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Proj ect Based Learning

on

PROCESS MODELLING and SIMULA TION

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TITUTIOl#S
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Year : 3 rd year(VI sem)

Topic : Response of level control in a cylindrical tank for various disturbances
in tuning PID parameters.
Submitted by

Name: S. HEMALATHA

Rcgd.no: 20335A0810

Department of Chemical Engineering,

MVGR College of Engineering (A), Vizianagaram

1
 Table Of Contents

---- -
Page Preparations
S.No Chapte r Title
Nos
- ----
Problem Statement: Significance: App!Jcatwns:
1 Introdu ction 3-4
Industry Operati ons
-- ----1
I
Publications related to experim ents atlca st 15
2 Literatu re Survey 5-6 reports
--- -- -- --
Mathem atical Diagram of Equipm ent and Std Operati ng
3 7 Procedu re
modell ing

Results & 8-11 Graphs , Results, Interactions with variabl es

4
Discuss ions

5 Conclu sions 12 Influence and effect of variable s

Referen ces 13 Source informa tion's

6

2
I. Jntroduction
fnr sc i\ o prohlc111 nnd
f: - Find 1)t1t the 11'sJl1llls1.· 11f i11fq.\1,111 llf sp ,l1' lll s
Problem Stt1Ti'lt1'.'II
1,, 111g 11 111,fi.·1 l1111ct1011
folh
rcgul.Ht)t\ pro bk m fo1 gi, l'll Pl!) p.ll.lllll'h'rs fo, rh1•
l 1111cg1,d. dcl l\.i lr\c , PII)
r 1s t'Om bin .1ti1,n ,if 1h11.'1.' m11tks i.l'., ptop11111011u
PID 1.''- ntrt,!k
1 s1• ol 11 s 1110 JC
It 1s m1. ,st usd ul in 1h1.• rndust11,tl .ippltci1l1011s l>t•c,111
ss
con tro lkr is 1wnlmca1 pr,,1.'t• 11 -.111 h1• opc1.1tcd hy t\\
o 111odc..:s er tit er
. \ 1.'n kss 1.lsrill.1t1nns , 1
benefits like. fast rcspt1ns1.' to this sl,1hJ/11y 111c1eu sc
I nwd 1.• PlD d1.•1 .·1c.1 s1.•s ,11.-.1dv st.i c11n1 due
ll'
automat1r 1.,r m.m u.1
st tJSC' 1111.•fhnd 111 t1111tr1!
' of Pl/> rn11trollc r. I'll>
·th1 .hl 1s th1.· mo
7ic gk r-~ 1c hn rs tuning m1. r l'rnporlromd r.;0111101
.md r1, mp k\ 1.' 1ln lwl k1 , 11 l'l1111111.1tt·s off:..cl 1•11o
controller ts a po,,·cr ful ely used m
out put 1lp1 .•1,1t1.· li111.•.i1 ly 1·,11 ly. I'll) n111trollc1 rs wid
hl 1ts
pro, idc:-s bc:-th.·r l.'.'ontrol due t1nc hc1111cal pl:111h nnd 11ucle:
rr power plant s me
the md1 1slt 11.• s. p1.•
industnal proc1.•ss. \lo st 1.)f
111odcs. propor11011,il . int egr
al,
kH ·I con t it,! sys tt·m s. II 1s cn111b111,lt1011 of' tl11cc at cs
depend upvn tan l- ~ponsc mid nlso eli nun
t'O ntro lk1 lwc .n1 sl' tt givl's nw,c fasr tt·
d
de m atiH·. PID is nwst use .idJw,t a one lc\ cl \\h ere 110
Fo r fas t res pon se PID cont1olk1 h.i w to
offset error from S)s tcm capnb1liti cs
arw hk and set pm nL Pl! ) con tw lkr ltmitL·d 111 11tc 11
s ,
error occur between proces tll task .
pk '- pro cesses ,1re rL'quirt·d to pcrfc.H nrrcctly then
especially when com con tH) IIL 'r paramL'lcts arc taken inr
sys tem If PID
PID 1s based on computer usrng PID controlle r
is uns tab le. PID do not pn n 1dc optimal control. By
input of conrrol proces s ke system .
k or mo re tan ks PJD con trnllcr reduces rise time to ma
tan c. PIO 1s most use d
we can control JeyeJ of one
n of thr ee mo des . pro port10nal inlcgral, de m ativ
It is combinatio tcm . Fo r
t res pon se and als o elim inates oflset error from sy~
more fas
controller because it g1Yes one lcn~I whcrc no crro1 occ
urs hctwecn process
ller h,n e to adj ust a
fast response PID con tro
ted 111 their capabilities
espccwlly when complex
con tro ller lirm
Yariable and set poinl. PID
per fon n task. ectly then
processes are required to con tro ller parameters arc taken incorr
sys tem . 1f PID
PID is based on computer n idc optimal control. By usm
g PID controller
uns tab le. PID do not pn
input of control process 1s
cs me tune 10 make systc-m
one tml 1. or mo re- tanks PID controller rcdtu.:
we can control lev el of 1chol 's method.
s me tho ds are gm ?n for le, cl control like Zicgler-N
response fast. The variou 111 PLC usmg l1cglc
r-N1chol's method. Cohen
-
d. Mo st PID 1m ple1 11e nted
Cohen-coon metho sists of:
gram of PID controller con
coon method. The blo ck dia
s which is to be controlled.
PLANT- it is p~ut of proces 1cc "h ich user want lo control CO
J\ TROLLER-
the var iab le fro m de,
FEEDBACK- 1t measures
pro ces s. It read and process error.
it is important part of s
gral and measured 111 second
SET POINT also called inte l) 7cd using Stmulink in MA
TLAB sofn, are . The
for bot h me tho ds are ana
The responses .
PID controller 1s gn en bd o\\
several methods for tuning
d
• Ziegler-Nichol's metho
3
 • Cohen-Coon method
A. Ziegler-Nichol's tuning Method:
inventedThis
· method
19 . hY JOIm C1 • Ziegler
h is developed . . &. l\athm11cl
• . B N1choh,
. Thi'i method
. , m . 40 , ad . a large 1mp·i'c•t ·111 ma k'· lllg pl 1) 1ccdback
r control 11cccpt,1blc to control
.
engineersPIDwllh the Ziegler
. . Nichol s ru 1,cs, cngmccrs
, . finally bud a prnc111:al nnd systematic ,,ay of
tunmg . loops 101 11nproved p,er fiormann:, • , 1\ "ftcr takmg . measurements of actual c;ystem
response, tunmg rule confidently rccommenc s
1 1 I 1c PID ga111s to use This method vnltd for open
loop plants follows following steps:
► First set. plant with a •s111 all g,1111 · up to oscilh:i11ons
. · .,liltI •mc1casc the gn111 . get started
► Then hnear oscillation rcquin:d fo1 tktcct1on of eontrnlkr output !-lnally ndJust the
controller
► parameter.
► Ziegler-Nichol's method is based on frequency response.
In this method two methods arc involved
• Open loop method
• Closed loop method
B) Cohen-Coon method:
This method based on first order system. After Ziegler Nichols method, Cohen-Coon
method is most used method. This method 1s devclop<.:d m 1953. Cohen-Coon rules were
designed for controllers with non-interactive controller algorithm. It is more flexible than
Ziegler-Nichols method, 1f obJective a fast response, then this method is used.
Cohen-Coon tuning method uses three process elements, which is process gain, dead time
and time. constant. For calculating gain and integral time Cohen-Coon method is not used,
because it requires a measurement of the process time constant. But Ziegler-Nichol's method
does not require a measurement of the process time constant. Cohen Coon method 1s requiring
the response of open loop system. Cohen-Coon tuning method work on process, where the dead.
time is Jess than the time constant. It also provides quarter amplitude damping. Cohen-Coon
rules target is quarter amplitude response dampmg. This type of tuning provides very fast
disturbance rejection. The Cohen-Coon margin for stability is low The small error pushes
system into instability. As compare Z-N method settling of P and Pl controller are less. This IS
good process models, offline and good for first order system It corrects steady state error
response given by Ziegler-Nichol's method. In this tuning method first obtam the process
reaction curve then measure the response.

4
2. Literature Survey

ln the present work , a si 111 PIe me ti10d 1or

r des1gn111g
. . PID controllers based on mternal
. model
1 1 Y ana lys1s
control principles and stab'l"t · 1s
· proposed. The PIO tunmg
. parameters arc given
. as
function of process model parameters. Simulation results on level controller m a cylindncal
tank and non-linear models are given to show the efficiency of the proposed controllers.

The IMC-Based PID Control Design Procedure:

The following steps are used in the IMC-based PID control system design
► Find the IMC controller transfer function, q(s), which includes a filter, f(s), to make q(s)
semi proper or to give it derivative action (order of the numerator of q(s) is one order greater
that the denominator of q(s)). Notice that this is a major difference from the IMC procedure.
Here, in the IMC-based procedure, we may allow q(s) to be improper, in order to find an
equivalent PID controller. The bad news is - you must know the answer that you arc looking
for, before you can decide whether to make q(s) proper or improper in this procedure. We
will generally guide you along the correct path.
► Find the equivalent standard feedback controller using the transformation wnte this m the
form of a ratio between two polynomials.
q(s)
g, (s) = I -gp
- (sq
) (s) (7.1)
► Show this in PID fonn and find kc, 'ti, 'to, Sometimes this procedure results in a PID
controller cascaded with a lag term ('r,) :

g,(s)= k,.[r/rns
2

1:,s
+-r,s+l][~l
tpS"+ I
(7_2)
► Perform closed-loop simulations for both the perfect model case and cases with model
mismatch. Choose the desired value for "A as a trade-off between perfomrnnce and

robustness.

❖ IMC-Based PID Design for a First-Order Process:

Find the PIO-equivalent to IMC for a first-order process.
k
gr(s)= P
rps+ I
Step 1. Find the IMC controller transfer function, q(s), which includes a filter to make q(s)

semi proper.

5
 q(s)=q(s)f{s)=g,.'(s)f(\)=~+I _
kr ).HI

q(s) = _!_ r ,,s + I

k,. ).s+ I
Step 2. Fmd the equivalent standa rd ~cc db ack
(7.3)controller usrng the tranc;formauon

r,,s+I
gc(s)= _q(\) = ~+I) T.\+I
1-g/s)q(s) 1-l rr5+ I - 7'ir
p

'T'r\tl~,.().s-tl) (7.4)
recall that the transfer funct10n for a Pl cnnt1 ollc, is

g.(s)=k, r,~+l
r1s (7.5)
Step 3. Rearrange (7.4) to fit the form of (7.5). Multiplying (7.4) by t t pp, we find

ge(s)=( ~ \TPs+l
~ k/,) ri· (7.6)
equating terms in (7 .5) and (7 .6), we find the following values for the Pl tuning

parameters.
r
k =-p
' kpJ..
ri == r,. (7. 7)
The IMC-based PID design procedure for a first-order process has resulted in a Pl control
Jaw. The major difference is that there are no longer two degrees of freedom in the tuning
parameters kc I () ,t - the IMC-based procedure shows that only the proportional gain needs 10
be adjusted. The integral time is simply set equal to the process time constant. Notice that the
proportional gain is inversely related to A , which makes sense. If A is small (closed loop 15
"fast") the controller gain most be large. Similarly, ,n
IS large (closed loop is "slow") the
controller gain most be small. Also notice that the same results were obtained using the d1rec1
synthesis method - a specified first-order closed-loop response for a first-order process lead 10 a
Pl controller with the parameter values in equation (77).

3. l\1athematical Modellin~
6
 Transfer function of process -

PID senings for, arious methods

r contra lier K T~ --+> ,..:;-
~-~~:1'-
r-- "V -

1;7-
..----+----+ I
1~1C-PlD -242.3356 0.2331 0.0155 0.0 I75

, SA-PID -568.633S 0.0848 0.0170

: DS-PlD -559.5157 0.1013 TooT4T- 071

t I __ j_
Transfer function of controller:

Variables: Load \'ariabk (0.1-1.0)

Measured, an able (0.1-1)

s:rpe

4. Results & Discussions

7
 IM C method) and
IM C-P IO con tro ller (PJD controller designed by
In this section, proposed is method) arc applied to
r (PI D con troller designed by stability analys
proposed SA-PID con trolle s and non -
for var iou s dis turbances for transfer function model
al tan k
level control in a cylindric proposed controllers. The
perfonnancc of the
the efficiency of the
linear models to show troller designed by direct
s is com par ed wit h DS -PID controller (PJD con
proposed controller
synthesis method).

Case study:
tional area A to which is
ich con sists of a tank of uniform cross-sec
Consider the system wh volumetric
h as a val ve, a pip e, or a weir. Assume that q,,, the
R suc linear relationship.
attached a flow resistance , 1s related to the head h by the
) throug h the res istance
flow rate (volume/time
I,
(fo
R
termine the
w q of liquid of con stant density renters the tank De
A time-varying volumetr
ic flo
n tha t relates head to flow.
transfer functio
ance around the tank:
analyz e this system by writing a transient mass bal
We can

( Ra1e of ] (Ra te of acc um ula tion )

Rate of )
of mass in tank
( ma~s llo\ \ in - mass flO\~ ou1 =

balance becomes
d in this analysis, the mass
In terms of the variables use
d(p Ah)
pq( I) - pq/) (1) = --
cft
dh
q(I) - qaU) = Adt-

vo and regulatory
tro ller and DS -PI D con troller parameters. The ser
, SA-PID con ler, SA-PID controller, and
DS-PID
The IM C-P ID controller
s tran sfe r fun ctio n mo del with IMC-PID control con tro ller s. The
pro ble m of the proces ula tory problems is almost sam
e for all the
ce of seIV o and reg IM C-P ID
controller. The perfom1an model with
IAE , and IT AE of the process transfer function h
ISE , model equatio ns wit
perfom1ance rn tem1s of trol ler. The simulation of non-linear
ller and DS -PI D con ange in product
controller, SA -PI D contro DS -PI D con tro ller for servo problem (ch
-PID contro ller and (FN )
TMC-PID controller, SA for the change in flow rate
e reg ula tor y pro ble m of constant volume CSTR ble m SA -Pl D
concentration CB . Th ost similar response. But for
regulatory pro
con tro ller s giv e alm per for ma nce
For servo problem, all the C-P ID controller and DS-PID
controller. The
par ed to the IM for both
controller is superior com JAE, and ITAE
tro ller s for non line ar models in terms of ISE, and
comparison of the propos
ed con parameters
based on nominal model
ula tor y pro ble ms . The controllers are designed ller is rob ust for model
servo and reg C-PID contro
ces s wit h per tur bed par ameters. The proposed IM
applied to the pro

8
 X 10304 SERVO PROBLEM FOR DS-PID
4r

-2
UJ
(/) -4 ,-
z
0
CL
(/)
UJ
er::
-61
-8

-10

-12 r

.14 L 6 8 10 12
0 2 4
TIME

Fig 3. Servo Problem ofDS-PID Controller

X 10304 RESGULATORY PROBLEM FOR DS-PID

o.5r
0

-0.5 ,-

-2.5 •

-3 -

-3.5 '"

1. L

4 6 8 10 12
2
TIME

Fig 4. Regulatory Problem ofDS-PID Controller

10
 5. Conclusions
Two PID controller design methods based on internal model control principles and
stability analysis method for level controllers in cylindrical tank is proposed. The proposed JMC-
PID controller and SA-PID controller are applied to control level controllers in cylindrical tank
carrying out Van de Vusse reaction. The perfonnance of the proposed JMC-PID controller and
SA-PID controller is compared with OS-PIO controller and the IMC-PID controller gives the
best performance for both servo and regulatory problems. The perfonnance of proposed IMC-
PID controller and SA-PIO controller for uncertainty in parameters considering one parameter at
a time is studied and compared with the performance of PID controller designed by DS-PlD
controller. The IMC-PID controller and SA-PID controller gives robust perfonnance compared
to DS-PlD controller. The performance comparison is given in tenns of ISE, JAE and ITAE for
both linear model and nonlinear linear model for both servo and regulatory problems. Simulation
results on non-linear model equations of level control in a cylindrical tank canying out Van de
Vusse reaction show that the proposed IMC-PID controller and SA-PID controller performs

better than controller designed by DS-PID controller.

12
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13