COMPLEX PID CONTROLLER

1. Cascaded PID Controller Design for Heating Furnace Temperature Control

The constituents of a furnace temperature control system are shown in figure above.

Whereas T1C is primary controller, T2C is secondary controller; T1T represents

measure temperature for the exports of raw materials, and T2T represents measure

temperature of the furnace hearth. The basic operation of the furnace temperature

control system is as follows.

The output of the primary controller (T1C) is given as set point to the secondary

controller (T2C). T2C controls the fuel flow. In the heating process, material which is

placed in the crucible is heated up to a specified temperature from the entrance to the

exit. From fuel Combustion chamber to the raw material export, there are three capacity

components in System temperature. They are furnace, hearth and the heated raw

materials.

The main controlled variable is the temperature of raw material in the export and sub

controlled variable is the temperature of the hearth in the furnace. The disturbance is

flow of the raw material.

 Furnace cascade PID control system model

The transfer functions for Primary and secondary process.

The transfer functions for disturbance:

2
Gd
10 s 1

The measurement gains are K m1 1; K m 2 1.4

The set point is a step (step time = 1, Init. = 0, Final = 1, sample time = 0). The simulation time:

0 t 50 .

The disturbance is step input D1 (step time = 20, Init. = 0, Final = 1, sample time = 0).

Simulate the process cascaded control using SIMULINK where PID controller value:
 2. PID feedback- feed forward controller for controlling Output fluid temperature in
shell and tube hear exchanger

Figure: Shell and tube heat exchanger control system

Temperature outlet is control variable, flow steam inlet is manipulated variable. Output fluid

temperature is measured by the thermocouple, and its output is sent to the transmitter. Finally,
temperature output is converted to a standard signal in 14-20 mA range. This transmitter unit

output is given to the PID controller unit. There is an orifice in this sheet, which creates pressure

difference. In fact, it reduces pressure and this pressure difference can be converted to

standard signal 4-20 mA using a transmitter.

In this control system, controller estimates error feed-forward and changes the control variable

before distortion can influence output. Controllers run control algorithm and send a combined

signal in order to control output temperature of shell and tube heat exchanger

The change in input fluid stream is the disturbance. The transfer function block for feedback-

feedforward control of heat exchanger (shell and tube) is shown:

The set point is a step (step time = 1, Init. = 0, Final = 1, sample time = 0). The simulation time:

0 t 100 .

The disturbance is step input D1 (step time = 33, Init. = 0, Final = 1, sample time = 0).

Simulate the process cascaded control using SIMULINK with the following transfer function and
PID controller parameters:
 0.1 10e s
Gv ; Gp
3s 1 30 s 1
0.05 1
Gm ; Gd
5s 1 20 s 1
18s 6.6 s 0.2
2
G ffc
27 s 2 30.9 s 1
Where K IP 1.1; K sp 1

3. PID control of three reactors

Consider the following third order process (cascade of three reactors)

The transfer function block for feedback control of 3 reactors is shown:

Design the feedback PID controller with step input of set point (step time = 1, Init. = 0, Final = 1,

sample time = 0). The simulation time: 0 t 30 .

The PID parameter is :

4. Temperature and Level Interactive Control in a Tank

Schematic of the process has been shown in figure above. It consists of a tank and two hot and

cold inputs that are used to control temperature and level respectively.
Material and Energy balances:

dh
A F H FC kh
dt
d (Th)
ACP Fci CPciTci Fhi CPhiThi kThCP
dt

Interactive Transfer Functions:

T ( s ) G p1 Fh ( s ) G p 2 Fc ( s )
H ( s ) G p 3 Fh ( s ) G p 4 Fc ( s )
where
1.6 2.8
G p1 ; Gp2
85s 1 462 s 1
2.8 7
Gp3 ; Gp4
462 s 1 85s 1

The transfer function block for temperature and level controller is shown:
The PID properties are:

The step input is shown:

Design the Simulink with the simulation time 0 t 30 .