2016 1st International Conference on Innovation and Challenges in Cyber Security (ICICCS 2016)

Design an Intelligent Controller for a Process Control

System
1
Meenakshi Sharma, 2Pallavi Verma, and 3Lini Mathew
1,2
ME Students (Electrical Engineering), NITTTR Chandigarh, India
1
meenakshibhardwaj90@gmail.com, 2pverma@gn.amity.edu)
3
HOD of Electrical Engineering Department, NITTTR, Chandigarh, India,
lenimathew@yahoo.com

ABSTRACT I. INTRODUCTION

Process control is one of the important Industrial application of process variables

problems in today industries. Precise
control of level, temperature, pressure and
flow is important in many process
applications. Now a days PID controllers
have found wide acceptance and
applications in the industries. The main
objective of this work is to improve the
performance of PID controller of water tank
system consists of various sensors
/transducers used for measurement of
process variables such as level, flow,
pressure and temperature. These systems
normally found in food and drink
manufacturing, petrochemical production,
water purification, sewage processing and
many other area of industry.
The Performance of the PID controller can
be improved using various soft computing
techniques such as Genetic Algorithm (GA),
Artificial Neural Network (ANN), Particle
Swarm optimizations (PSO), Fuzzy logic
controller (FLC), In this paper GA and PSO
used to improve the performance of the
water tank system using gain optimization.
KEYWORDS - PID Controller, Water tank
system, GA, PSO
control abound, such as in food processing,
nuclear power, generation plant, industrial
chemical processing and pharmaceutical
industries. In industries process variables
such as level, flow, pressure, temperature
are controlled by PID controller, such
advances have been made in control
techniques; this is due to its simplicity and
ability to apply a wide range of situations
[1]. PID controller is the most commonly
used controller strategy in feedback control
loop in the process control industry. It can
be used in different forms such as stand
alone, or in combination with logic control
system, to make complicated automation
systems used for energy and power
production, manufacturing, and latter used
for oil refining plants [2]. Its widespread use
is attributed to its simple structure and
robust performance over a wide range of
operating conditions [3]. On the other hand
tuning of a PID controller is rather difficult
and is a time consuming process. There are
several optimization algorithms which can
be used for searching optimal gain
parameters a very basic one is random
search [4].

In this study GA and PSO used to

optimization of parameters of PID
controller. Therefore, an extensive study on
the optimization of the controller parameters
is necessary PID controller algorithm is
described by Eq. 1

978-1-5090-2084-3/16/$/31.002016 IEEE
217
2016 1st International Conference on Innovation and Challenges in Cyber Security (ICICCS 2016)
( )= ( )+ ( ) + ( )
Figure 1 Block Diagram of PID
Controller
Where u (t) is the control signal and e (t) is
error of the control system. The PID control
parameters consist of the proportional gain
(KP), integral time (KI), and derivative time
(KD). Figure 1 shows the conventional PID
controller. The effect of KP is to decrease
the steady state error by increasing the value
of gain but it never eliminates the error. KP
can also reduce the rise time of the system.
The action of the integral gain is to eliminate
steady state error but the tendency for
oscillation also increase by this action. The
derivatives gain the effect of increasing the
system stability and reducing the overshoot
of the system as well as improving its
settling time [5]. To obtain this control
mechanism a PID controller is used which
can be tuned by intelligent algorithms such
as GA, PSO. PID controller has been put use
for many engineering application since the
last two decades any many methods have
been developed to tune the PID controller
like Ziegler- Nichols rule, symmetric
optimum rule, internal model control and
PSO. These tuning rules provide method for
calculation of the parameters for the tuning
of PID controller. GA and PSO are used for
optimization of the parameters of PID
controller [6].
II WORKING PRINCIPLE
218
The concept of developing gain optimization
using GA/PSO that would be used to
improve the water tank system to facilitate
the knowledge of process variables such as
level, flow, temperature, pressure. The main
goal of this system is to improve the
performance of PID controller for a water
tank system of process rig PCT-100.
Obtaining equations pertaining both
situations are formulated and then used to
find transfer function which have input
variable as input flow rate of entry of water
tank system and controlled variable as
height in the exit tank. To obtain accurate
liquid level control, feedback the controlled
liquid level and compared with the reference
input. Then an actuating signal which is
proportional to the difference of the input
and the output is sent to PID controllers,
which wills then take a corrective action
such as increasing/decreasing of inflow rate
to tank or changing the valve to maintain the
liquid level tank at desired level to decrease
the error.
GA & PSO tuned
Gain Parameters
Controlled
PID Controller Process
Desired Comparators Controlled
Input Output
Figure 2 Block Diagram to Tune the
Control Process Variable Using PSO/GA
Algorithms
III. MATHEMATICAL MODELING
Consider an open water tank with cross-
sectional area A, as shown in Figure 2,
Water is pumped into the tank at the top at
2016 1st International Conference on Innovation and Challenges in Cyber Security (ICICCS 2016)
rate of flow of qin cubic meters per second.
Water is flowing out of the tank via a hole in
the bottom of the tank of area a. The rate of
flow of water through the hole is following
the Bernoulli equation given by:
qout = a2gh (2) a) Genetic Algorithm
Figure 3 Simple Water Tank
where h is level of tank and g is gravity.
Conservation of mass yields the equation
A = qin - qout = qin a2gh (3)
Parameters in equations 3.2 are h = 25cm, r
= 9.5cm, a = 0.07cm and surface area of
tank is A=2057.5cm 2058cm
Integrating the equation (3), and taking
laplace transform of the above equation
H(s) = (qin a2gh)
The simulink model shown in Figure 4
Figure 4 Simulink Model for Water Level
III. TECHNIQUES OF INTELLIGENT
CONTROLLERS
Advanced Process Control (APC) refers to
an advance range of techniques and
technologies implemented within industrial
process control systems and advanced
process controls are usually deployed
optionally and in addition to basic process
219
controls. These basic process controls are
developed and built with the process itself,
to facilitate basic operation, control and
automation requirements [8].
Genetic Algorithm (GA) is a global
optimization algorithm which is derived
from evolution and natural selection.
Genetic algorithm cannot always provide
optimal solution; it has its own advantages
and it is a powerful tool for solving complex
problems. The basic thought of genetic
algorithm shown in flow graph
Population members
Generation = 0
Evaluate fitness value of
population members
Selection
Crossover
Gen = Gen+1 Mutation
No
Is it the last
generation
Yes
Stop
Figure 5 Flow graph for GA algorithm
1) Randomly producing an original
population whose number of individuals
is a constant N.
2016 1st International Conference on Innovation and Challenges in Cyber Security (ICICCS 2016)
2) Second step is producing next
generation by crossing over and
mutation among individuals.
3) Forming the new population of these
N individuals from the generation of 2
4) Producing the next generation by
repeating the step 2 and step 3 until
obtaining the individual which satisfies
conditions.
b) PSO ALGORITHM
PSO simulates the behaviors of bird
flocking. Suppose the scenario: a group of
birds are randomly searching food in an
area. There is only one piece of food in the
area being searched. PSO is initialized with
a group of random particles (solutions) and
then searches for optima by updating
generations. In each iteration, each particle
is updated by following two best values. The
first one is the best solution (fitness) it has
achieved. The fitness value is also store.
This value is called pbest. Another best
value that is tracked by the PSO is the best
value, obtained so far by any particle in the
population. The best value is a global best
and called gbest. When a particle takes
part of the population as its topological
neighbors, then this best value is a local best
and is called lbest. After finding the two best
values, the particle updates its velocity and
positions as per equation (3.16) and (3.17).
vik+1 = wvik +c1 rand1 () x (pbesti-sik) + c2
rand2 () x (gbest-sik) .. (4)
where, vik is the velocity of agent i at
iteration k, w is the weighting function, cj is
the weighting factor. rand is the uniformly
distributed random number between 0 and
1,sik is the current position of agent i at
iteration k,pbesti : pbest of agent i, gbest:
gbest of the group.
sik+1 = sik+ vik+1 ..
(5)
k+1
si : modified position
IV. SIMULATION AND RESULTS
SIMULINK MODEL FOR WATER
LEVEL
220
The simulink model of water level shown in
Figure 4 has been incorporated with PID
controller and PSO/GA and is shown in Fig.
5. The set point is defined by unit step
function which represents the desired set
point. The output of simulink model which
represents the output values of process
variables.
Figure 6. Block Diagram to Control
Water Level Using PSO/GA Algorithm
After using PSO algorithm to tune the
parameters of PID controller, the results of
process variables (water level, temperature
and flow rate) which are gotten, after the
execution of PSO algorithm code at setpoint
8 then we got the values of settling time, rise
time, overshoot, steady state error etc.
10
8
Set Point
Measured Value
Water Level
4
2
0
0 100 200 300 400 500 600
Time
Figure 7 Control of Water Level Using
PSO Algorithm at SP=8
The simulation results of water level system
using PSO algorithm and PID controller
shows that the rise Time is 0.3986s, settling
time is 0.7006s, overshoot is 0 and the
2016 1st International Conference on Innovation and Challenges in Cyber Security (ICICCS 2016)

steady state Error is 0. When the setpoint is 25

20 the simulation results of water level

control shown in Figure 8. The rise Time is 20

0.6817s, settling time is 7.0207s, overshoot Set Point

Water Level
15 Measured Value
is 6.111 and the steady state Error is 0.
50 10

40 5
Temperature Control

Set Point
Measured Value
30 0
0 100 200 300 400 500 600
Time

20 Figure 10 Control of Water Level Using

10
GA Algorithm at SP=20

0
0 100 200 300 400 500 600 V. COMPARISON OF RESULTS
Time

Table 1 Water level Control with and

Figure 8 Control of Water Level Using without PSO/GA
PSO Algorithm at SP=20
The simulation results of water level control
Control System Performance Parameters
using genetic algorithm at setpoint 8 shown
in Figure 8. The rise time is 0.2598s, settling method for Settling Rise Steady Overshoot
time is 0.4499, overshoot is 0.2284 and the
PID
steady state Error is 0. Time time State
10 controller error
8
Set Point
Measured Value
Controlling
6
Water Level

4
process
2
variable 90 30 0.2 0
0
0 100 200 300 400 500 600
without
Time

PSO/GA
Figure 9. Control of Water Level Using Controlling
GA Algorithm at SP=8 process 0.7006 0.3986 0 0
At the setpoint 20 the simulation results of variable with
water level control shown in Figure 9. The
rise time is 0.2636s, settling time is 0.4594s, PSO
overshoot is 0.2290 and the steady state Controlling
Error is 0.
process 0.4499 0.2598 0 0.2284
variable with
GA

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2016 1st International Conference on Innovation and Challenges in Cyber Security (ICICCS 2016)
Now from Table 1. It is found that the
output approaches to the input very rapidly
when we are tuning the PID controller with
PSO/GA algorithm. It shows that rise time is
very small. Also settling rime of the output
by using PSO/GA is very small which
shows that the output attain the steady state
value very fast. While in case of the results
without PSO/GA algorithm the Rise time
and settling time are very large. Also the
steady state error reduces in large amount.
But there are some oscillations when we
tune PID parameters manually .But by using
PSO/GA algorithm there are no oscillations
or very small number of oscillations in the
results also the peak time of the waveform is
very small using PSO/GA algorithm. There
is small overshoot in some results using
PSO/GA algorithm but overall system
performance using PSO/GA algorithm is
better than the system without PSO/GA
algorithm.
VI. CONCLUSION
PID controller parameters by using PSO/GA
algorithm because manual tuning of the PID
controller is a tedious process and it takes
very long time because it is based on hit and
trial method. So to make the PID controller
speed faster, PSO/GA algorithm is used.
PSO/GA algorithms tune the PID controller
parameters by reducing the fitness function
which is error function. The performance
parameters (Rise time, Settling time, Steady
state error and overshoot) are improved by
using PSO/GA algorithm.
ACKNOWLEDGMENT
I am greatly thankful to honorable Dr. M.P.
Poonia, DIRECTOR, NITTTR Chandigarh,
Dr. Lini Mathew Associate Professor &
Head, Electrical Engineering Department
and Mrs. Shimi S.L, Assistant Professor,
Electrical Engineering Department for their
worthy guidance and help in writing this
paper.
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