Chemical and Biomolecular Engineering Department.

University of Cantabria
SESSION 6

EXERCISE 6.1 (EXAMPLE)

Use the Direct Synthesis design method to calculate PID controller settings for the process

Consider three values of the desired close-loop time constant: c= 1, 3 and 10. Evaluate the values of
the parameters of the tuned controllers for unit step changes in both the set point and the disturbance,
assuming Gd= G

b) consider that you actually estimated an incorrect process gain (of value K=2) in your model.

EXERCISE 6.2 (CASE STUDY)

Consider the blending tank system shown in the Figure 1. A feedback control system is used to reduce
the effect of disturbances in feed composition x1 on the controlled variable. Do the following:

a) Using the information shown below, derive a transfer function for each block and draw the block
diagram of the feedback control system using XCOS/Simulink.
b) Using the IMC method (see Table 1 below), determine a PI type of controller considering c= .
c) Simulate the closed-loop response for the controller obtained after a step disturbance of +0.2.
d) Repeat part c) for a set-point step change of -0.1.
e) Repeat part d) calculating a PID controller using a direct synthesis method. Compare this
dynamic response to the response in part d). Try several values of D and analyze the effect of
this parameter on the controlled response. What value of D gives better
results?

Figure 1. Blending system tank with a feedback control type.

1

Computer laboratory of Chemical Process Dynamics and Control

Degree in Chemical Engineering 2016/2017
 Chemical and Biomolecular Engineering Department. University of Cantabria
Process Information
The pilot-scale blending tank has an internal diameter of 2 m and a height of 3 m. Inlet flow rate w1 and
inlet composition x2 are constant. The nominal steady-state operating conditions are as follows:
w1 = 650kg/min x1 = 0.2 h =1.5m

w2 = 350 kg/min x2 = 0.6 =1g/cm3 x = 0.34

The overflow line maintains a constant liquid volume in the tank.
Instrumentation:
The range for all of the electronic signals is 4 to 20 mA.
Current-to-pressure transducer: The I/P transducer acts as a linear device with negligible dynamics. The
output signal changes from 3 to 15 psi when the input signal changes full-scale from 4 to 20 mA.
Control valve: the behavior of the control valve can be approximated by a first-order transfer function
with a time constant of 0.083 min. A 1.2 psi change in the signal to the control valve produces a 300
kg/min change in w2.
Composition measurement: The zero and span of the composition transmitter for the exit composition
are 0 and 0.5 (mass fraction), respectively. A one-minute time delay is associated with the measurement.

Deliverables: the report containing the block diagram in Simulink, the comparative plots, the results of
the calculations of the controller parameters and a proper discussion of the simulations response.

Computer laboratory of Chemical Process Dynamics and Control

Degree in Chemical Engineering 2016/2017
 Chemical and Biomolecular Engineering Department. University of Cantabria

Table 1. IMC-Based PID controller settings for Gc(s)

3
Computer laboratory of Chemical Process Dynamics and Control
Degree in Chemical Engineering 2016/2017
 Chemical and Biomolecular Engineering Department. University of Cantabria
a) Firstly, we calculate the dynamics of the blending tank:

dV
=w1 +w 2w
dt
dxV
=w1 x 1+ w2 x 2wx
dt

Dealing with the previous equations and making the necessary transformations:
' ' ' ' ' '
Vs X ( s ) =w1 X 1 ( s )w1 X ( s ) + w2 ( s ) x 2w 2 X ( s )x w 2 ( s )
Then:
x 2x
X ' (s) w 1+ w 2 2.6104
Gp= = =
w2( s ) V 4.71 s+1
s+1
w 1+ w 2

w1
X ' (s) w 1+ w 2 0.65
Gp= = =
X1 (s ) V 4.71 s+1
s+1
w 1+ w 2

Finally, the dynamics of the instrumentation is:

250
Gv=
0.083 s+1

Gi/p= 0.75
Gm=32*e-s

As a result the block diagram of the control process could be seen below in Figure 1.

Computer laboratory of Chemical Process Dynamics and Control

Degree in Chemical Engineering 2016/2017
 Chemical and Biomolecular Engineering Department. University of Cantabria

Figure 1. Block Diagram

b) Using the block diagram which appear in figure 1.

1.45es
G=
(0.083 s+1)(4.71 s+1)

Using Pad 1/1 we transform the exponential term:

1.45(10.5 s)
G=
(0.083 s+1)(4.71 s+1)(1+0.5 s)

Once we have the G following the instructions of the book Process Dynamics and control and
we calculate Gc [1]:

G c
Gc =
1GG c
Computer laboratory of Chemical Process Dynamics and Control
Degree in Chemical Engineering 2016/2017
 Chemical and Biomolecular Engineering Department. University of Cantabria

Now we should find the terms G- and G+

1.45
=
(0.083 s+1)(4.71 s+1)(0.5 s +1)
G

+=( 10.5 s )
G

Following the method explained in the book we calculate Gc* then:

0.5 s +1

(0.083 s +1)(4.71 s+ 1)
G c =

Finally, as we have Gc* and G, we are able to find Gc:

1 ( 0.083 s+1)(4.71 s+1)(0.5 s +1)(s +1)

Gc=
2.9 s (3 s +1)

Finally we could approximate this equation to:

K es
Gc=
s(s+1)

In table 1 we could see that this equation is the case O then:

Kc=0.616
I =11.293
D=2.2

c)
Computer laboratory of Chemical Process Dynamics and Control
Degree in Chemical Engineering 2016/2017
 Chemical and Biomolecular Engineering Department. University of Cantabria
Introducing the parameters which we have calculated before and the disturbance the response
could be seen in Figure 2.

Figure 2. Closed-looped response after a disturbance

With the parameters calculated the response gets stabilized with little oscilation. As a result,
the parameters seem to be good.

Computer laboratory of Chemical Process Dynamics and Control

Degree in Chemical Engineering 2016/2017
 Chemical and Biomolecular Engineering Department. University of Cantabria

d)
Introducing the change in the set point the response could be seen in Figure 3.

Figure 3. Response after a change in the set point

After a change in the set point it is seen than the response of the system is fast, and in a sort
time reach the new steady state. That is important again because if the response does not
stabilized that would mean that the controller parameters are wrong.

Computer laboratory of Chemical Process Dynamics and Control

Degree in Chemical Engineering 2016/2017
 Chemical and Biomolecular Engineering Department. University of Cantabria

e) Direct Synthesis Method:

Y
1
Gc= [
( Ysp ) ] d
G Y
1(
Ysp ) d

We have calculated G in part b and ( YspY )

d
is:

s
e
s+1

Y
( ) Ysp d
=

Then operating both equations G and ( YspY ) d

we get that:

Gc=

Computer laboratory of Chemical Process Dynamics and Control

Degree in Chemical Engineering 2016/2017