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1.0 INTRODUCTION
Multivariable control is a technique that allows us to deal with more than one control
at the same time. The proposed of a multivariable control system is to tune the PID
parameters by using the internal model control (O'Dwyer, 2006). According to Ziegler-
Nichols (1942), multivariable control system used the open loop time response to get the
controller’s gain. Multivariable control systems provide the mechanism that allows the set
point to be change without disturbing the other ones and without driving them away from
the set points. It is called as decoupling, as the manipulated variable control is a technique
that provides the decoupling of interacting variables (ZUO, LIU & ZHU, 2015).
The multivariable control based on two PID controllers and a static decoupling in
order to minimize the interactions between the process variables. This allows to control
either the temperature or level separately or control both variables at the same time
(Ogunnaike & Harmon Ray, 1982). Temperature control is divided into two categories,
which are one is exercised typically by single-loop self-tuning proportional integral
derivative (PID) controllers and by multivariable self-tuning controllers (Gawthrop, 1990).
The multivariable self-tuning control method has been developed in order to overcome
the shortcomings and it is been proved to be effective for barrel (ZUO, LIU & ZHU,
2015). The proportional-integral-derivative (PID) controller has become controller widely
used in industry applications. The PID controller family consisting of P, PI, and PID, are
been played as the heart of control engineering practice (Minorsky, 1922).
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According to Cohen Coon (1953) and Ogunnaike & Harmon Ray (1982), PID
controller was introduced as the best and pioneer strategies, same as Ziegler-Nichols
method in PID controller tuning, based on trails and errors methodology and the process
reaction curves on which Cohen-coon method is grounded. This method also entirely
valid in cases with unit response of the system is S-shaped, while Ziegler-Nichols method
will give a rise to high overshoot, high oscillation and longer settling time for the higher
order system. Multivariable control system is different from traditional single-variable
controllers, which they can regulate than one process variable by using more than one
actuator at once.
According to O'Dwyer (2006), over the past two decades, there are three hundred and
eight publications of use of PID and PI controller for the compensation the processes with
time delay have been recorded. The ability of PI and PID controllers to compensate most
practical industrial processes, which led to the wide acceptance in industrial applications.
It is about 98% of control loops in the pulp and paper industries was controlled by PI
controllers, and in process control applications is more than 95% of the controllers are the
PID type (Astrom & Hagglund, 1995).
1.2 Objectives
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In this experiment, we used Temperature Flow Process Control in auto mode in order
to understand the process behavior. A PID controller has a set point (SP) that the operator can
set to the desired temperature. A temperature of 18˚C is used as starting for the set point of P
control in this experiment. The Controller’s Output (CO) sets the position of the control valve
and the temperature measurement, called the Process Variable (PV) gives the controller its
needed feedback. A closed-loop control system known as feedback control system. This form
of control system has one or more feedback loops or circuits that seek to overcome the errors
inherent in the system. In cascade control arrangement, there are two or more controllers,
which one controller output drives the set point of another controller (Jacques F, 2011).
First, we set up the master to manual mode. Then, we also set the value of process
gain, and integral time, for slave controller with 0.66 and 1 respectively. This is because the
tuning for slave control-loop using proportional control only. This is to observe the
temperature of PV value based on time. Other than that, before tune for cascade control, we
turned master controller into auto mode and the parameter values for master controller at P,
PI and PID control are set up for the process gain , time delay, and time constant. These are
to observe the time taken for the PV starting to change until it reached the set point. As the
temperature of heater rises towards the set point, the slave’s heater output falls.
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2.0 METHODOLOGY
2.1.2 Materials
Water
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The water level in tank TK-701 and TK-702 was ensured to be at least
80% full or at the overflow line.
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703HV-001 Close /
703HV-002 Open /
703HV-003 Open /
703HV-005 Open /
703HV-006 Close /
704HV-002 Open /
704HV-003 Open /
704HV-004 Close /
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1) The process plant with power, air and water was set up.
3) The chiller, 705CH-001 was turned on. The chiller was setted to below 20ºC.
4)The data logging START icon was clicked in the trending graph screen to
download the data to the drive.
8) The "AUTO" button was clicked to put the controller (701TIC-001) into auto
mode.
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11) In the trending graph screen, the data logging STOP icon was clicked to
download the data to the drive. The PV value was recorded for 60 seconds in
Table 3.
12) Step 8 was repeated by entering the MASTER PID vale and different Set Point
(SP) calue according to Table 4.
13) The steps above were repeated for each settling in the table for three trials using
P,PI and PID Control.
14) The results were recorded and the graph were plotted.
Parameter Value
Gain, Kc 0.66
Reset, τ1 1
Rate, τD -
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0 18.26
10 20.55
20 20.97
22
30 20.62
40 20.45
50 20.34
60 20.25
21.5
20.97
21
Temperature (C)
20.55 20.62
20.45
20.34 20.25
20.5
20
19.5
19
18.5 18.26
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9:53:42 AM 9:53:52 AM 9:54:02 AM 9:54:12 AM 9:54:22 AM 9:54:32 AM 9:54:42 AM
Time
PV SP
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For this experiment, the slave configuration controller (secondary controller) was
being tested to be observed. The slave was the flow rate of the hot water. Based on the
experiment data Table 4 and Graph 1, this experiment was conducted on automatic mode of
slave PID Controller. The slave controller in this experiment was flowrate which means this
experiment was to control the flow rate (slave) to achieve the set point temperature (master).
The set point of the experiment was set at 22°C. Thus, the slave should respond to achieve
the target master. Based on the graph, it can be seen that the starting temperature of the liquid
was 18.26°C at time, 9:53:42 AM. Since the set point has been set to achieve 22°C, the flow
rate (slave) respond to the signal to achieve the temperature (master) and it increased until the
temperature achieves 20.97°C at time, 9:54:02 AM. However, the flow rate cannot stand by
itself to reach the process variable (PV) to the set point. Besides, the flow rate is inversely
proportional to the time. Thus, when observed back the graph 1, the temperature of 20.62°C,
at time, 9:54:12 AM the PV started to decrease until temperature of 20.25°C at time, 9:54:42
AM. This is because of the flow rate of the hot water supply decreases and less heat transfer.
Therefore, the temperature of the PV cannot achieve the target set point and become
decreases with time.
tD - - - - 1.1 6.1
For the master PID controller experiment, the master configuration controller (primary
controller) is being tested to be observed. However, in this experiment, it involves the slave
configuration since the master configuration got the output from the slave. This experiment
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was conducted on automatic mode of master PID Controller but it was separated into 3
controllers which are P controller, PI controller, and PID controller.
P Controller
Based on the experiment data Table 5 and Graph 2, the set point of the experiment was set
28°C. Thus, the slave should respond to achieve the target master. Based on Table 5, trial 1
starting temperature of the liquid was approximately around 24°C at time, 09:55:45 AM and
ended at time, 09:59:13 AM with gain, Kc is 4.3. For trial 2, the starting temperature was the
same with trial 1, starting at time, 10:00:07 AM and ended at time, 10:04:19 AM with gain,
Kc is 6.3. In the P controller, the gain, Kc is proportional to the error. Based on graph 2, it can
be seen that trial 2 has larger Kc compared to trial 1. Thus, the error in trial 2 was bigger
compared to the error in trial 1. This making the secondary controller (slave) taking time to
send an output to the primary controller (master) since it has to face the error in both trial but
the controller taking more time trial 2.
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10:00:09 AM
10:00:17 AM
10:00:25 AM
10:00:33 AM
10:00:41 AM
10:00:49 AM
10:00:57 AM
10:01:05 AM
10:01:13 AM
10:01:21 AM
10:01:29 AM
10:01:37 AM
10:01:45 AM
10:01:53 AM
10:02:01 AM
10:02:09 AM
10:02:18 AM
10:02:26 AM
10:02:34 AM
10:02:42 AM
10:02:50 AM
10:02:58 AM
10:03:06 AM
10:03:14 AM
10:03:22 AM
10:03:30 AM
10:03:38 AM
10:03:46 AM
10:03:54 AM
10:04:02 AM
10:04:10 AM
10:04:18 AM
TIME
Graph 2: Process behaviour graph of Master P controller with Trial 1 and Trial 2
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PI Controller
Based on the experiment data Table 5 and Graph 3, the set point of the experiment was 36°C.
Based on Table 5, trial 1 starting temperature of the liquid is approximately around 32°C at
time = 10:04:41 AM and ended at time = 10:05:16 AM with gain, Kc = 6.3 and Integral time,
Tt = 5.0. For trial 2, the starting temperature is 33°C, starting at time = 10:05:44 AM and
ended at time = 10:07:03 AM with the same gain in trial 1, Kc = 6.3 but different Integral
time, Tt = 11.0. In the PI controller, the P controller has gain, Kc that was proportional to the
error. However, the I controller will overcome this error to give a better performance for the
process but the process will undergo sluggish under the PI controller. Based on the graph 3,
trial 1 has a short time to reach the set point compared to the trial 2 that have the longer time
but in case of performance even though trial 1 have short time reaching the set point it does
not have a good performance compared to trial 2 that have longer time reaching the set point
but it has a good performance process. This showed that trial 2 is better in performance
progress for the process but it undergoes sluggish.
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35
TEMPERATURE (°C)
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32
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30
10:06:28 AM
10:06:38 AM
10:06:47 AM
10:05:28 AM
10:05:31 AM
10:05:34 AM
10:05:37 AM
10:05:40 AM
10:05:43 AM
10:05:46 AM
10:05:49 AM
10:05:52 AM
10:05:55 AM
10:05:58 AM
10:06:01 AM
10:06:04 AM
10:06:07 AM
10:06:10 AM
10:06:13 AM
10:06:16 AM
10:06:19 AM
10:06:22 AM
10:06:25 AM
10:06:31 AM
10:06:35 AM
10:06:41 AM
10:06:44 AM
10:06:50 AM
10:06:53 AM
10:06:56 AM
10:06:59 AM
10:07:02 AM
TIME
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PID Controller
Based on the experiment data Table 5 and Graph 4, the set point of the experiment was 44°C.
Based on the Table 5, trial 1 starting temperature of the liquid is approximately around 40°C
at time, 10:07:20 AM and ended at time, 10:09:50 AM with gain, Kc is 6.3, Integral time, Tt
is 11.0 and derivative time, tD is 1.1. For trial 2, the starting temperature is also at 40°C, with
the starting time of 10:10:04 AM and ended at 10:14:01 AM with the same gain in trial 1, Kc
is 6.3, same different integral time, Tt = 11.0 but different derivative time, tD is 6.1. In the
PID controller, theoretically P controller has gain, Kc that was proportional to the error, the I
controller will overcome this error to give a better performance for the process but the
process will undergo sluggish which will overcome by D Controller. Based on the graph 4,
the trial 1 had a short time to reach the set point compared to the trial 2 that have the longer
time to reach the point but both trials have a good performance process. Based on the data in
Table 5, it should be trial 2 that was reacting faster to the process since it has a bigger value
of derivative time, tD but in this experiment, its happened oppositely. This is because the
change of heat transfer was decrease and the temperature of the set point was react to
equilibrium temperature because the maximum temperature of the controller can go was
around 55°C. Thus, the heat transfer was lower at trial 2 and it does not have enough required
heat energy to react to the process.
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42
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40
39
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10:09:51 AM
10:09:59 AM
10:10:07 AM
10:10:15 AM
10:10:23 AM
10:10:31 AM
10:10:39 AM
10:10:47 AM
10:10:55 AM
10:11:03 AM
10:11:11 AM
10:11:19 AM
10:11:27 AM
10:11:35 AM
10:11:43 AM
10:11:51 AM
10:11:59 AM
10:12:07 AM
10:12:15 AM
10:12:23 AM
10:12:31 AM
10:12:39 AM
10:12:47 AM
10:12:55 AM
10:13:03 AM
10:13:11 AM
10:13:19 AM
10:13:27 AM
10:13:35 AM
10:13:43 AM
10:13:51 AM
10:13:59 AM
TIME
Graph 4: Process behavior graph of Master PID controller with Trial 1 and Trial 2
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4.0 CONCLUSION
Multivariable Control System provides the mechanisms that allow us to change the set
point of controlled variables without driving them away from their set point and maintain
controlled variables at independent set point. This effect is called decoupling. We can
therefore also say Multivariable Control System is a technique that provides the decoupling
of interacting variables. To achieve this, the control actions cannot be computed individually,
as in the case where there is only one single input and one single output of the controller.
Instead, the actions of all manipulated variables must be determined in a coordinated way
with multiple inputs and multiple outputs. In single loop control of a multivariable process
the simplest yet most common way to control a multivariable process is using single loop
control with PID controllers. There is one control loop for each process output variable which
is to be controlled. The control system structure is represented by transfer functions although
these subsystems are generally non-linear dynamic systems.
Temperature – Flow Process Control in cascade control utilizes two control loops
which are a master loop and a slave loop. The master loop contains the primary or master
controller and monitors the primary variable while the slave loop contains a secondary, or
slave controller which monitors a second variable. The main purpose of cascade control is to
minimize the disturbances that affect the secondary variable before them because pronounced
changes in the primary controlled variable. Thus, a cascade control system does not have to
wait for the primary controlled variable to change before initiating corrective action. A
change in the secondary controlled variable is sufficient to do so. This is because
Temperature – Flow Process Control in cascade control is effective when the slave loop is
more responsive than the master loop.
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The performance of the Multivariable Control System is showing that there have six
graphs based on the master configuration as shown in discussion which it was separated into
3 controllers which are P controller, PI controller, and PID controller. From the discussion,
we can conclude that the time taken for each graph back to the set point had a different time
based on their difference values. For theoretical statement had mention that the time taken
between P, PI and PID controller must be different. The PID controller supposed to be faster
back to the set point than the other controllers. But in this experiment, we can manage to get
PI had a short time back to the set point than the other controller.
5.0 RECOMMENDATIONS
In order for the experiment to be done in a perfect condition, several steps can be
taken in order to improve the accuracy of the results. Firstly, the students need to make sure
them shutting down the equipment first, then starting up the equipment back for each
different setpoint. In order to make the data and the graphs will be more accurate. Next, the
students needed to understand manual lab and instructions first before starting the
experiment. This is because if they understand the instructions, students will make sure all
external loads connected to output do not exceed the rating of output module in order to
prevent overcurrent exceeding the rating of output module could cause fire, damage or
erroneous operation.
Then, do the experiment under the guidance and surveillance of the lab assistant. Lab
assistants are acknowledgeable the critical situation and they also know all the precaution
steps when they have an emergency situation. If experiment have an emergency situation, lab
assistant will make sure all the students survive from the damage or injured and they also will
lead all the students to exit from the laboratory. Last but not least, students make sure to
completely turn off the power supply before loading or unloading the module. If students not
make sure that all the electric current turning off before the entire student out of the site
experiment, the electric current will be exceed overheating that causing the explosion and
caught on fire.
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6.0 REFERENCES
Astrom, K., & Hagglund, T. (1995). PID Controller, theory, design, and tuning. Retrieved
from https://aiecp.files.wordpress.com/2012/07/1-0-1-k-j-astrom-pid-controllers-
theory-design-and-tuning-2ed.pdf
Closed-Loop Step Responses. Retrieved from
http://folk.ntnu.no/skoge/prost/proceedings/adchem-2012/files/0024.pdf
COHEN, G., & COON, G. (1953). Theoretical Consideration of Retarded Control. Retrieved
from http://folk.ntnu.no/skoge/puublications_others/Cohen%20and%20Coon%20
(1953)%20-%20Theoretical%20Consideration%20of%20Retarded%20Control.pdf
Collins.I (2014). How Does Cascade Control Work?. Retrieved from https://www.west-
cs.com/news/how-does-cascade-control-work/
Control Station. (n/d). What Is Cascade Control? How Is Cascade Control Configured?.
Retrieved from https://controlstation.com/cascade-control-cascade-control-
configured/
Cornieles, E., Saad, M., Gauthier, G., & Saliah-Hassane, H. (2006). Modeling and Simulation
of a Multivariable Process Control. 2006 IEEE International Symposium on
Industrial Electronics. https://doi.org/10.1109/ISIE.2006.296039
Hans H. E. (2007). Multivariable Control. Retrieved from
https://www.chemengonline.com/multivariable-control/?printmode=1
J.G. Ziegler, and N.B. Nichols, "Optimum Settings for Automatic Controllers" Trans. ASME,
Vol. 64, 1942. Retrived from
https://staff.guilan.ac.ir/staff/users/chaibakhsh/fckeditor_repo/file/documents/
Optimum%20Settings%20for%20Automatic%20Controllers%20(Ziegler%20and%
20Nichols,%201942).pdf
Jacques F, S. (2011). Process Control for Practitioners (pp. 279-313). United State:
OptiControls Inc.
Jeng.J.C. (2012). Identification and Controller Tuning of Cascade Control Systems Based on
Mathworks. (n/d). Designing Cascade Control System with PI Controllers. Retrieved from
https://ww2.mathworks.cn/help/control/examples/designing-cascade-control-system-
with-pi-controllers.html
N. Minorsky (1922). “Directional stability of automatically steered bodies, “American
Society of Naval Engineering, vol. 34, 1922, pp.284.
O'Dwyer, A. (2006). Handbook of PI and PID controller tuning rules (2nd ed.). London:
Imperial College Press.
Ogunnaike, B., & Harmon Ray, W. (1982). Computer-aided multivariable control system
design for processes with time delays. Computers & Chemical Engineering, 6(4), 311-
326. doi: 10.1016/0098-1354(82)85007-2
Puangdownreong, D., & Sakulin, A. (2012). Obtaining an Optimum PID Controllers for
Unstable Systems using Current Search. Retrieved from
https://pdfs.semanticscholar.org/95ac/7d349dcb41ea9570557fb3cf8c836f331823.pdf
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SMJC 3721
CHEMICAL PROCESS
ENGINEERING LABORATORY 2
LAB REPORT ON MULTIVARIABLE
CONTROL SYSTEM
(TEMPERATURE- FLOW PROCESS
CONTROL)-GROUP 15
NAME:
VIVI BONG EE THING (A16MJ0173)
AIMISYAHMI HARITH BIN ZULKIFLI (A16MJ0189)
SITI NORAZILA BINTI ASHARI (A16MJ0147)
SITI NURFATIHA BINTI HALIL (A16MJ0148)
SITI ZAHARAH BINTI EDI (A16MJ0150)
SECTION: 02 (3/SMJC)
LECTURER’S NAME:
DR. NOR RUWAIDA BINTI JAMIAN
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