TABLE OF CONTENT

Content Page

1.0 Title 2

2.0 Introduction 2

3.0 Methodology 9

4.0 Results 14

5.0 Discussion 18

6.0 Conclusion 22

7.0 Recommendation 23

8.0 References 24

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1.0 TITLE
Multivariable Control System (Temperature-Flow Process Control)

2.0 INTRODUCTION

2.1 OBJECTIVE

The objectives of this experiment are:

● To interpret the Piping & Instrument Diagram (P&ID).
● To understand the liquid temperature and flow process control (cascade control).
● To understand the behavior of liquid temperature and flow cascade process and plant
operation.
● To understand and demonstrate the effect of load disturbance and set point
disturbance on liquid temperature and flow cascade process.

2.2 BACKGROUND

A control system is an interconnection of components forming a system configuration

that will provide a desired system response (Stachowicz, 2010). There are two types of control
system which are open loop and closed loop. Open loop control system has no feedback and it is
difficult to control output with accuracy. For closed loop control system, it must have feedback
and sensor on output. It used a measurement of the output and feedback of this signal to compare
it with the desired output. Due to the increasing complexity of the system under control and the
interest in achieving optimum performance, the importance of control system engineering has
grown in the past decade. Furthermore, as the systems become more complex, the
interrelationship of many controlled variables must be considered in the control scheme.

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 According to Tham (1999), processes with only one output being controlled by a single
manipulated variable are classified as single-input single-output (SISO) systems. In contrast, the
systems with more than one input and more than one output are known as multivariable or
multi-input multi-output (MIMO) systems. In process industries, any unit operation capable of
manufacturing or refining a product is unable to function with a single control loop. The unit
operation such as chemical reactors, distillation columns and heat exchangers typically requires
control over at least two variables, for example, product rate and product quality.

A set point is given to each variable (process output variable) which is to be controlled.
Many of the control variables are available for manipulation by the controller function in order to
control these variables. As stated by Buskerud (2009), if there are cross couplings in the process
which is one control variable gives a response in several process output variables, multivariable
process is difficult to be controlled. There are mainly two problems of controlling a multivariable
process if these cross couplings are not counteracted by the multivariable controller. The first
problem is the changing of one set point not only affect and cause a response in the output
variable corresponding to the setpoint, but also in each of the process output variables. Next,
when an ordinary single loop of PID control is used, a controller will “observe” a complicated
dynamic system which consists of the multivariable process with all control loops. Thus, each of
the PID controllers is difficult to be tuned, and the stability robustness of the control system may
be small (Buskerud, 2009).

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2.3 THEORY

2.3.1 Multivariable control system

As stated by Denizen (2017), multivariable control system define a system in which the
variable interacts strongly. This system contains more than one input and output in order to
control the process. A system with an equal number of inputs and outputs is said to be square.
The input of disturbance causes a change of response from at least one output. The disturbance in
any variable can cause a change in response in any output in its signal path. These paths can be
direct or indirect by depending on the design of system. In most control system, a particular input
disturbance cause one output to respond by a larger percentage than the other outputs. The
response of the other output is called interaction. Interaction is often a result of system design
and cannot be avoided. However the system must either correct or compensate for interaction.
Figure 1 shows the multivariable control system block diagram.

Figure 1: Multivariable control system block diagram (Stachowicz, 2010).

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2.3.2 Single loop control with PID controllers

Single loop control with PID controllers is the most common and simplest way to control
multivariable process. In the system, there is one control loop for each process output variable
which is to be controlled. As shown in Figure 2 which is the control system structure, the
subsystems are represented by transfer functions although these subsystems are generally
non-linear dynamic systems (Buskerud, 2009).This process has only two control variables and
two process output variables, thus the process is a 2x2 multivariable process

Figure 2: Single loop control of a 2x2 multivariable process (Buskerud, 2009).

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2.3.3 Pairing of process output variables and control variables

The determination of the pairing of process output variable and control variable is
required in single loop control of a multivariable process. A natural rule for choosing this pairing
is: The strong process couplings (from control variable to process output variable) should be
contained in the control loops. Following this rule is an effective use of the control variable, and
supports stability robustness against variations of the dynamic properties in other parts of the
control system (Buskerud, 2009).
According to Seborg, Edgar and Mellichamp (2004), it is easy to determine the strong
pairings in most cases. For example, a heated liquid tank where both temperature and flow are to
be controlled. The two control variables are power supply via a heating element and pump
supply. This process is multivariable with cross couplings since both power supply- temperature
supply (control variable 1) and pump supply (control variable 2) influences both process output
variables (flow and temperature). The flow of liquid is influenced by the power supply due to the
increasing in the average speed of molecules as temperature increases.

2.3.4 Cascade control

Cascade control is an advanced application of the PID which can improve the
performance of control system over single-loop control whenever either (1) Disturbances affect a
measurable intermediate or secondary process output that directly affects the primary process
output that want to control; or (2) the gain of the secondary process, including the actuator, is
non-linear. In the first case, a cascade control system can limit the effect of the disturbances
entering the secondary variable on the primary output. In the second case, a cascade control
system can limit the effect of actuator or secondary process gain variations on the control system
performance. Such gain variations usually arise from changes in operating point due to setpoint
changes or sustained disturbances (Morari & Zafiriou, 1989). A cascade control system reacts to
physical phenomena shown in Figure 3 below:

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Figure 3: Cascade control system block diagram (Vandoren, 2014).

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In the water heater example:

Variable Parameter

Setpoint (SP) Temperature desired for the water in the tank

Primary controller (master) Measures water temperature in the tank and asks the
secondary controller for more or less heat

Secondary controller (slave) Measures and maintains steam flow rate directly

Actuator Steam flow valve

Secondary process Steam in the supply line

Inner loop disturbances Fluctuations in steam supply pressure

Primary process Water in the tank

Outer loop disturbances Fluctuations in the tank temperature due to

uncontrolled ambient conditions, especially
fluctuations in the inflow temperature

Secondary process variable Steam flow rate

Primary process variable Tank water temperature

Table 1: The variable and parameter in the water heater example

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3.0 METHODOLOGY

3.1 APPARATUS AND MATERIALS

● P&ID

3.2 PROCEDURE

3.2.1 Start-up procedure

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Table 2: Hand Valve position

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3.2.2 Understanding the process behaviour

PARAMETER VALUE

Gain Kc 0.66

Reset τ i 1

Rate τ d

Table 3: Slave PID parameter

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 Time (s) PV (°C)

10

20

30

40

50

60

Table 4: process behaviour for Slave PID

P Control PI Control PID Control

Trial 1 Trial 2 Trial 1 Trial 2 Trial 1 Trial 2

Kc 4.3 6.3 6.3 6.3 6.3 6.3

τi 5.0 11.0 11.0 11.0

τd 1.1 6.1

Table 5: PID value for Master Controller

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3.2.3 Shut-down procedure

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4.0 RESULT

4.1 TABLES

Time (s) 0 10 20 30 40 50 60

PV (℃) 23.06 22.98 22.95 22.89 22.87 22.85 22.82

Table 6: Process behaviour for slave PID

P Control PI Control PID Control

Trial 1 Trial 2 Trial 1 Trial 2 Trial 1 Trial 2

Kc 4.3 6.3 6.3 6.3 6.3 6.3

Tt - - 5.0 11.0 11.0 11.0

td - - - - 1.1 6.1

Time 10:53:33 10:56:54 11:02:40 11:04:03 11:07:43 11:12:53

start

Time 10:56:35 11:02:09 11:03:29 11:07:20 11:12:24 -

end

Table 7: PID values for master controller

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4.2 Graph

Graph 1: Process variable against time for slave PID

Graph 2: Graph of temperature against time for P control (Trial 1)

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Graph 3: Graph of temperature against time for P control (Trial 2)

Graph 4: Graph of temperature against time for P1 control (Trial 1)

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Graph 5: Graph of temperature against time for PI control (Trial 2)

Graph 6: Graph of temperature against time for PID control (Trial 1)

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5.0 DISCUSSION

Figure 4: Block diagram of cascade control system

Figure 4 above shows the block diagram of cascade control system. Cascade control is an
advanced application of the PID that can improve control of systems that are subject to
significant lag (“What Is Cascade Control? How Is Cascade Control Configured?”, n.d.). The
cascade system can be applied effectively to such inactive processes when a related and faster
responding loop is available. When applied in accordance, the faster loop serves as an early
warning mechanism that buffers the impact on its slower counterpart, allowing for smoother
control and enhanced performance.

Figure 5: Temperature-Flow cascade block diagram

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 The Figure 5 above shows the cascade block diagram of temperature-flow. The master
for this process would be temperature and the slave of this process is flow. The intrinsic
interaction that occurs between two control systems is used in one control loop determined by
measurement of a different variable for which interaction exists. Two measurements are taken
from the system. Each is used in its own control loop. Set point of inner loop is decided by
controller output of outer loop. Cascade control yields preferable control of the outer loop
variable than is accomplished through a single variable system. The temperature controller
creates the correction signal based on the actual temperature. This correction signal is used as the
set point input to a flow controller. The flow controller signal positions the control valve, which
regulates the flow of hot liquid from the vessel.

The purpose of cascade control is to improve process performance by reducing or

eliminating the effects of a known disturbance through control of an early warning variable
(“The Pros and Cons of Cascade Control”, n.d.). There are few benefits that are achievable
through the application of cascade control. When using this cascade control system, loops that
correctly apply the cascade architecture respond more effectively to disturbances. This is due to
the inner loop is both closer to the source of the disturbance and faster than the outer loop. This
combination allows the process to correct for upsets more quickly. Then, the inner loop helps to
correct for nonlinearities such as Stiction that are associated with the Final Control Element
(FCE). The inner and outer loops rely on the same FCE. Due to its faster dynamics the inner
loop adjusts for FCE nonlinearities ahead of the outer loop, thereby minimizing negative effects
to the process. After that, faster inner loop reduces the overall variability experienced by the
process. Since the inner loop is able to respond more quickly to disturbances than the outer loop,
it reduces the severity of a given disturbance and limits the degree of variability that would
otherwise impact the process. Lastly, the outer loop can be tuned more conservatively. Since the
inner loop makes more rapid adjustments the outer loop no longer needs to be nimble. The
steadier control benefits downstream processes.

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 Table 6 shows the process behaviour for slave PID. The results were jotted in the Table 6.
From the results obtained, as the time increase the temperature of the process variable (PV) will
decrease. But there is no obvious gap between the changes. The declination can be plotted and
the Graph 1 shows the graph of PV (℃) against time (s). The set point was set to 29℃ and an
increment of 4℃ for every PID values. Table 7 shows PID values for master controller. The
value of K​c​ was set to 4.3 and the response time was 182 seconds. Graph 2 shows temperature
against time for P control for Trial 1. In Graph 2, the loop tends to cycle around its the PV,
making it unstable. Oscillations can originate from within the control loop or be caused by
external factors like tuning, internal oscillations, nonlinear process, coupled interaction and
more. Oscillations generated internally can be caused by faulty equipment or by tuning. For Trial
2, the loop is shown in Graph 3. A value of 33℃ was set for the set point. The value of K​c​ was
set to 6.3 and the response time was 315 seconds. There is a large gap for 36 seconds before the
control variable loop (CV) decreased and it became stable. The loop takes too long to get to its
set point after a disturbance or set point change.

Graph 4 shows the graph of temperature against time for P1 control for Trial 1. The K​c
value of 6.3 was chosen and the value T​t​ was 5.0. The set point was to be set with 37℃. The
response time for this trial was 49 seconds. This is currently the best response time if to be
compared to P controller (Trial 1 and Trial 2) as it has faster response time to achieve the set
point. The time delay was 4 seconds. The PV in Graph 4 gradually increased after the new set
point was introduced and then maintained until it reached the set point. Graph 5 shows
temperature against time for PI control for Trial 2. The setpoint was set to 41℃. The value of K​c
was 6.3 and the value of T​t​ was changed to 11. There was no time delay. The CV kept going
constantly until it achieved the set point. The response time was 197 seconds.

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 Graph 6 shows temperature against time for PID control for Trial 1. The K​c​ was set to
6.3, the T​t​ was set to 11, and the t​D​ was set to 1.1. A value of 45℃ was to be set for the set point.
To achieve the set point, the graph took 281 seconds. There was also no time delay after setting
the new set point. The graph continuously going constant before reaching the set point.
Unfortunately, for Trial 2 for PID control, the graph could not achieve the set point and it took a
lot of time. The response time did not achieve the set point. This is probably due to some
technical problems or fault diagnosis.

Overall, the best PID controller is PI control, Trial 1. This is due to the fast time
response.

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6.0 CONCLUSION

To conclude, cascade control, where applicable, provides a simple method for substantial
improvements in control performance and it is also described as simple and effective. The outer
loop process lag plays the role of the disturbance lag in the controller design. The inner loop can
be implemented as either a PID control system. There is no need for the inner loop process to be
faster than the outer loop process in order for a well-designed cascade control system to provide
significant performance advantages over a single-loop control system. Cascade control should
always be used if a process with relatively slow dynamics (like level, temperature, composition,
humidity) and a liquid or gas flow, or some other relatively-fast process, has to be manipulated to
control the slow process.

In order to investigate the process behaviour of Temperature-Flow cascade control, for

each of the PID controller, two trials were made. The best PID controller is PI control, Trial 1,
due to the fast time response.

The experiment conducted met the objectives which understand the liquid temperature
and flow process control (cascade control), understand the behavior of cascade process and plant
operation, understand and demonstrate the effect of load disturbance and set set point disturbance
in liquid temperature and flow cascade control and interpret the P&ID.

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7.0 RECOMMENDATION

Firstly, students should have understood on the experiment that will be done. Prepare the
lab manual and go through it before experiment. At early the experiment, there are changes in the
procedure in lab manual, and it make the process become a little bit late to explain on the new
step. Any changes in procedure should have been told before the experiment so that the process
can be smoothly and clear. Then, there are several problems that occur during the experiment
which the system does not achieve the initial parameter to start the experiment. Lab assistant
have to reset the system a few times before the reading reach the initial value to start the
experiment. Thus, it causes the time to done the experiment become longer than the expected
time and also affect the next group to do the experiment. All setup should be done early so that if
there are any problem occur it can be counter before student start the experiment.

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8.0 REFERENCES

● Buskerud, H. (2009, January 12). Multivariable control. Retrieved from

http://techteach.no/fag/seky3322/0809/mimo/mimo_pid_control.pdf

● Denizen. (2017, October 1). Multivariable Control System. Retrieved from

https://automationforum.in/t/what-is-multivariable-control-system/2498

● Morari, M., Zafiriou, E. (1989). Robust Process Control. Prentice Hall, NJ.

● Seborg, Edgar, Mellichamp. (2004). Process Dynamic and Control, Wiley 2nd edition.

● Stachowicz, M. S. (2010, January 19). Introduction to Control Systems. Retrieved from

https://www.slideshare.net/Hondafanatics/introduction-to-control-systems

● Tham, M. T. (1999, July). MULTIVARIABLE CONTROL: AN INTRODUCTION TO

DECOUPLING CONTROL. Retrieved from
https://pdfs.semanticscholar.org/adc2/561a043eb67600edefb646fa942187871414.pdf

● Vandoren, V. (2014, August 17). Fundamentals of cascade control. Retrieved from

https://www.controleng.com/articles/fundamentals-of-cascade-control/

● Diagnosing and Solving Control Problems | Control Notes. (n.d.). Blog.opticontrols.com.

Retrieved from ​http://blog.opticontrols.com/archives/456

● A Tutorial on Cascade Control | Control Notes. (n.d.). Blog.opticontrols.com. Retrieved

from ​http://blog.opticontrols.com/archives/105

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● What is cascade control loop? Advantages of the cascade control loop. (2017). Industrial
Automation, PLC Programming, scada & Pid Control System. Retrieved from
https://automationforum.in/t/what-is-cascade-control-loop-advantages-of-the-cascade-contro
l-loop/2423

● Cascade Control System. (2018). Instrumentation and Control Engineering. Retrieved from
http://instrumentationandcontrollers.blogspot.com/2011/05/cascade-control-system.html

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