open-loop Tuning Method (2)
 Main principles: (contd.)
◦ The sigmoidal shape can be adequately
approximated by the response of a first order
system with dead time
A PVm K e - Td s
CO
Gfpm = ~ ,
CO ts + 1
where
B
time K =
A
B Actual response
PVm B
t = , S is the slope of the
S sigmoidal response at
Approximate
response the point of inflection
S
Td =time elapsed until the
Td time system responded
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Cohen-Coon Open-loop Tuning Method (3)
 Once the value of process parameter are
obtained, the PID parameter can be calculated
from the following table
Controller P Im D

1 t Td
P only K 1 + 3t - -
Td

1 t Td 30 + 3Td /t
PI K 0.9 + 12t Td -
Td 9 + 20Td /t

1 t 4 Td 32 + 6Td /t 4
PID K 3 + 4t Td Td 11 + 2T /t
Td 13 + 8Td /t d

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Ziegler-Nichols
Open-loop Tuning Method (1)
 Proposed in 1942 by J. G. Ziegler and N. B. Nichols of
Taylor Instruments (now part of ABB instrumentation in
Rochester, N.Y.) 2
 It is done in manual mode
 It is a way of relating the process parameters (i.e. delay
time, process gain and time constant) to the controller
parameters (i.e. controller gain and reset time)
 It has been developed for use on delay-followed-by-
first-order-lag processes

J. G. Ziegler and N. B. Nichols, Optimum Setting for Automatic Controllers, Trans. ASME,Vol. 64, pp.
2)

759-768, 1942.
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Ziegler-Nichols
Open-loop Tuning Method (2)

The Procedure
1. Put the control system in MANUAL (without feedback)
2. Adjust the controlled system manually to the desired
operating point (start-up control loop)
3. Apply manually a STEP change of the controller output
(CO) (usually 5 – 10 % or depending of your process
gain)
4. Wait until the process variable (PV) is settled at
steady-state condition

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Ziegler-Nichols
Open-loop Tuning Method (3)
5. Determine process parameter (delay time, process
gain and time constant) from the graphics

P
CO OUTPUT LEVEL

TEMPERATURE

Line drawn through

point of inflection

PV
R

L
TD
TIME

FIGURE 6: PROCESS REACTION CURVE - SIMPLE

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Ziegler-Nichols
Open-loop Tuning Method (4)
6. Once the value of process parameter are obtained, the
PID parameter can be calculated from the following
table
Controller P (Kc) Im D

P only
1 t - -
K Td

0.9 t
PI K Td
0.33 Td -

1.2 t
PID K Td
2 Td 0.5 Td

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Ziegler-Nichols
Closed-loop Tuning Method (1)
 Proposed in 1942 by J. G. Ziegler and N. B. Nichols of
Taylor Instruments (now part of ABB instrumentation in
Rochester, N.Y.)
 Also known as continuous cycling or ultimate gain
methods
 It has been developed for use on delay-followed-by-
first-order-lag processes
 It has been refined for other specific process control
objectives

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Ziegler-Nichols
Closed-loop Tuning Method (2)
The Procedure
1. At the controller, select proportional-only (P-ONLY) control, i.e.
set P to the lowest value (PB to the highest value) and Im to
infinity (Ir to zero) and D to zero (smallest possible influence of
the controller)
2. Adjust the controlled system manually to the desired operating
point (start-up control loop)
3. Set the manipulated variable of the controller to the manually
adjusted value (reset bias b) and switch to automatic operating
mode
4. Continue to gradually increase P (decrease PB) until the
controlled variable encounters harmonic oscillation. If possible,
small step changes in the setpoint should be made during the P
adjustment to cause the control loop to oscillate
5. Take down the adjusted P value as critical proportional-action
coefficient Pcrit
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Ziegler-Nichols
Closed-loop Tuning Method (3)

The Procedure (contd.)

6. Determine the time span for one full oscillation
amplitude as tcrit, if necessary by taking the time of
several oscillations and calculating their average

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Ziegler-Nichols
Closed-loop Tuning Method (4)

The Procedure (contd.)

7. Once the value for Pcrit and tcrit are obtained, the PID
parameter can be calculated from the following
table

Controller P Im D

P only 0.5 Pcrit - -

PI 0.45 Pcrit 0.833 tcrit -

PID 0.6 Pcrit 0.5 tcrit 0.125 tcrit

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Ziegler-Nichols
Closed-loop Tuning Method (5)

Modified Ziegler-Nichols setting

Controller P Im D

PID original 0.6 Pcrit 0.5 tcrit 0.125 tcrit

PID some overshoot 0.33 Pcrit 0.5 tcrit 0.33 tcrit
PID no overshoot 0.2 Pcrit 0.3 tcrit 0.5 tcrit

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Ziegler-Nichols
Closed-loop Tuning Method (6)
 Examples
4e-3.5s Pc = 0.95
Gp(s) =
7s+1 tc = 12

Controller P Im D

PID original 0.57 6.0 1.5

PID some overshoot 0.31 6.0 0.4

PID no overshoot 0.19 6.0 4.0

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Ziegler-Nichols
Closed-loop Tuning Method (6)

Advantages of continuous cycling method

 No a priori information on process required
 Applicable to all stable processes
 Only a single experimental test is needed
 It does not require trial and error
 The controller settings are easily calculated

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Ziegler-Nichols
Closed-loop Tuning Method (7)

Disadvantages of continuous cycling method

 Time consuming

 Loss of product quality and productivity during

the tests
 Continuous cycling may cause the violation of

process limitation and safety hazards

 Not applicable to open-loop unstable process

 First-order and second-order process without

time delay will not oscillate even with very large

controller gain
 Motivates Relay Feedback Method (Åström and Hagglund,
1984)
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Lambda Tuning (1)
 Developed for achieving smooth setpoint
response or load change
 Guarantees stability, robustness and no
overshoot
 Very popular in pulp & paper industry

Two basic steps of lambda (l) tuning:

◦ Process model identification
◦ Lambda tuning
 1st order process with dead time
 Integrating process (i.e. level control)

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Lambda Tuning (2)
1st Order Process with Dead Time
Procedure:
 Manually, bump the CO then observe the PV
m

The estimated process parameters:

Du
Dy
• Process gain: Gp = D u

0.283Dy
• Process time constant:
tp = 1.5(T2 – T1)
0.632Dy

• Process dead time: Td = T2 – tp

T1 T2
time

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Lambda Tuning (3)

1st Order Process with Dead Time (contd.)

Lambda Tuning:
 Choose the desired closed-loop time

constant, l (typically 2 to 3 times the process

constant)
PID  sluggish response!
tuning parameters:
2tp + td
• Proportional gain: P =
2Gp(l + td)
td
• Integral action: Tm = tp + 2

t p td
• Derivative action: D =
2 tp + td

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Lambda Tuning (4)

Lambda Tuning’s Rule of Thumb:

◦ Integral time should no be smaller than the process
time constant
◦ Level control oscillating? Remove nearly all integral
action
◦ Poll time should be less than one-tenth the process
time constant
◦ Filter time constant should be less than one fifth the
process time constant
◦ Closed-loop time constant is usually greater than the
process time constant

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 Visual Loop Tuning (1)
Problems
 The loop is

unstable (or How to improve the

apparently so) performance of a loop
 The loop is
by using NO algebra?
sluggish in
response to upsets
or setpoint
PV changes
m
SP
SP SP

PVm PVm

Apparently unstable response “Good” response? Sluggish response

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Visual Loop Tuning (2)
Apparent Instability PVm
 The loop oscillates SP
◦ Because of excessive feedback, or
◦ Of being perturbed periodically by
another process
Procedure:
◦ Put the loop in manual (if it is safe to do so)
◦ In manual mode, the process appears to settle down 
poorly tuned
Tuning problems:
◦ Is the oscillation caused by too much or too little
gain/integral/ derivative or their combinations?

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 Visual Loop Tuning (3)
Apparent Instability (contd.)
Tuning procedure:
◦ Self-regulating Processes
 If the value of I (min/repeat) is less than half of the oscillation period
m t
 First, Increase the value of Im
 If the value of Im (min/repeat) is longer than the oscillation period, it is safe to decrease the gain ( P)

t
SP SP

PVm PVm

Apparently unstable response Increasing the value of Lowering the gain (P)
Im (min/repeat)
◦ Non Self-regulating Processes
 Use the longest value of Im (min/repeat) as much as possible or completely remove the integral action. If the problem
persists, then lowering the gain (P)

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Visual Loop Tuning (4)
Sluggish Response
Common causes:
SP
◦ The loop usually has no
derivative action PVm

◦ The value of Im (min/repeat) is

long relative to the process
response time
◦ The value of gain is too low

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Visual Loop Tuning (5)
Sluggish Response (contd.)
Tuning procedure:
1. Adjusting Gain
 Set the Im as longest as possible and set D to zero.
 Place the controller in manual mode, then step out the
CO at a reasonable value
 Immediately put the controller back in auto mode. Watch
the process response to know what the controller action
PVm PVm PVm
does
 Repeat the process until we get one cycle of process

Too much output

Swinging more than swinging
one cycle Swinging less than one cycle Swinging in one cycle
gain Too little gain Reasonable gain achieved
 lowering the gain  increasing the gain

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Visual Loop Tuning (6)
Sluggish Response (contd.)
Tuning procedure:
2. Adjusting Integral Action
 Place the controller in manual mode, shorten the value of
Im, then step out the CO at a reasonable value
 Immediately put the controller back in auto mode. Watch
the process response to know what the controller action
does
PVm original
 Repeat the process until
PVm we get the PVm ramps back to
PVm original
SP SP
setpoint about half as fast as it moved away from
SP PVm
setpoint form theToCO
Response with reasonable gain
step
little I Reasonable Im
(swinging in one cycle) (swingingm at setpoint)

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Visual Loop Tuning (7)
Tuning map for gain (P) and reset effect (Im)
No reset Increasing reset Fast reset
(small repeat/min) (integral) action (more repeat/min)
(large min/repeat) (less min/repeat)

Low gain (P)

(wide PB)
Increasing proportional
action

High gain (P)

(narrow PB)

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Visual Loop Tuning (8)
The Effect of Adding Derivative

a) Best tuning
achieved with b) Too little derivative
proportional and
integral modes only

c) Derivative added
gain increased d) Too much derivative
integral action faster

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What is Autotuning?
 Autotuning (also known as self-tuning) is a
feature supplied by many controller, PLC and
DCS vendors that allows the controller to
“tune itself”
 It minimize the task of a control engineer in

manually tuning the loops

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Why Autotuning?
 The process is nonlinear or operated under
widely varying conditions
 Need various combination of tuning parameters
for different operating condition  can be also
accomplished by using operator’s log
 The process characteristic change rapidly
 Frequent manual changing of the tuning
parameters can not be expected to be able to
produce satisfactory results
 The end user doesn’t have the knowledge or
experience for successful manual tuning

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Autotuning Categories
A variety of autotuning techniques found on
the market:
 Scheduled tuning
 On-demand tuning
 On-line tuning

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Scheduled Tuning (1)
 Merely, an automation of the “operator’s log”
concept
◦ The users have to provide the correct value either
by means of a table look-up or a user-written
program
 Tuning parameters are changed automatically
as operating points change
 No assessing and modifying of the controller

performances by determining improved

tuning parameters

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Scheduled Tuning (2)
From
table look-up or
user-written program

Gain Reset Deriv.

SP
S PID Process

PVm

Region Boundaries Gain Reset Deriv.

1 0 – 30% P1 I1 D1
2 30 – 70% P2 I2 D2
3 70 – 100% P3 I3 D3

 Example: Fisher DPR900TM Single-loop Controller

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Session Summary
 Manual tuning of PID controller can be
conducted in various ways by means of some
plant test
 There simply is no way to analytically tune a

controller if we do not know the type of

algorithm and the units
 Autotuning simplifies the tuning procedure of

PID controller

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