eBook

Top 6 Questions to Answer to Reduce Process Variability eBook

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Top 6 Questions to Answer to Reduce Process Variability

There are times when a process variable (PV) shows an unacceptable level of variability around its setpoint (SP) while being regulated by a PID controller. In order to improve the quality of regulation of the process variable, there are six important questions to consider.

In this eBook we provide the six questions along with subsequent observations to help you in answering the questions.

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Tuning Rules for PI anad PID

Tuning Rules for PI and PID

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Tuning Rules for PI and PID

Determining Which Controller to Use

A key challenge in setting up a control system is determining what type of controller to use. The PID controller is generally accepted as the standard for process control, but the PI controller is sometimes a suitable alternative. A PI controller is the equivalent of a PID controller with its D (derivative) term set to zero.

It is important to understand how controllers interact with each different type of process. For details, see Table 1.

Table 1 – How PI and PID Controllers Interact with Different Kinds of Processes

Controller Pl Controller PID Controller
Effective for These Processes Fast processes, such as flow, pressure, and some temperature loops. Slower processes, such as level and insulated temperature.
Tuning Parameters P = Proportional
I= IntegralPl controller is the equivalent of a PID controller with its D (derivative) term set to zero.		 P = Proportional
I= Integral
D = DerivativeThe derivative term is particularly important for integrating processes, such as level, position, & well-insulated temperature.In general, using a derivative term can significantly increase the speed of the response of a non-integrating process and suppresses overshoot.
Response Speed Response is slower, thus enabling a smooth and accurate PV change. Response is faster, thus enabling setpoint to be reached more quickly.
Overshoot Overshoot will likely occur. Reduced or no overshoot.
Download the data sheet
MANTRA v6002

MANTRA Advanced Process Control Software v6.0.0.2

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ControlSoft is pleased to announce the release of MANTRA Advanced Process Control Software v6.0.0.2. MANTRA v6.0.0.2 includes the following updates:

  • I/O Array Blocks – Six new I/O Array blocks have been added to the standard I/O block list. The blocks include Input Array (Boolean), Input Array (Integer), Input Array (Float), Output Array (Boolean), Output Array (Integer), and Output Array (Float).
  • Block Watch Window Automatic Tunable Upload – The tunable values edited from the Block Watch windows can now be uploaded automatically to the project database after updating the value in the Kernel.
  • OPC Device Status Detailed Dashboard – A detailed OPC Device information and connectivity status dashboard is now available in the Service Monitor Kernel icon.

For the full list of updates, please see the MANTRA Software 6.0.0.2 Release Notes, publication MN339C-EN, included with the software download.

Need help with advanced techniques for process control beyond basic PID control? Consider our Advanced Process Control Techniques training to learn about cascade control, override control, gain scheduling, feedforward compensation, and model-based control.

About ControlSoft

Since 1985, ControlSoft has been a global provider of platform-independent process control software and engineered solutions. Our products and services are sought by prominent companies in leading industries. By keeping a focus on improving plant availability, production efficiency, operational safety, and environmental compliance, we continue to deliver world-class control solutions for our customers.

Media Contact

Paul Botzman
pbotzman@controlsoftinc.com
phone 440-443-3900, ext. 101

Contact us to learn more about MANTRA.

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MANTRA is a registered trademark of ControlSoft Inc.

INTUNE v7501

INTUNE and INTUNE+ Software v7.5.1.0

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ControlSoft, Inc. is pleased to announce the release of INTUNE PID Loop Tuning Tools and INTUNE+ CLPM Software, v7.5.1.0.

INTUNE PID Tuning Tools includes robust auto-tuning and advisory adaptive-tuning tools that minimize the effort needed to optimally tune your PID controllers.

INTUNE+ CLPM Software is a non-intrusive plant management and process control predictive maintenance tool that combines process control monitoring with powerful diagnostic and tuning features.

INTUNE v7.5.1.0, includes includes the following enhancements:

  • Diagnostic Script, Retry-On-Error Option – The Diagnostic Script Plugins now have the option to automatically retry execution after an unhandled exception in the script.
  • OPC Array Datatypes – The IO driver will now detect unsupported OPC DA array datatype tags and report an error in the IO Quality column for the controller property.
  • Historian Data Status Dashboard – Trend Control now provides a Historian data dashboard to report information when loading historical data.
  • Command-line Enhancements for Auto-Start and Auto-Recovery – The INTUNE service command-line options have been updated to support starting/stopping the service and starting/stopping the INTUNE project together or in separate commands.

For the full list of updates, please see the INTUNE Software v7.5.1.0 Release Notes, publication MN113B-EN, included with the software download.

Want to learn more about PID tuning? Consider our PID Loop Tuning training to learn about PID control fundamentals, how to evaluate the health of PID loops and how to tune a PID controller.

About ControlSoft

Since 1985, ControlSoft has been a global provider of platform-independent process control software and engineered solutions. Our products and services are sought by prominent companies in leading industries. By keeping a focus on improving plant availability, production efficiency, operational safety, and environmental compliance, we continue to deliver world-class control solutions for our customers.

Media Contact

Paul Botzman
pbotzman@controlsoftinc.com
phone 440-443-3900, ext. 101

Contact us to learn more about INTUNE software.

Contact Us

INTUNE is a registered trademark of ControlSoft Inc.

Applying PID Control to Non-linear Processes

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Matt Petras, Alireza (Ali) HajiValizadeh
August 30, 2023
Control Engineering: https://www.controleng.com/articles/are-you-applying-a-pid-control-to-non-linear-processes-correctly/

Cascaded PID Control of Tank Outlet Temperature

Tuning Cascade Loops

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AdaptTune Third Recommendation

Derivative Tuning for PID Control

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MANTRA Advanced Process Control

MANTRA Software v5.6

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ControlSoft is excited to announce the release of MANTRA Software v5.6 which includes the following user interface and tool enhancements:

  • Block Execution Sequence Tool – The Block Execution Sequence dialog has been updated with new
    features and usability enhancements.
  • Block Parameter Watch Windows – Block-specific Watch Windows now have the block name removed from all block parameters for better readability. The block name is now part of the window title instead.
  • Project Watch Window Tabs – The last selected Watch Window tab is now saved in the project. When re-opening the Watch Window, the tab is automatically restored and selected.
  • Input/Output Connector Traversals – Additional functionality has been added for Input and Output Connector Block traversals.
  • Online Monitor and Offline Block Parameter Modes – Online Monitor mode is now distinguishable from Offline mode in block diagrams.
  • Block Diagram Selection Dialog – The Dialog to select a block diagram has been expanded for better visibility of project names and diagram lists.
  • Module Versioning – Module and project versions are reported more consistently with additional information in the Help -> About dialog.

For detailed information, please see the MANTRA Software v5.6.0.1 Release Notes, publication MN338A-EN, included with the software download.

For more help with advanced techniques for process control strategies beyond basic PID control, including cascade control, override control, gain scheduling, feedforward compensation, and model-based control, consider our Advanced Process Control Techniques training.

Schedule a Demo
INTUNE & INTUNE+

INTUNE PID Tuning Tools and INTUNE+ CLPM Software v7.0

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ControlSoft, Inc. is pleased to announce the release of INTUNE PID Loop Tuning Tools and INTUNE+ CLPM Software v7.0. INTUNE PID Tuning Tools includes robust auto-tuning and advisory adaptive-tuning tools that minimize the effort needed to optimally tune your PID controllers. INTUNE+ CLPM Software is a non-intrusive plant management and process control predictive maintenance tool that combines process control monitoring with powerful diagnostic and tuning features.

INTUNE v7.0 includes enhanced tuning formulas to improve PID terms for time-constant dominant non-integrating processes. Improvement is pronounced for slow dynamics.

Figure 1 – Adaptive Tuning

Adaptive Tuning

In addition, INTUNE v7.0 also includes the following updates:

  • OSIsoft PI Data Driver that easily connects to a OSIsoft PI server to access data.
  • OSIsoft PI Data Import that easily connect to PI AF SDK to access historical data in INTUNE’s DataTune plugin. You can map process datapoints to PI historical tags (PV, SP, CO, Mode).
  • Server and Tag Browsers that can be integrated with other data drivers including OPC DA and OPC UA.

INTUNE+ CLPM v7.0 includes all the INTUNE v7.0 updates, as well as a new WebUI. You can connect this WebUI to an INTUNE+ CLPM project after it is completed and deployed for a clear and concise view of loop performance.

Figure 2 – INTUNE+ CLPM WebUI

INTUNE+ WebUI

For detailed information, please see the INTUNE Software v7.0.0.2 Release Notes, publication MN112A-EN, included with the software download.

About ControlSoft

Since 1985, ControlSoft has been a global provider of platform-independent process control software and engineered solutions. Our products and services are sought by prominent companies in leading industries. By keeping a focus on improving plant availability, production efficiency, operational safety, and environmental compliance, we continue to deliver world-class control solutions for our customers.

INTUNE is a registered trademark of ControlSoft Inc.

Media Contact

Paul Botzman
pbotzman@controlsoftinc.com
phone 440-443-3900, ext. 101

Schedule a Demo
PID Loop Tuning Pocket Guide v7

PID Loop Tuning Pocket Guide v7 Now Available

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We’re excited to share a new version of the PID Loop Tuning Pocket Guide to help your team simplify processes so you can deliver your best. As fellow engineers, we know that properly tuned PID loops are crucial to enhancing your plant’s performance. That’s why we’ve thoughtfully redesigned this pocket guide based on your feedback.

This quick reference guide introduces your team to the process of manual PID tuning. It covers things like:

  • Process definitions and controller terms
  • Types of PID loops
  • Tuning methods and loops
  • PID tuning tools
  • And more

Download the guide today and learn how to efficiently tune PID loops.

Download Pocket Guide

We created this pocket guide to solve for simple solutions. If your needs are more complex, our team of field engineers and PhD’s would love to hear about it.

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