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Executive Summary
Proportional, integral and derivative (PID) controllers are the most widely used
controllers in Multiple-Input-Multiple-Output (MIMO) in most process industries. This
is due to their simplicity, easy implementation and their robustness. Various tuning
methods like the Cohen-Coon (C-C) method and the Zeigler-Nichols (Z-N) method have
been recommended for optimum set-up of PID controllers. In the project the
performance of a three tank MIMO system was tuned based on the Cohen-Coon and
Zeigler-Nichols method to determine the optimum PID parameters. The Relative Gain
Array of the system was also determined for best pairing suggestions. The PID
parameters, gain, integral time and derivative time were calculated to be 1, 600 and 120
for optimum performance of the controller. The RGA suggested that it is best to pair
water inflow with tank level, and solids inflow with outlet slurry density.
Keywords: Cohen-Coon, Zeigler-Nichols, PID Controller, MIMO, RGA
1. Table of Contents
1.
Introduction..........................................................................................................1
3.1.1.
3.1.2.
3.2.
3.3.
3.4.
3.5.
3.6.
Density of Qout...........................................................................................................7
4. Conclusions...........................................................................................................7
5. References.............................................................................................................8
6. Appendix...............................................................................................................9
2. Introduction
According to Fichte (2005), Ferrosilicon is a ferroalloy, an alloy of iron and silicon with
average silicon content in the range of 15 and 90 per cent by weight. In this project
ferrosilicon is used ain a pilot plant to make a dense-medium bath utilising three
identical tanks. The main objective of this project is to develop a Simulink model that
can control the level in each tank and also the final slurry density as recommended. This
will be done by determining the optimum PID controller parameters, and also determine
the Relative Gain Array (RGA) for controlling the level of tank 3 to a desired value and
to also maintain the final slurry density at a desired constant value. The RGA will help
in such a way that it gives the possible way for pairing the inputs and outputs for a
Multiple-Inputs-Multiple-Outputs (MIMO) system.
Where
Qout 1
and
out 1
Tank 2:
1 | Page
spillage =
( 1C s ) + W C s
FeSi
( )
2.4
goes to 0
dM
=M M out 2.6
dt
V tank= A tank h ; M =tank A tank h 2.7
d ( Ah )
=Q out2 out 2Q out out 2.8
dt
dh
=Qout 2 out 220 h out 2.9
dt
For perfect mixing, density within the tank is the same as the density of outlet stream;
dh Q out2 out 2 20 h
=
2.10
dt
A out
A
h=
Qout 2 out 2
1
20 h dt 2.11
A
out
2 | Page
out =
Also the dynamic volume balance was performed. These equations were used to
construct the simulation for the project. See appendix for block diagrams.
3 | Page
Figure 3.1 Input reaction curve in response to a step disturbance from initial steady
state to final steady state of 30l/min
Figure 3.2 Output reaction curve in response to a step change from initial steady state
to final steady state of 30l/min
The process parameters that were obtained from the reaction curves above were as
follows.
N=reaction rate=
Cp
7.91
0.1898 4 l
=
=
T
4 1 . 67
min2
L NL
8.333 min
R=lag rati o= =
=
=0.20
T C p 4 1. 67 min
4 | Page
7.91l
min
7.79 l
min
Cohen & Coon recommended the following expressions for calculating PID parameters:
Gain , K =
100
P
R
=
1.33+ =6.90
Xp
NL
4
( )(
X p=14.49
Integraltime , T i=
L ( 32+ 6 R )
=1.895 103 min=18.95 s
( 13+8 R )
Derivative time , T d =
4L
=2.924 104 min=2.93 s
( 11+2 R )
Gain , K =
100 1.2 P
=
=6.00
Xp
NL
X p=16.67
Integraltime , T i=2 L=1.667 103 min=16.67 s
Derivative time , T d =0.5 L=4.167 104 min=4.17 s
5 | Page
Figure 3.4 Curve depicting the effect of V2 opening at 50% on tank 3 outlet flowrate
The figure above shows that when the step change of V2 opening to 50% is introduced,
the systems established steady state is disturb, thus the system moves away from this
initial steady state until a new steady state operation is reached. The new steady state
flow is established at approximately 1.5 seconds, and Q out moves from 20l/min to a new
6 | Page
value of 24.26l/min. The density of the slurry is maintained at 2000kg/m 3 using the
density control loop. The same phenomenon is observed for the height of tank 3. The
height level moved from the initial steady state value until new steady state was
established.
Figure 3.5 Curve depicting the effect of V2 opening to 50% on height of tank 3
Figure 3.6 Curve showing the effects of spillage disturbance on tank 3 outlet density.
7 | Page
Upon introduction of the spillage stream, the density of tank 3 outlet stream decreased.
The density PID controller was used to maintain the density at the required value of
2000kg/m3. The control valve, V2, was opened slightly above 50%.
1.555 0.222
0.222 1.555
From the RGA above it advisable to pair water inflow with tank 3 level and the solids
(FeSi) with the slurry density since
l 11
and
l 22
l 12
and
l 21
respectively.
5. Conclusions
The aim of the project was to simulate a three tank system with multiple inputs and
outputs in order to tune the PID controller and to also study the effects of disturbances
on the plant. Also the RGA of the system was determined to determine the best coupling
8 | Page
of the systems parameters. After fine tuning the controller, the PID parameters, gain,
integral time and derivative time were determined to be 1, 600 and 120 respectively. The
RGA suggested that it is best to couple the water inlet flowrate with tank 3 level and the
solids flowrate with the outlet density.
6. References
Fichte R. (2005). Ferroalloys, Ullmans enclopedia of industrial chemistry, Weinheim:
Wiley-VHC, doi: 1002/14356007.a10_305
Svrcek W.Y., Mahoney D.P., Young B.R. (2014). A Real-Time Approach to Process
Control, 3rd ed. UK: Wiley. Pp., 303-305
9 | Page
7. Appendix
10 | P a g e
11 | P a g e
12 | P a g e
13 | P a g e
14 | P a g e