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Industrial Process Engineering Laboratory

Laboratory questions for 28/03/2014

1.

Design

P, PI and PID controller for the control of a heating process

dynamics

which is found to have the following

G

f

(

s

)

1

0.5

s

1

G

p

(

s

)

0.236

(7

s

1)(5

s

1)

e

2.2 s

G

m

(

s

)

1

  • I. Use Cohen Coon (CC) open loop method (Process reaction curve method) for finding the parameters (tuning)

K t P II. In P-only controller, change the value of t by  25% from
K
t
P
II.
In P-only controller, change the value of
t
by  25% from the tuned value and analyse the effect on rise
t
e
r
p
s
ss
time (
), % overshoot (%OS ), peak time (
), oscillations, settling time (
), steady state error (
), ISE,
IAE, ITSE, ITAE for closed loop performance with unit step change in set point.
T
t
I
III.
In PI controller, change the value of
t
by  25% from the tuned value and analyse the effect on rise time (
t
r
p
s
ss
), % overshoot (%OS ), peak time (
), oscillations, settling time (
), steady state error (
e K
P
ITSE, ITAE for closed loop performance with unit step change in set point. (Keep the value of
as the CC value)
), ISE, IAE,
unchanged
T
IV.
In PID controller, change the value of
), % overshoot (%OS ), peak time (
t
D
t
by  25% from the tuned value and analyse the effect on rise time
t
e
r
p
s
ss
(
), oscillations, settling time (
), steady state error (
K
), ISE, IAE,
T
P
I
ITSE, ITAE for closed loop performance with unit step change in set point. (Keep
unchanged as the CC value)
and
values
K
,
T
P
I
D
V.
Analyse the effect of
Controller
Parameter
T t
and
on output dynamics:
t
t
e
r
p
s
%OS
Oscillation
ss
K
s
T
P
T
I
D
Increases
  • 2. Test the ability of designed PID controller for disturbance rejection. Give disturbance in the form of pulse with magnitude = -0.5, Time period = 200s and duty cycle = 5% to the process (add with the real process output, Note: summation should be before the feedback). And analyse the closed loop performance.

  • 3. If the FCE is subjected to constraint that it will get saturated at -4 and +4. Analyse the closed loop performance. Note:

    • 1. Simulation time should be high enough to understand the dynamics properly.

    • 2. In all closed loop analysis, use two scopes. (Scope 1: Process output and Set point; Scope 2: Controller output and Final control element output).

    • 3. See Appendix -1, for some guidelines for Cohen Coon tuning method.

Lalu Seban, Assistant Professor, Dept. of E&IE, NIT Silchar

Appendix - 1

The Cohen-Coon (C-C) Process reaction curve method is a PID tuning technique which uses the open loop step analysis for finding the parameters of PID controller for the closed loop system. The steps to follow are given below.

i.

Detach the controller from the closed loop system. The input is given as the manipulated variable (to the final

ii.

control element). The output is taken from the process (in reality the sensor circuit output). So C-C method checks the dynamics of final control element, process (and sensor) in the test for finding the tuning parameters. Make sure the process is at an initial steady state.

iii. Introduce a step change in the manipulated variable.

iv.

Wait until the process settles at a new steady state.

v.

From the reaction curve (output response) to the step change at input, find its approximate FOPTD (First Order Plus

Transport Delay) model. (Identify gain K , time constant , transport/time delay ) vi. Identify the PID parameters from the table provided by Cohen Coon.

Appendix - 1 The Cohen-Coon (C-C) Process reaction curve method is a PID tuning technique which

Lalu Seban, Assistant Professor, Dept. of E&IE, NIT Silchar