Bangladesh University of Engineering and Technology

Course No.: CHE 402

Course Name: Chemical Engineering Laboratory V

Experiment No.: 06
Name of the Experiment: Study of Process Control - I

Submitted by,
Md. Abdullah Al Kafi
Student ID: 1602055
Level-4, Term-1
Department- ChE

Submitted to-
Mesbah Ahmad
Lecturer
Department of Chemical Engineering, BUET

Date of Performance: 23/05/21

Date of Submission: 31/05/21
Summary
The main objectives of this experiment were to learn how to develop a first order plus time delay
(FOPTD) model using step change data and then use the data developed model to design and tune
Proportional Integral Derivative (PID) controllers. The experiment was carried out in ‘Simulink’
and obtained data from simulation was used in ‘MATLAB’ to produce plots. An open loop setup
was used to develop FOPTD model. For a step input, output response was observed in the scope.
The significance of controller gain (Kp), time delay (θ) and time constant (τ) was understood from
the open loop response curve. A closed loop setup was used for designing PID controller. Internal
Model Control (IMC) was used to calculate P, I and D values from FOPTD parameters. Integral
of absolute error (IAE) was used for tuning purpose.
Simulink Block Diagram

Figure 1: Simulink block diagram for open loop

Figure 2: Simulink block diagram for closed loop

Result and Discussion
Given;
Controller gain Kp = 2
Time constant τ = 55 + 12 = 67 seconds
Step time = 5 seconds
Initial value of input = 0
Final value of input = 2
Time delay, θ = 10 seconds
For these data the open loop response curve is shown bellow

X: 82
Y: 2.53

θ τ

Figure 3: Open loop response curve

From the graph we can see that at t = ( step time + θ + τ ) the output response is 63.2% of the
final output value.
Data needed for PID controller was calculated by Internal Model Control (IMC) method. Three
sets of tuning were made for both PI and PID controller. Integral Absolute Error was calculated
for each simulation set. These data are tabulated bellow

Table 1: Tuning parameters for PI and PID controllers

Integral
Type of
Observation P I D Absolute
controller
Error (IAE)

IMC 1.036 0.015 0 667.50

Tuning 1 1.050 0.020 0 652.90

PI
Tuning 2 1.100 0.025 0 661.90

Tuning 3 1.150 0.030 0 669.60

IMC 1.317 0.018 6.128 556.70

Tuning 1 1.500 0.020 6.500 501.00

PID
Tuning 2 2.000 0.030 7.000 358.80

Tuning 3 2.500 0.040 7.500 324.60

For closed loop setup PID values were used from this table. The input output responses from the
simulation were plotted in MATLAB. Resulted curve is shown bellow
Figure 4: Closed loop response curve for PI controller

Figure 5: Closed loop response curve for PID controller

The initial value of P, I and D was calculated using IMC method. Tuning was performed in order
to reduce Integral Absolute Error (IAE). Some important observations were made during
simulation. When only proportional controller is used the output never reach the setpoint. There is
always an offset between setpoint and output. This is because when error becomes small, controller
action becomes negligible and it does not affect the system. So, if only proportional controller is
used desired condition is not obtainable unless setpoint is set at a higher value than original
setpoint. This shortcoming can be neutralized by adding integral controller wit proportional
controller. As integral controller takes action according to area created by error with time. So, set
point can be reached using PI controller. However integral controller is not used alone because at
the beginning the created area remains small so the controller action. So, controller cannot respond
rapidly and it takes longer time to reach setpoint. The performance of PID controller is better than
PI controller which can be seen from figure 4 and 5. Derivative action is used to speed up the
response or to stabilize the system. Derivative controller cannot be used alone as for a system with
constant error controller with take no action.
 Appendix

Sample Calculation
Change of Output
Process gain, Kp = =2
Change of input

Kp e−θs
Transfer Function, G(s) = τs+1
2e−10s
= 67s + 1

Calculation of controller parameters by IMC method

1. For PI controller:
1 τ
Controller gain, Kc = K
p θ + τ/3

1 67
=2× 67 = 1.036
10+
3

Integral time or reset time, 𝜏I =𝜏= 67 s

P = Kc = 1.036
Kc
I = τI = 0.015

2. For PID controller:

θ
1 τ+2
Controller gain, Kc = K θ
p τ/3 +
2
10
1 67+
2
= 2 × 67 10 = 1.317
+
3 2

θ
Integral time or reset time, 𝜏I =𝜏+ 2 = 72
τθ
Derivative time, 𝜏D =
2τ + θ
67 ×10
= = 4.65
2 ×67+ 10

P = Kc = 1.317
Kc
I = τI = 0.018

D = Kc × 𝜏D = 6.128