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ISA Transactions
journal homepage: www.elsevier.com/locate/isatrans
Design of nonlinear PID controller and nonlinear model predictive controller for
a continuous stirred tank reactor
J. Prakash , K. Srinivasan
Department of Instrumentation Engineering, Madras Institute of Technology, Anna University, Chennai-44, India
article
info
Article history:
Received 7 September 2008
Received in revised form
4 February 2009
Accepted 9 February 2009
Available online 19 March 2009
Keywords:
CSTR
PID controller and model predictive
controller
abstract
In this paper, the authors have represented the nonlinear system as a family of local linear state space
models, local PID controllers have been designed on the basis of linear models, and the weighted sum of
the output from the local PID controllers (Nonlinear PID controller) has been used to control the nonlinear
process. Further, Nonlinear Model Predictive Controller using the family of local linear state space models
(F-NMPC) has been developed. The effectiveness of the proposed control schemes has been demonstrated
on a CSTR process, which exhibits dynamic nonlinearity.
Crown Copyright 2009 Published by Elsevier Ltd on behalf of ISA. All rights reserved.
1. Introduction
PID controller and linear model predictive controller are
the two most popular control schemes that have been widely
implemented throughout the chemical process industries for the
past two decades. However, control of nonlinear system using
above linear control schemes dont give satisfactory performance
at all operating points, the reason being that the process
parameters of the nonlinear process will vary with the operating
conditions. Moreover, the PID controller tuned at one operating
condition may not provide satisfactory servo and regulatory
performances at shifted operating points. It should be noted that,
to achieve improved closed loop performance a different set of
controller settings for each operating condition have to be used.
In the case of model based control schemes, the accuracy of the
model will have a significant effect on the closed loop performance
of the control system. The multiple-linear models concept has been
used in the recent years for modeling of nonlinear systems [1].
In addition, multiple-linear model based approaches for controller
design [25] have attracted the process control community. A
plethora of multiple-model adaptive control schemes have been
proposed in the control literature [69]. Gao et al. [10] has
proposed a nonlinear PID controller for CSTR using local model
networks. Omar Galan et al. [11] have reported the real-time
implementation of multi-linear model based control strategies on
the laboratory scale process.
Corresponding author.
E-mail address: prakaiit@rediffmail.com (J. Prakash).
0019-0578/$ see front matter Crown Copyright 2009 Published by Elsevier Ltd on behalf of ISA. All rights reserved.
doi:10.1016/j.isatra.2009.02.001
274
1H
, c
Cp , Cpc
x(k)
y(k)
u(k)
A
B
C
Ki
K c ,i
T r ,i
Td,i
NP
Nc
WE
WU
Concentration (mol/l)
Temperature (K)
Coolant flow rate (l/min)
Feed flow rate (l/min)
Feed concentration (mol/l)
Feed temperature (K)
Inlet coolant temperature (K)
CSTR volume (l)
Heat transfer term (cal/(min K))
Reaction rate constant (min1 )
Activation energy term (K)
Heat of reaction (cal/mol)
Liquid density (g/l)
Specific heats (cal/(g K))
True state variable
Measured variables
Process inputs
State transition matrix (continuous domain)
Input matrix (continuous domain)
Measurement matrix
Steady State gain of the ith process model
Proportional gain of ith PID controller
Integral time of ith PID controller
Derivative time of ith PID controller
Prediction horizon
Control horizon
Error weighting matrix (N-MPC)
Controller weighting matrix (N-MPC)
control scheme [19] have been already attempted on the CSTR process which is considered for the simulation study in this paper.
Even with the introduction of powerful nonlinear control strategies such as nonlinear internal model control schemes and neural
adaptive control, the proposed control schemes remain an attractive control strategy, because it offer advantages such as simple design and low computational complexity.
The main contributions of the paper are as follows: firstly, the
nonlinear system is represented as a family of local linear state
space models. Secondly, local PID controllers have been designed
on the basis of local linear models, the weighted sum of the
output from local PID controllers has been used to control the
nonlinear process, and finally a nonlinear model predictive control
scheme using the family of local linear state space models has been
proposed to control nonlinear process.
The organization of the paper is as follows. Section 2 discusses
the TS fuzzy model. Section 3 presents the design of nonlinear PID
controller. Section 4 deals with nonlinear model predictive control
schemes formulation using local linear models. Section 5 deals
with analytical (first principle) model based predictive control
formulation. The process considered for simulation study has
been discussed in Section 6. Simulation results are presented in
Section 7 and the conclusions drawn from the simulation studies
in Section 8.
x = f (x, u, d)
(1)
y = g (x, u, d).
(2)
(3)
(4)
(5)
yi (k) = Ci xi (k)
(6)
where, zj (k) are the premise variables and Mij (k) are the fuzzy sets.
i , i , and Ci are known time invariant matrices of appropriate
dimensions. In this work it is assumed that such a model of the
process can be developed from the first principles by linearizing
them around different operating steady state values (x i and u i ). The
global system behavior is described by a fuzzy fusion of all linear
model outputs. For a given input vector, u(k), the global state and
output of fuzzy model are inferred as follows:
x(k) =
N
X
hi (z (k))[i (x(k 1) x i )
i=1
+ i (u(k 1) u i ) + x i ]
y(k) = Cx(k)
(7)
(8)
i (z (k))
(k)
i (z (k)) =
g
Y
(9)
Mij
(10)
i (z (k)).
(11)
j =1
(k) =
N
X
i=1
N
X
hi (z (k)) = 1.
(12)
i=1
275
(17)
where
3. Nonlinear PID controller (N-PID) design using local linear
models
In this section, the design of local PID controllers on the basis
of local linear models, which were described in the previous
section, is discussed. Further, the method to combine the local
PID controller outputs yielding a global controller output has been
outlined. The global controller output u(k) has been determined by
the following rules:
Rule i (i = 1 : N )
(18)
(19)
where,
K c ,i
T r ,i
T e(k) +
J =
(Kc ,i Td,i )
[E (k + j/k)]T WE [E (k + j/k)]
j =1
Nc 1
(13)
j =0
Np
X
x(k + j + 1/k) =
for j = 1, . . . , Np .
(20)
(21)
for j = 1, . . . , Np
1u(k + Nc /k) = 1u(k + Nc + 1/k)
= 1u(k + Np 1/k) = 0 .
(k+j+1)T
i =1
for j = 1, . . . , NP .
(25)
for j = 0, 1, . . . , NP 1. (26)
To account for plant model mismatch and unmeasured disturbances, a simple unmeasured disturbance estimator similar to the
dynamic matrix control scheme is incorporated as follows:
yc (k + j/k) = y(k + j/k) + d(k + j/k)
d ;
F x( ), u(k + j|k), d
(23)
(k+j)T
i =1
(22)
(24)
j = 0, 1, . . . .Np 1
for j = 0, . . . , Nc 1
(15)
where
(16)
(27)
for j = 1, . . . , Np .
(28)
276
Table 1
Operating data for CSTR process.
For fuzzy dynamic model design for the CSTR process, the
coolant flow rate (qc ) has been chosen as the premise variable
and triangular membership functions have been used to partition
the input space qc . The universe of discourse is divided into five
intervals which are defined by the linguistic variables, very low
[97 100], low [97 100 103], medium [100 103 106], high [103 106
109] and very high [106 109] respectively. Further, local model
parameters (consequent part of TS fuzzy model) are determined
by linearizing the nonlinear differential equations ((35) and (36))
around the centers of the fuzzy region partitioning the operating
space of the system. The detailed design procedure of the fuzzy
dynamic model for the CSTR process has been reported in Senthil
et al. [22]. The linear time invariant discrete state space models
(Refer Eqs. (5) and (6)) for five different operating points of CSTR
are:
u(k/k) .min
. . u(k + Nc 1/k)J
Process variable
100.0 l/min
1 mol/l
350 K
350 K
100 l
7 105 cal/(min K)
7.2 1010 min1
1 104 K
2 105 cal/mol
1 103 g/l
1 cal/(g K)
(29)
where,
J =
1.2040e001
1 =
1.5350e+002
3.1008e003
1.4438
1.2927e004
1 =
.
9.6293e002
Np
X
[E (k + j/k)]T WE [E (k + j/k)]
j =1
Nc 1
(30)
(31)
(32)
3.2672e003
1.4733
1.3035e004
2 =
.
9.4559e002
for j = 1, . . . , Np
1u(k + Nc /k) = 1u(k + Nc + 1/k)
H
(33)
= 1u(k + Np 1/k) = 0 .
(34)
E
=
(35)
(CA0 (t ) CA (t )) k0 CA (t ) exp
dt
V
RT (t )
dT (t )
q(t )
(1H )k0 CA (t )
E
=
(T0 (t ) T (t ))
exp
dt
V
Cp
RT (t )
c Cpc
hA
+
qc (t ) 1 exp
(Tc0 (t ) T (t )) . (36)
Cp V
qc (t ) Cp
The state x(t ) and input u(t ) vectors are given by x(t ) = [CA ; T ]
and u(t ) = [qc ].
3.4252e003
1.5012
1.3074e004
3 =
.
9.2643e002
y yc (k + j/k) y
L
dCA (t )
1.7133e001
2 =
1.4362e+002
j =0
uL u(k + j/k) uH
3.5731e003
1.5270
1.3038e004
4 =
.
9.0506e002
3.7084e003
1.5504
1.2913e004
5 =
.
8.8085e002
1 0
C =
.
For the CSTR process considered for the simulation study Senthil
et al. [13] has shown that the linear dynamic model is not able
to capture the dynamic behavior of the CSTR process, whereas the
fuzzy dynamic model is able to capture the dynamic nonlinearity
adequately.
7.2. Nonlinear PID controller (N-PID) design for CSTR process
7. Simulation studies
In all the simulation runs, the process is simulated using the
nonlinear first principle model (Eqs. (35) and (36)). The true
state variables are computed by solving the nonlinear differential
equations using differential equation solver in Matlab 6.5.
277
Fig. 1. Servo response of CSTR with F-NMPC, N-PID, and A-NMPC (a) Process output (b) Controller output.
Ki
s2 + 2i n,i s + n2,i
i = 1 : 5.
2i
;
n,i Ki
Tr ,i =
2i
;
n,i
Td,i =
1
2i n,i
278
Table 2
Damping factor and un-damped natural frequency at different operating points.
Operating point
Damping factor
Freq. (rad/s)
0.661
3.93
Process gain
0.0028
0.540
3.64
0.0032
0.416
3.34
0.0037
0.285
3.03
0.0043
0.141
2.71
0.0052
Table 3
PID controllers parameters at different operating points.
Operating point
Kc ,i
119.4321
92.6928
67.4294
43.2812
19.1813
Table 4
ISE values of F-NMPC, N-PID, and A-NMPC for setpoint tracking.
Sampling instants interval
A-NMPC
F-NMPC
N-PID
10 k 49
50 k 79
80 k 120
2.52e05
8.84e05
1.55e05
3.68e05
9.42e05
2.67e05
5.07e05
1.47e04
3.10e05
Table 5
ISE values of A-NMPC, F-NMPC and N-PID in the presence of setpoint change and
load change.
Sampling instants interval
A-NMPC
F-NMPC
N-PID
10 k 69
70 k 119
120 k 175
1.16e05
1.17e04
5.51-06
1.18e05
1.43e04
2.77e06
1.66e05
2.03e04
1.11e05
Tr , i
Td , i
0.3367
0.1926
0.2973
0.2546
0.2491
0.3601
0.1876
0.5792
0.1037
1.3124
NMPC schemes for CSTR have been developed with the sampling
time of 0.083 min, prediction horizon of NP = 5, and control
horizon of Nc = 1.The error weighting matrix and the controller
weighting matrix used in the N-MPC formulation are WE =
1e4 and WU = 0. The following constraints on the manipulated
input (coolant flow rate) are imposed 95 < qc < 108.
7.4. Servo performance
The setpoint variations as shown in Fig. 1(a) have been
introduced for assessing the tracking capability of the proposed (i)
F-NMPC formulation using the local linear models, (ii) proposed
N-PID control scheme using multiple-linear PID controllers and
(iii) analytical/first principle model based NMPC(A-NMPC). From
the response, it can be inferred that, the F-NMPC formulation
based on local linear models, N-PID control scheme using multiplelinear PID controllers and A-NMPC scheme are able to maintain
the reactor concentration at the setpoint. The ISE values of FNMPC, N-PID and A-NMPC are reported in Table 4. From Table 4,
it can be inferred that the ISE values of A-NMPC and F-NMPC have
been found to be considerably less than N-PID. The variation in
the controller outputs is presented in Fig. 1(b). The observations
(qualitative) of the above simulation study are as follows:
Both the proposed controllers and A-NMPC are able to maintain
the setpoint at the desired value. However, the performances of
F-NMPC and A-NMPC at all the operating points are found to be
better than N-PID, as there is less overshoot and settles to the
setpoint faster. The F-NMPC provides performance comparable to
that of A-NMPC.
Fig. 2 presents histograms of computation time at each
sampling instant obtained using A-NMPC and F-MPC. It can be
concluded that the computation time per iteration (Matlab 7.0,
Intel Core 2 Duo Processor-2.13 GHz) of the proposed F-NMPC
algorithm is in the range 0.010.7 s, whereas, for the A-NMPC
algorithm, the value is in the range of 0.251.6 s. For the N-PID the
computation time per iteration has been found to be in the range
0.0010.0016 s.
The proposed F-NMPC helps to reduce the number of computations needed, compared to the rigorous model based NMPC (ANMPC). Also, in the A-NMPC, the nonlinear differential equations
have to be numerically integrated to obtain the predicted estimates
of the output variables. On the other hand, in the F-NMPC, although
more matrices are needed, all of them have constant values, which
limit the calculation to (i) the determination of weights, which will
279
Fig. 4. Servo and regulatory responses of CSTR with F-NMPC, A-NMPC and N-PID (a) Process output (b) Controller output.
Fig. 5. Servo response of CSTR with N-PID for various values of filter time constant (a) Process output (b) Controller output.
280
Fig. 6. Servo response of CSTR with F-NMPC for various values of prediction horizon (a) Process output (b) Controller output.
Fig. 7. Performance of N-PID in the presence of measurement noise (a) Process output (b) Controller output.
instants and the value has been maintained upto the 110th
sampling instants and is then brought back to 350 K. (Refer Fig. 3).
The ISE values are computed for A-NMPC, F-NMPC and N-PID and
are reported in Table 5. The ISE value of F-NMPC and A-NMPC have
been found to be considerably less than that of N-PID for the servoregulatory performance case also. The following observation can be
drawn from the simulation studies
From 10th sampling instants to 70th sampling instants of
Fig. 4(a), it can be inferred that the controllers (A-NMPC, N-
PID and F-NMPC) are able to reject the disturbance quickly and
bring the reactor concentration back to the nominal value of
the setpoint. This part of the simulation demonstrates that the
controllers are able to reject the disturbance at the nominal
operating point.
281
Fig. 8. Performance of F-NMPC in the presence of measurement noise (a) Process output (b) Controller output.
Table 6
Mean and standard deviation of the true value of the controlled variable for various values of alpha.
Alpha
F-NMPC ( )
N-PID ( )
0.25
51 k 100
251 k 300
451 k 500
51 k 100
251 k 300
451 k 500
51 k 100
251 k 300
451 k 500
0.0989(3.28e04)
0.1107(7.15e04)
0.0989(3.57e04)
0.0988(4.31e04)
0.1107(8.09e04)
0.0988(4.48e04)
0.0988(4.58e04)
0.1107(7.15e04)
0.0988(3.59e04)
0.0989(2.32e04)
0.1108(4.24e04)
0.0989(2.64e04)
0.0989(2.93e04)
0.1108(4.31e04)
0.0989(2.61e04)
0.0989(3.09e04)
0.1108(4.23e04)
0.0989(2.72e04)
0.5
0.75
type (lamda 0.5 and 1.5). For lamda value equal to 0.25, it can
be observed that controller output was found to be aggressive, as
compared to other values of lamda (Refer Fig. 5(b)).
7.7. Performance of F-NMPC for various values of prediction horizon
In order to assess the effect of the prediction horizon, we
have performed simulation studies for various values of prediction
horizon. The closed loop responses to step changes in the setpoint
and for various values of prediction horizon are shown in Fig. 6.
In all the simulation runs, a control horizon of 1 is used. For the
process considered for simulation study the prediction horizon
seems not to have appreciable effect as shown in Fig. 6. The
setpoint tracking performance has been found to be almost the
same for all the values of prediction horizon.
7.8. Performance of N-PID and F-NMPC in the presence of measurement noise
The performances of the proposed N-PID and F-NMPC control
schemes in the presence of measurement noise are shown in
Figs. 7 and 8 respectively. In both the control schemes, Gaussian
white noise of mean zero and standard deviation of 0.0012 mol/l
has been added to the true value of the process variable (reactor
concentration). A digital first order filter has been used to filter
the noisy process measurement and the control calculations are
282