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Disturbance
d
Setpoint
filter
Controller
Go
Process
,r
Output
C =
1 + G^-
(I)
(3)
PROCESS CONTROL
(6)
1 I
'/'
If'
11
11
jl
1
50
(7)
Smith
Ii
1
100
Oesired response
Proposed
/here
K^-^ f'{o)
(8a)
150
250
200
300
(8b)
350
Time
3)
(8c)
1.2
--DePa()randO'Malley
- - Rotstein and Lewin
,'\ --Huang and Chen
f / \ - -Proposed
' ' Proposed (with setpoint filter)
1,0
0.8
;
i \ ',
0.6
0,4
0.2
0.0
i-0.2
-0.4
-0.6
Tuning rules for any class of process mode! can then be obtained
from Eq. 8 in a straightforward manner. The integral and/or derivative
time constants, T/, T^j, from Eq. 8 ustaally have positive values. A few processes have strong lead terms
and thus show significant overshoots in response to
DePaorandO'Malley
- Rotstein and Lewin
step changes in the input. In this case, it might be
- - Huang and Chen
extremely difficult for the process to give a desired
- -Proposed
overdamped response with a simple PID controller
Proposed (with setpoint filter)
alone. Therefore, tbe PID controller cascaded with
a low-pass filter such as \l(as+ 1) or l/Cai,^ + Of|j +
1) is recommended to compensate for the effect of
the lead term. Tuning rules for the PID parameters
and the filter time constants for tbis case are also
available based on the proposed approach (see Lee,
et al.,-^ for more details).
-0,8
FKS. 3
10
Time
15
20
(4)
Tuning rules for FOPDT and SOPDT models. Tbe most commonly used approximate models for chemical processes are the first-order plus
dead-time {FOPDT) model and/or the secondorder plus dead-time (SOPDT) model given as:
FOPDT:
SOPDT: G{s) =
Ke'
- q/{l-Gq)\q
^ (h +1)' 1
as well.
Although the resulting controller is physically realizable, it
does not have the standard PID form. Therefore, the main issue
for developing a PID tuning rule is how to find the PID controller
that approximates the ideal controller given by Eq. 4 most closely
over the control relevant frequency range. In the generalized
IMC-PID method, it is solved using the approximation based on
a Maciaurin series.
The controller G^ can be approximated to a PID controller by
first noting that it can be expressed with the integral term as:
Tuning rules for the two typical models are shown in Table 1
where (^r= ^- Note that the tuning rule for the SOPDT model
is available not only to the overdamped systems but also to tbe
underdamped systems.
In this method, tbe closed-loop time constant, X,, is used as a tuning parameter to adjust the speed and robtistness of the closed-loop
system. Extensive simulation has been done to find the best value
of X/6 in the senses of robustness and performance. As a result, \ / 6 =
0.5 is recommended as a practical guideline for a good starting \'alue.
Eor small H/T (typically less than 0.2), a detuning might be considered
to account for constraints on manipulated variables. As the model
uncertainty increases, X should increase accordingly. Note that the
closed-loop response becomes sluggish as \ increases.
E x a m p l e . As an example, consider a process with the SOPDT
model as:
PROCESS CONTROL
G{s) =
(9)
L2
R1
FIG. 4
K^
r,
TQ
e^ L e l
Ke"'
K{X+Q)
TS-l-1
FOPDT
S{X + Q)[
2{X+Q)
^
SOPDT
K(X+Q)
(X^S^+2^X5-M)
6(^-1-9),
T.
TJ
e'
d.\A + KJ)
Process model
Kc
T/
9^
1
Integrating
Drocess 1
1
Integrating
Drocess 2
Distributed
Darameter
arocess
x-i---
s{xs+1)
/C(X-h9)
(T'S'+25-CS+1)
2T
X 1
^-.9^6
^'
1
Inverse
Drocess 1
2J
9^
(^\^\]
/C{-v+1)e-
/c(x+e+2xj
(TS + 1)
X,
X-He-H2x^
1 J
1
Inverse
arocess 2
X 1
X'
Inverse
process 3
'
s(xs+l)
(X-h9-.2xJ
(xV-.2^xs-e1)
C
^ "
^ f\^^'0
2
X-h9-f-2x I 6
J
1 -
^ , I W - M + ^W
a
(-TJ+1)e'"
( V + ' X ' ^ + l' for the inverse processes.
Continued
HYDROCARBON PROCESSiNG JANUARY 2006 89
PROCESS CONTROL
Ke'
FODUP:
Ts-\
SODUP: G{S) =
xs \){as + l
The generalized IMC-PID approach can be extended to integrating and unstable processes.'' Additionally, a setpoint filter,
(f,., shown in Fig. 1 is designed not to give overshoots in servo
problems. Most unstable processes in the process industries can
be modeled unstable processes with one RHP po!e (FODUP and
SODUP), unstable processes with two RHP poles and integrating unstable processes. Tuning rules based on the generaHzed
IMC-PID method for these processes are listed in Table 3. In the
case where the offset by the tunmg rules ni Table 2 is critical for
integrating processes, consider the tuning rules in Table 3 because
we can design the PID controllers by considering the integrating
processes as the FODUP or SODUP model (see Lee, er al.,^ for
more details). An extensive simulation indicates X/9 = 1-2 as a
practical guideline for X.
Example. As an example, the following process is considered:^'
500
1,000
1,500
2,000
2,500
Time
FIG. 5 '
(10)
Figs. 3a and 3b show the closed-loop responses of the unstable process given by Eq. 10 to a unit step change in setpoint,
R, and load, ^. The results shown in the figures illustrate the
superior performance of the generalized IMC^^-PID method.
TABLE 3. Generalized IMC-PID tuning rules for FOPUP and SODUP processes
Process
Process
model
Kc
^|
To
Setpoint filter
-xa
V+ae-9^/2
2>. + 9-a
Ke"'
FODUP
TS-1
-K{2X^Q~a)
1
(XS + 1
ZArf -l- 9 Ct
-x+a + a Ke''
SODUP (a)
A -f (Xo D / i
i/j -l- H (X
as+1
2X-fe-a
,
4A -l-D(X,-l-o / o Ot.U
/i
4A. + D Ct
1
Ke"
SODUP (b)
DA ~O(,+Ot,D D / /
4>.+e-a,
{a/+a,s+l)
in FODUP and SODUP(a); u;, , values are calculated by solving 1 - ^"'^ +a,S+ )e
{Xs +1}'
desired closed-loop response is C//? = e " ' " / ( X ^ - f 1)' in SODUP(b).
90
PROCESS CONTROL
TABLE 4 . Generalized IMC-PID tuning rules for cascade control systems
Process
Process
model
FOPDT
(innerloop)
Reference
trajectory
fc
/c,(?.,-fe,)
TjS + 1
SOPDT
^^^
^,
^'''"^''2(x,+e,)
/D
FOPDT
(outer-
x,s+l
/c,(x,-.e,-He,)
loop)
SOPDT
(T,S + 2 ^ , 1 , 5 - . 1)
''
(innerloop)
(outerloop)
'^2(x,+ej
T,
(3 ''M
D,
'2(X,+e,)
1 O \2
'''-='2a,+e,+9.)
^,
1
V +1
control in the chemical process industries. The generalized IMCPiD method was extended to cascade control systems.^ Tuning
rules based on the generalized IMC-PID method for FOPDT
and SOPDT in cascade control systems are shown in Table 4.
X.i/(B| + 61) = *^-5 and XI/ST = 0.5 are recommended as a practical guideline for k.
Example. As an example to evaluate the robustness against a
structural mismatch in the plant model, the following complicated process was tested:
13.35+1
+ 20s + \
100S +
(IIJ
10.2f"
66.49J
2.988^ -3,66i
(12)
Y o n g h o L e e is a manager of operations planning in GSCaltex Corp., Korea. He holds BS, MS and PhD degrees in chemical
engineenng from KAiST, Dr. Lee began his professional career as
a process engineer and designed fine chemical, hydrocarbon and
gas processes. His industriai experience has focused on modeling,
optimization and control of refinery and petrochemical plants. He can be reached at
e-mail: cl 5959@9scaltex,co,kr,
M o o n y o n g L e e is a professor m the school of chemical engineering and technology at Yeungnam University, Korea, He holds a
BS degree in chemical engineering from Seoul National University,
and MS and PhD degrees in chemical engineering from KAIST.
Dr. Lee had worked in the refinery and petrochemical plant of SK
company for 10 years as a design and control specialist Since joining the university
in 1994, his areas of specialization have included modeling, design and control of
chemical processes. He is the corresponding author and can be reached at e-mail,
mynlee@yu.ac.kr.