PowerFlow Paper Solutions

Control Tuning Guide

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Overview

Proper control tuning ensures the system responds effectively to profile deviations while maintaining stability. This guide covers the key parameters and a systematic tuning approach.

Control Modes

Mode Description Recommended For
Integrating Accumulates error over time for gradual correction Standard operation (recommended)
Static Direct proportional response to current error Fast response requirements
Manual No automatic control Testing, commissioning
Dynamic Adaptive with correlation analysis Variable process conditions
Recommendation

Start with Integrating mode for most applications. It provides smooth, stable control and eliminates steady-state error.

Key Parameters

Control Gain

Determines how aggressively the system responds to errors:

Control Gain Range: 0.1 - 1.0
0.2 Conservative
0.4 Typical
0.7 Aggressive

Higher gain = faster response but risk of oscillation

Control Interval

Time between control calculations:

Control Interval Range: 30 - 120 seconds
30s Fast
60s Typical
90s Slow

Should be ≥ scanner traverse time

Filter Depth

Smoothing applied to profile data:

Filter Depth Range: 0.0 - 1.0
0.1 Light
0.3 Typical
0.6 Heavy

Higher = more smoothing, slower response

Deadband

Minimum error before action is taken:

Deadband Range: 0.2 - 2.0 g/m²
0.3 Tight
0.8 Typical
1.5 Wide

Prevents valve hunting on small variations

Tuning Procedure

  1. Start Conservative

    Begin with low gain (0.3) and long interval (90s)

  2. Enable Control

    Put zones in AUTO mode, starting with center zones

  3. Observe Response

    Watch profile 2-sigma over 15-30 minutes

    • Profile improving: Continue at current settings
    • Profile stable: Consider increasing gain
    • Profile oscillating: Reduce gain immediately

  4. Increase Gain Gradually

    If stable, increase gain by 0.1 and observe

  5. Reduce Interval

    Once gain is optimized, try reducing interval to 60s

  6. Fine-tune Filter and Deadband

    Adjust based on profile noise and valve activity

Optimization Tips

If Profile is Oscillating

  • Reduce control gain by 20-30%
  • Increase control interval
  • Increase filter depth
  • Check zone mapping is correct

If Response is Too Slow

  • Increase control gain gradually
  • Reduce control interval (not below scanner time)
  • Reduce filter depth
  • Check valves are responding correctly

If Valves are Hunting

  • Increase deadband
  • Reduce control gain
  • Increase stepping limit
Gradual Changes

Always make small, gradual parameter changes. Large changes can destabilize the process. Allow 15-30 minutes between changes to observe the full effect.