Visualize the Core of Process Automation in Action

PID Control Simulation

Experience the fundamentals of Proportional-Integral-Derivative (PID) control with this interactive simulation. Used extensively in industrial automation, PID controllers regulate variables such as temperature, pressure, and flow with precision and stability. This tool demonstrates how each tuning parameter influences system behavior—offering engineers, students, and decision-makers a clear, intuitive grasp of one of automation’s most essential components. It’s a reflection of Orion Technical’s deep-rooted expertise in control systems engineering.

Orion Technical Solutions - PID Control Simulation

Orion Technical Solutions – PID Simulation

PAUSED

Simulation

Controller Setup

Process Setup

Auto Tune

Training

Notes

Controller Mode

Setpoint (PSI)

Manual Output (%)

Signal Damping:

seconds

Process Disturbances

Tank Inflow Disturbance (% of max)

0%

Tank Discharge Disturbance (% of max)

0%

Process Noise

DISABLED

Raw Process Variable

50.0

psi

Filtered Process Variable

50.0

psi

Output Makeup

Proportional

Integral

Derivative

Controller Output

Response Trend

Process Variable

Filtered PV

Setpoint

Controller Output

Valve Position

Measurement Tool

To use: Click the blue "Measure" button above, then click and drag on either chart to create a measurement box. The tool will display time difference (Δt), value difference (ΔPV), and rate of change (slope). Click "Clear All" to remove all measurements.

No measurements yet.

Controller Tuning

Proportional Gain (Kp):

Integral Time (Ti, seconds):

Integral Gain (Ki = Kp/Ti): 0.75

Derivative Time (Td, seconds):

Derivative Gain (Kd = Kp*Td): 0.00

Derivative on:

Controller Bias (%):

Controller Limits

Controller Output Limits (%):

to

Integral Term Limits (%):

to

Anti-Reset Windup

Anti-Reset Windup:

DISABLED

Anti-Reset Windup prevents integral accumulation when the controller output is saturated, resulting in faster recovery and less overshoot when returning from limit conditions.

Process Parameters

Process Gain:

Time Constant (seconds):

Dead Time (seconds):

Valve Parameters

Positioner Time Constant (seconds):

Rate Limit (%/second):

Dead Time (seconds):

Valve Characteristic:

Effective Valve Range (%):

to

Auto Tune Parameters

Enter your process parameters to calculate recommended controller settings for different response types.

Process Gain:

Process Time Constant (seconds):

Total Deadtime (seconds):

Use Current Process Values:

PID Control Training Topics

Key concepts and learning topics that can be demonstrated with this simulator.

Fundamentals of PID Control

Understanding Process Variable, Setpoint, and Error
The Proportional Term: Immediate Response
The Integral Term: Eliminating Steady-State Error
The Derivative Term: Anticipating Changes
Controller Bias and Its Role

Advanced Topics

Anti-Reset Windup Strategies
Signal Damping and Noise Filtering
Derivative on Error vs. Process Variable
Bumpless Transfer Techniques
Process Disturbance Rejection

Using This Simulation

This simulation models a pressure control system with a control valve regulating flow into a pressure vessel or header.

Key Features:

Raw vs Filtered PV: Shows the effect of signal damping on noisy measurements
Output Makeup Chart: Visualizes how P, I, and D components combine to form the controller output
Process Disturbances: Simulate real-world upsets with inflow and discharge disturbances
Process Noise: Add realistic measurement noise with configurable characteristics
Measurement Tool: Analyze response characteristics by measuring time, amplitude, and rate of change

Tips:

Use signal damping to filter noisy measurements, but be aware it adds lag to the control response
Enable Anti-Reset Windup to prevent integral accumulation during output saturation
Try derivative on PV instead of error to avoid derivative kick on setpoint changes
The Output Makeup chart helps understand which control term is dominating the response