INDUSTRIAL APPLICATION

TEMPERATU

Pressure
RE EXOTHERMI
Temperature
Reactor loading
Reflux rate C
Purity of input
reactants

HYDROGENATION REACTOR

INPUT
CATALYST
DEGREE OF
TEMPERATURE

To
ensure
safe
and
Assure
ACTIVITY
temperature
normal
conditionsTIME
of
operation..

To maintain the temperature at an

acceptable value
Ensure a high conversion of 2ethyl-hexenal to 2-ethyl-hexanol
SPECIFIC
VOLUMETRIC
FLOW RATIO
MANIPULATED
VARIABLE

Model Predictive Control (MPC)

MULTIVARIABLE
PROCESS

DISTILLATION COLUMN
ADJUSTING
TEMPERATURE

PETROLEUM REFINERIES

5 Manipulated
Disturbance
Variables
variables
2 product flows
Feed rate
Reflux
Composition &
Reboiler
enthalpy
heat temperature
Coolant
Condenser
Cooling

2
levels

5 control
variables
2
pressu
temperatures re

Top
Toptemperature
temperature
LOOP 1

MPC WILL Feed-forward

OPTIMIZE THE
Reflux
signal
SET POINT ! flow

LOOP 2

Steam
flow

Bottom
Bottom
temperature
temperature

MIMO system:
Impeller continuously
stirs theof
content
of a tank or reactor
Formation
product
DEPENDS
Proper
mixing

CSTR

Reactor Achieve specific

temperature
output

EXOTHERMIC
REACTORS

Feed flow
rate

safety
problems
exotic
behavior

rapid
increase in
temperature
behavior

multiple
steady
states

Control
process

temperat
ure
control
loop

Temperature

LOOP
INTERACTI
CHAN
ON
GE
PROCESS!

concentra
tion
control
loop

CHAN
Influence
GE Reaction
concentra
tion

Coolant
jacket

Change feed
flow rate

coola
nt
Reacti
on
mass

rate

g
n
i
y
Var
w
Flo
e
rat

Temperat
ure

TWO STATE
VARIABLES
CONTROL
VARIABLE
REACTOR
TEMPERATURE
REACTOR
CONCENTRATION
CONTROL
SYSTEM

INTERACTIO

MANIPULAT
ED
VARIABLE
FEED FLOW RATE
COOLANT FLOW RATE
OUTPUT
VARIABL
E
INPUT
VARIABL
E

DISTURBANCE

NS
EACH OUTPUT CAN BE CONTROLLED
INDEPENDENTLY

MIM
O

Complex

Inherent
nonlinear
ity

RESEARCH
BACKGROUND
Challengin
g

THEORY
PROCESS MODEL (LEVEL)
Unsteady state models are known as dynamic
models.

Dynamic models and simulation allow transient

process behaviour without disturb the process.

Allow alternative control strategies.

Control the process variables.


MASS
BALANCE :

where V = Ah
If the valve is an orifice :
Pressure at the bottom of the tank :
Overall equation : A = Where =

Non-linear

THEORETICAL
MODEL
Developed using the principles of chemistry, physics and
biology.
Derived theoretical property and phenomenological
models.
More complex but provides understanding.
To develop new concepts.

EMPIRICAL MODEL
Derived by experimental fitting data.
Relies on experience or observation.
Generally based on research.
Easier to manipulate.


EMPIRICAL
MODEL DEVELOPMENT
Model are determined by making small changes in the input variables.
Resulting dynamic response is used to determine the model. STEP-

TEST METHOD
FIRST ORDER (FO)
where

Steady state;
u(0)=0, y(0)=0,
uinput=0 to M at
t=0

By referring to Figure, the intercept of the tangent at t = 0 the horizontal line,

(y )/KM= 1, occurs at = . So, can be estimated from a step response plot using the
value of t at

which the response is 63.2%.

FIRST ORDER MODEL PLUS TIME DELAY

(FOPTD)
To
improve the agreement between model and experimental.
1. K is found by calculating the ratio of steady state change in y to
the size
of the input step change, M.
2. Intersection of the tangent line and the time axis is the time delay.
3. If the tangent is extended to intersect the steady-state response
line
(where y = KM), the point of intersection corresponds to time t = +
Sundaresan and

Karishnaswamy s
Method

GRAPHICAL TECHNIQUES FOR SECOND

ORDER (SO)

/ = 0 , where system becomes first-order

/ = 1 , where critically damped case

SOPTD

CONTROLLER
TUNING
Selection of tuning parameters to ensure the best response of the
controller.
control of the physical process.
Provides sensing, analysis, andTUNNING
TECHNIQ
UE

Open
Loop Z-N
Tuning
Method
Method

Controller
Controller
P
P

Cohen
Cohen
Coon
Coon

PI

PID

--

--

Closed
Loop Z-N
Tuning
Metho
d

Contro
ller

Ziegle
rNichol
s

0.5Kcu

PI

0.45Kcu

Pu/1.2

PID

0.6Kcu

Pu/2

Pu/8

PI

0.31Kcu

2.2Pu

PID

0.45Kcu

2.2Pu

Pu/6.3

Tyreus
Luybe
n

OPEN LOOP Z-N

TUNING

Determine
time constant
and time delay.

Calculate
controller
setting.

Input the
controller
setting to the
Indusoft of PI
controller and
run the
system.

Based on
process
reaction curve,
choose the
best controller.

Repeat all the

step for PID
setting.

Record the
data and plot
the process
reaction curve.

Run the
simulation with
both process.

Insert the
same
controller and
same step
change.

Record the
data and plot
the process
reaction curve.

Set LSV at
50.5% and
start logging
data.

After I
minutes,
increased LSV
at 60.5%.

CLOSED LOOP Z-N TUNING

In the PID block

of Matlab
Simulation, the
integral is set as
0 and the
derivative is set
as large as
possible.

The proportional
term is set at a
low value.

Run the system

by induced a 5%
step change
after 1 minutes.

Observe process
reaction curve by
using scope.

After sustained
oscillation
obtained, the
proportional
value is the
ultimate gain,
KCU.

Input the
controller setting
to the Indusoft
controller and
run the system.

Plot the reaction

curve.

Insert calculated
setting to thE
PID controller in
Simulink.

By using KCU
and PU, the
controller setting
are determined
using ZieglerNichols method.

Based on the
process reaction
curve, the
ultimate period,
PU can be
obtained.

Set the LSV at

30% and start
logging data.

After 1 minutes,
increase the LSV
to 35% and start
logging data.

Record the new

steady state and
plot the curve.

Repeat for other

controller and
choose the best
controller.

Compare for the

process reaction
curve.

NTROLLER PERFORMANCE
The purpose of quarter-amplitude
damping is to eliminate any error
between the setpoint and process
variable.

Problem presents:
1. It makes the loop very oscillatory.
2. It causes a loop to overshoot its
set-point.

3. Not very stable and have low

METHODOLOGY
SYSTEM
FAMILIARIZATI
ON

CONTROLLER
TUNING
PROCESS
MODELLING

Level control loop

SYSTEM
FAMILIARIZATION
Before start,

-The parameter, CV, MV

and DV is identified
- General start-up
procedure conducted
- Valve configuration
remain UNCHANGED
and
CONSTA
CONSTANT
NT

STORAGE
TANK

PUM

SHUT
STARTDOWN
UP
PROCEDURE
PROCEDURE

Pump
Switched
Level
controlpressure
loop
on AUTO MODE

VALVE
CONFIGURATION
Temperature control
loop
MANUAL
MODE
TMV 80%to
monitored

is
avoid HIGH pressure
ADJUSTED
LSV 50%
system tested at LMV
80%
and
=LMV
not fluctuate
a lot
20% to verify the functionality
of
valve
system is turned of
VALVE CONFIGURATION WILL

REMAIN UNCHANGED

STEP TEST
METHOD
After general start-up

PROCESS
MODELLING
procedure...

steady state

TMV
80%

EXP.
DATA
LMV
50%
Ave.

+
10%

AFTER STEADY
STATE...
REPEATED 2x WITH SAME STEP

CLOSED LOOP Z-N

TUNING

CONTROLLER TUNING*

OPEN LOOP
C-C
TUNING

Z-N
RELATION
Continuou
s cycling
c

Process
reaction
curve

Pu

K c
I and D = 0

Evaluate
controller
Step introduced
to control
setting
imply the I and loop
D is as
large as possible and zero

REALCONTROLLER
IMPLEMENTATION AND SIMULATION
SETTING
After the general start-up
COMPARISON
C-C METHOD SE 271

procedure....

Z-N METHOD
EVALUATED
AND
ANALYSE
TMV
80%
PROCES
S
REACTI
ON
CURVE

50%
ANALYSIS AND
COMPARED
+5%
RISE
TIME
step
SETTING
change
TIME
After the system has reach
DECAY RATIO
steady state....

SE 271
SISO
FAMILIARIZATION OF MODEL SE 271
(MIMO)
(Level)

PROCESS MODELLING

FO

Steady
state

MV step

changes

Process
FOPT
reaction
D
curve
SO
PT
D

Paramet
Paramete
ers
rs
Evaluatio
Evaluati
n
on

P
=36
s
u
CLOSED LOOP
CONTROLLER
TUNING

CONTINUOUS
CYCLING METHOD
(SIMULATION)

Kc = small
value
I = Zero
D = Zero

Continuous Cycling
Kc=Kcu=16.1

OPEN LOOP
CONTROLLER
TUNING

STEP TEST
METHOD

No obvious
overshoot in
No
realLarge
overshoo
Kc
implementat
Slight
ion Value
t
oversh

oot

Oscillatory
Ignored
Sustained
Z-N
steady
Shorter
transmitter oscillatio
CONTROLLER
rigorous
Offset
state
more
tand
than
Simulation
r Oscillation
final
tuning
with no
n
at
PERFORMANCE
Reach
steady
prior
than
5%
PI to rise
method
control
steadyoscillation
time state faster
bandwidth
element
state

PERFORMANCE CRITERION

PID
C-C

Oscillatio

n
bandwidt
h more
than

Sustain
ed
QAD
PI tr is longer
oscillati
achieved
by C-C than PID due toon

lack of
derivative term

relation

PID
controll
er
better

ERROR ANALYSIS AND RECOMMENDATION

Flowrate
variation

MV 80% will be very

sensitive to the
variation in level loop
MV 50% liquid flow to
Water
the tank level
is too low

variation in
T-201
Reduce

Noi
se

flowrate from
the
Water
Less
sensitive
temperature
level in THydrostatic
Pressure
control
201 loop