Industrial Instrumentation

and Control
INSTR F343
BITS Pilani
Note to students

These slides should only be considered as supporting

material. To have a thorough understanding of the
course, these must be accompanied by textbooks,
reference materials and lecture notes.

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Outline

• Continuous controller modes

• Proportional controller
• Integral control mode
• Derivative control mode
• Composite modes
• Dynamics of these controllers in feedback loops
• Variants of PID controller
• Tuning aspects
• Discrete time implementation
• Intelligent PID control structures

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Controller modes

Error (e)
=r–b Controller output (u)
Reference (r)
Controller

Measured value (b)

• Discontinuous controller mode

• Continuous controller mode

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Continuous controller modes

Most commonly used continuous feedback controllers are

• Proportional controller (P controller)
• Proportional – Integral Controller (PI controller)
• Proportional – Integral – Derivative Controller (PID
controller)
• Proportional – Derivative Controller (PD controller)

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Proportional controller

• An extension of two-position or multi-position controller

mode.
• A way to have a smooth and linear relationship between
error and controller output.
• Over some range of errors, the controller output has a
one-to-one relationship with error.

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Proportional controller…

𝑝 = 𝐾𝑃 𝑒𝑃 + 𝑝 0
Where,
KP = proportional gain (% per %),
eP = error,
p(0) = controller output in steady state or when error is zero.

Proportional Band (PB): A range of errors over which the

controller output changes from 0% to 100%. In this range only,
a one –to –one correspondence exists between controller
output and error.

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Proportional controller…

Effect of very
high gain???

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Proportional controller:
OFFSET
• Most of the time, to correct the disturbance effect or
setpoint change, there is a small amount of residual error
which exists in steady state. This constant residual error
is called ‘OFFSET’.

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Proportional controller:
OFFSET…

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Simulated response for G(s) =
2/(10s+1) with setpoint of 4

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Example

• Consider the proportional-mode level-control system of Figure

given below. Valve A is linear, with a flow scale factor of 10 m3/h
per percent controller output. The controller output is nominally
50% with a constant of KP = 10% per %. A load change occurs when
flow through valve B changes from 500 m3/h to 600 m3/h. Calculate
the new controller output and offset error.

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Solution

For achieving new steady state, the

valve must move to a new value of
600 m3/h.
So,
p = KpeP + p(0)
60% = 10*eP + 50%
eP = 1% (OFFSET error)

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Integral mode of control

• In order to remove offset occurred by P controller, one can use

an integral controller.
• It will integrate the error and generate the controller action
until error reduces to zero.

𝑡
𝑝 𝑡 = 𝐾𝐼 න 𝑒𝑃 (𝑡) 𝑑𝑡 + 𝑝(0)
0
Where, KI = Integral gain
Another way to look at this equation is,

𝑑𝑝
= 𝐾𝐼 𝑒𝑃
𝑑𝑡
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Integral controller mode…

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Integral controller mode…

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Proportional Integral controller
(PI controller)
𝐾𝑐 𝑡 1
𝑐 𝑡 = 𝐾𝑐 𝑒 𝑡 + න 𝑒(𝑡) + 𝐶𝑠 𝐺𝑐 𝑠 = 𝐾𝐶 (1 + )
𝜏𝐼 0 𝜏𝐼 𝑠

Reset action

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PI controller

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Derivative control

Also called as rate action OR anticipatory control

𝑑𝑒𝑝
𝑝 𝑡 = 𝐾𝐷
𝑑𝑡

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Derivative control mode…

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PID controller

𝐾𝑐 𝑡 𝑑𝑒(𝑡)
𝑐 𝑡 = 𝐾𝑐 𝑒 𝑡 + න 𝑒(𝑡) + 𝐾𝐶 𝜏𝐷 + 𝐶𝑠
𝜏𝐼 0 𝑑𝑡

1
𝐺𝑐 𝑠 = 𝐾𝐶 1+ + 𝜏𝐷 𝑠
𝜏𝐼 𝑠

𝐾𝐼
𝐺𝑐 𝑠 = 𝐾𝑃 + + 𝐾𝐷 𝑠
𝑠

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PID controller

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Dynamic behavior of the
feedback controlled processes

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Dynamic behavior of the
feedback controlled processes

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Effect of a proportional
controller
If,

Remarks,

• It remains first order with respect to load and

setpoint change.
• The time constant has been reduced, which
means that closed loop response has become
faster.
• The static gains have decreased.

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Offset due to P controller

Offset = Offset =
𝐾𝑑
′
𝐾𝑝 𝐾𝑐 𝟏 0 − 𝐾𝑑′ = 0 −
1 − 𝐾𝑝 = 1 − = 1 + 𝐾𝑝 𝐾𝑐
1 + 𝐾𝑝 𝐾𝑐 𝟏 + 𝑲𝒑 𝑲𝒄
𝑲𝒅
=−
𝟏 + 𝑲𝒑 𝑲𝒄

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Problem 1

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Problem…

Find the offset for a unit

step setpoint change and
unit step disturbance.

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Effect of proportional controller
on a second order process

Remarks,

• It remains second order with respect to

setpoint and load change.
• The static gains have decreased.
• Bothe, the natural period and damping factor
decreases.

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Effect of proportional controller
on a second order process

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Effect of integral control action

Say, and, for a pure integral action,

The output with respect to setpoint change, will become,

𝐾𝑝 𝐾𝑐
𝐺𝑝 𝐺𝑐 𝜏𝑝 𝑠 + 1 𝜏𝐼 𝑠
𝑦(𝑠) = 𝑦𝑆𝑃 (𝑠) = 𝑦𝑆𝑃 (𝑠)
1 + 𝐺𝑝 𝐺𝑐 𝐾 𝑝 𝐾𝑐
1+
𝜏𝑝 𝑠 + 1 𝜏𝐼 𝑠
Where, 𝜏𝐼 𝜏𝑝
1 𝜏= ൗ𝐾 𝐾
𝑦(𝑠) = 2 2 𝑦 (𝑠) 𝑝 𝑐
𝜏 𝑠 + 2𝜁𝜏s + 1 𝑆𝑃
1 𝜏𝐼
𝜁= ൗ𝜏 𝐾 𝐾
2 𝑝 𝑝 𝑐
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Effect of integral control action

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Simulation results
[G(s) = 2/(2s+1)], Setpoint = 4

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Simulation results
[G(s) = 2/(2s+1)], Setpoint = 4

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Remarks on Integral control

• The value of KC and tI can change the response from

overdamped to critically damped to underdamped as well.
This should be handled with proper tuning of these
parameters.
• As integral action increases (KC increase or tI decreases),
the damping factor decreases, and thereby related
characteristics comes into play.
• Sluggish response can become faster but at the expense
of oscillations.

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Some info using pole-zero
map

Integral gain
increasing

Integral gain
increasing

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Some info using pole-zero
map

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Effect of derivative control
action
For a derivative control action,
GC = KC tD s
Assuming again Gf and Gm equal to unity,

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Effect of derivative control
action

• The derivative control does not change the order of the response.
• The value of effective time constant of the closed loop response is
higher than the open loop system. Thus the response of controlled
process is slower than that of the original first order process.

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Effect of derivative control action
on a second order process

• The derivative control does not change the order of the response.
• The closed loop response is more damped and thereby sluggish
than the open loop system. This behavior increases the robustness
in the system.

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Effect of composite control
action: PI controller
• The order of the response increases by one (effect of integral
mode)
• The offset is eliminated (effect of integral mode)
• As KC increase the response becomes faster and more
oscillatory to setpoint changes. Use of certain values of KC
may make system even unstable.
• As tI decrease, integral action increase and response become
more oscillatory with larger overshoots.

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PI controller and Integral
controller comparison

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Do it yourself…

• Plot poles of closed loop system (take a first order system) for a PI
controller and also find the effect of increasing proportional action
and integral action (a) independently and (b) simultaneously as well.

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Effect of PID controller

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Problem in parallel PID
structure

KC

Error (e) + Controller output (u)

KC /𝜏𝐼 𝑠 +
+

KC𝜏𝐷 𝑠

Parallel PID structure

• Problem of integral windup
• Problem of noise sensitivity due to derivative action
• Problem of proportional and derivative kick

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Integral windup

What is integral windup?

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Integral windup

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Remedy for integral windup:
Anti-windup control

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Noise sensitivity due to
derivative action

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Noise sensitivity due to
derivative action

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Magnitude variation for different
actions of a PID controller

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Effect of Derivative action:
time domain

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Remedy: Bandwidth limited
derivative action

Inclusion of a first order low pass filter

(High frequency gain)

Another representation of bandwidth limited derivative,

(High frequency gain)

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Bandwidth limited derivative
action

For, Proportional
gain = 5, tD = 0.2,
and n = 5.

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Proportional Kick

Consider a step change in the error,

• Due to proportional action, a sudden change in the controller output
will be experienced.
• This can affect the operation of actuator/final control element present
in the loop.
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Proportional kick

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Remedy: Proportional kick

I – P structure for suppressing proportional kick

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Process behavior for I – P
controller

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Derivative kick effect

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Effect of derivative kick

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Remedy: Derivative kick

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Process behavior for I – PD
controller

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 BITS Pilani

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