DESIGN OF PID FEEDFORWARD

CONTROLLER FOR CONTROLLING OUTPUT

FLUID TEMPERATURE IN SHELL AND TUBE
HEAT EXCHANGER.

GROUP MEMBERS:

APARNA ARUN

HAMAD PULLIKAL

IRIS GOPAL

MOUNISHA MOHAN

TASNEEM IBRAHIM

AIM:
Simulation of PID Feed forward Controller for controlling output fluid temperature in shell and tube
heat exchanger.

PROBLEM FORMULATION:
In a chemical process, heat exchangers are used in order to transfer heat from one hot fluid
through the solid wall to a cold fluid. There are various types of heat exchangers in industry.
Certain type of these heat exchangers, which are known as shell and tube heat exchangers have
been produced in different configurations as well as various sizes and can operate in high
pressure. These heat exchangers apply in fields such as condensation, electricity production,
chemical processes, medicine, etc. one shell and tube heat exchanger is a set of parallel tubes,
which are enclosed in a cylindrical cover. In heat exchangers, one fluid flows in tubes and other
fluid around tubes.
Researches about controlling heat exchangers have dealt with other heat exchangers like plate
exchangers and control plans like neural network, and fuzzy network in order to control output fluid
temperature of these heat exchangers. Therefore, there is less attention to controlling these heat
exchangers' temperature. It is necessary to mention that regarding domestic research, there is no
valid plan in order to control temperature of these heat exchangers and this work in unique in this
regard. Here we deal with a shell and tube heat exchanger and one-input-output system using
experimental data. Output fluid temperature of heat exchanger should be kept in an optimized point
regarding process need. Then a PID controller runs with feed-forward controller in order to reach
control purpose. Also we are analyzing designed controller performance is done in the time
domain. In order to evaluate designed controller performance, unit step response analysis and
performance indicators are used. Processes modeling and controllers' design indicators steps have
implemented in MATLAB software Simulink.

THEORY:
Feed-forward, sometimes written feedforward, is a term describing an element or pathway within
a control system which passes a controlling signal from a source in its external environment, often
a command signal from an external operator, to a load elsewhere in its external environment. A
control system which has only feed-forward behavior responds to its control signal in a pre-defined
way without responding to how the load reacts; it is in contrast with a system that also
has feedback, which adjusts the output to take account of how it affects the load, and how the load
itself may vary unpredictably; the load is considered to belong to the external environment of the
system.

In a feed-forward system, the control variable adjustment is not error-based. Instead it is based on
knowledge about the process in the form of a mathematical model of the process and knowledge
about or measurements of the process disturbances.

Sometimes pure feed-forward control without feedback is called 'ballistic', because once a control
signal has been sent, it cannot be further adjusted; any corrective adjustment must be by way of a
new control signal. In contrast 'cruise control' adjusts the output in response to the load that it
encounters, by a feedback mechanism.

With feed-forward control, the disturbances are measured and accounted for before they have time
to affect the system. In the house example, a feed-forward system may measure the fact that the
door is opened and automatically turn on the heater before the house can get too cold. The
difficulty with feed-forward control is that the effect of the disturbances on the system must be
accurately predicted, and there must not be any unmeasured disturbances. For instance, if a
window was opened that was not being measured, the feed-forward-controlled thermostat might
still let the house cool down.

Feedforward control is distinctly different from open loop control and teleoperator systems.
Feedforward control requires a mathematical model of the plant (process and/or machine being
controlled) and the plant's relationship to any inputs or feedback the system might receive. Neither
open loop control nor teleoperator systems require the sophistication of a mathematical model of
the physical system or plant being controlled. Control based on operator input without integral
processing and interpretation through a mathematical model of the system is a teleoperator system
and is not considered feedforward control.

RESULTS AND DISCUSSIONS:

Using the experimental data PID controller Simulink with feed-forward controller for shell and tube
heat exchanger is shown in figure
For PID controller, the amount of Kc , d i parameters are obtained by ZieglerNichols closed
loop regulation method,

Kc 0.185

P8

I0

D2

And the graph obtained by applying the method is shown below:

Purpose of designing control systems in time range is using features and characteristics of system
time domain. These characteristics are often expressed as standard values in ascending time,
settlement time, maximum jump, peak time, and stable mood error by unit step response. In this
designed controller, settlement time and maximum mutation were evaluated using unit step
response analysis.

For a good PID controller, the output should have

1)less settling time,

2) less oscillations

3) minimum error

At first when we used PID controller, there were many oscillations and it was not settling. But then
when we used PD controller, we got a minimum settling time along with the minimum disturbances.

The first disturbance settles at 250 sec. we give the second disturbance at 700 sec and it settles at
820 sec.
We changed the tuning from 0.16 because we were not getting the settling point at 1, so we had to
tune it to 0.185 to get the perfect set point.

CONCLUSION:
Regarding the above results, we can control output fluid temperature in shell and tube heat
exchanger in the least possible time without considering non-linearity of the process. By controlling
output fluid temperature in shell and tube heat exchanger; we can have significant savings in
energy consumption.

REFERENCES:
https://en.wikipedia.org/wiki/Feed_forward_(control)
http://article.sciencepublishinggroup.com/pdf/10.11
648.j.jeee.s.2015030201.17.pdf