REAL TIME PERFORMANCE ANALYSIS, FAULT DETECTION AND CONTROL IN CONICAL TANK SYSTEM
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1 REAL TIME PERFORMANCE ANALYSIS, FAULT DETECTION AND CONTROL IN CONICAL TANK SYSTEM S.Pooja Dr.S.Vijayachitra 2 (Electronics and Instrumentation Engineering, Anna University, Erode, India, oojainst27@gmail.com) 2 (Electronics and Instrumentation Engineering, Anna University, Erode, India, dr.svijayachitra@gmail.com) Abstract Conical tank system is a non-linear system. Due to its non-linear behaviour, it is a challenging roblem to control the liquid level in the tank. Real time rocesses are always exhibits non-linear roerty. In many rocess industries like Chemical industries, Petroleum industries, Paer industries, Water treatment lants, Fermentation industries etc.., it is referred to have conical tank system because, it leads to better drainage of solid mixtures, slurries and viscous liquid at the bottom of the tank. In this roject work, Internal Model Controller(IMC) is designed and resonse of the rocess is obtained in both simulation and real time. Due to changes in rocess arameters the behaviour of the system can be varied. To measure an exact erformance of the system, the faults introduced into the conical tank system and to be detected. If not, the faults which degrade the erformance of the system. Various fault diagnosis methods are to be considered. PID controllers are used to detect the faults in conical tank system. Consequently, they can rovide better outut erformance which can be measured in terms of overshoot, set oint tracking and settling time. Keywords Conical tank system, PID controller, Internal Model Control, Fault diagnosis and estimation. INTRODUCTION Conical tank system is a nonlinear system which consists of broad area at the uer end and becomes narrow at the lower end. In the a lication of rocess industries, controlling the hysical variables such as flow, level, temerature and ressure is a challenging one even at different disturbances are occurred into the rocess. Proortional Integral Derivative(PID) controller are mostly used in rocess industries due to its accetable erformance[]. Mostly in level based control rocess, the shae of the tank has major role in rocess. The availability of the tank in the rocess industries in the shae of linear and nonlinear like cylindrical tye, sherical tye and conical tye etc... In cylindrical tye tanks, there will not be better drainage. To achieve comlete drainage of the liquid, conical shaed tank is referred in rocess industries. In rocess industries, the liquids will be rocessed in conical tanks for chemical storage, concrete mixing, food rocessing and waste roduct draining etc... So that, to control the level of the conical tank is a challenging roblem due to its continuous variation in the area of cross section of the conical tank. Thereafter, a non-linear controller is designed by Anandanatarajan et al. [2] on the basis of a variable transformation for the first order non-linear rocess with dead time, which is tested on a conical tank level rocess with dead time. The Ziegler Nichols PI controller gives an oscillatory resonse even at the nominal oerating oint. In [], P. Aravind et al. roosed a nonlinear model of conical tank level control system and real time system designs are analysed and their imlementation of the PI controller is done by direct synthesis method and skogestad method. In [2], D. Hariharan et al. designed the mathematical modeling of single conical tank, two conical tanks of non-interacting tye system and two conical tanks of interacting tye system is designed and also obtained the resonses of the rocess. In [4], J. Arutha Vijay Selvi et al. roosed conventional PID and IMC, are considered and are comaratively analysed using standard robustness measures for stability and erformance. In [], Jeffrey E. Arbogast et al. imlemented the novel IMC correlations calculate a filter time constant based uon the modal of the rocess and the user s choice for the closed loo time constant. The set oint tracking and disturbance rejection erformance of the IMC tunings are also demonstrated. In [6], D. Angeline Vijula et al. imlemented the mathematical modeling of a conical tank system has obtained and then model based controller(imc) has designed for controlling the level of the conical tank system. In [7], E. Kesavan et al. roosed IMC based PI and scheduled PI for nonlinear systems are designed. The servo mechanisms are analysed by adding the disturbance to the rocess and outut is retained to the setoint of the rocess. In [8], S. Vadivalagi et al. resented the arameters are otimally and robustly adjusted with resect to the system dynamics. In [9], P. Suganthini et al. roosed the IMC controller which roven that the IMC control method is to enhance the stability of the conical tank system. In [], T. Pushaveni et al. designed the Model Predictive Controller(MPC) to track the setoint changes IJRE - International Journal of Research in Electronics Volume: 4 Issue:
2 and load disturbances which control the level and also to enhance the stability in the conical tank system. In [], L. Ren et al. analyzed the rocess noise which includes sensor fault information. The sensor inciient fault can be detected by the distribution of the feature extracted from rocess noise in KPCA(Kernal Princile Comonent Analysis) sace. The intention of this aer is to design and comare the erformance of PID controller and IMC controller. The roosed schemes are imosed on the non-interacting conical tank system which is stationary in time, but nonlinear roerty in oerating level. Futhermore, the objective is to analyse the erformance of the noninteracting conical tank system and then to detect the occurrence of abnormalities in the conical tank system. The aer is organized as follows: Section II rovides a brief descrition about conical tank system. Section III moves to focus on mathematical modeling of noninteracting conical tank system. Design and selection of PID controller arameters are discussed in Section IV. In Section V, IMC controller is designed and comarative simulation results are also resented. Section VI, methods of fault diagnosis is rovided. Finally, conclusions are drawn in Section VII. 2. PROCESS DESCRIPTION IJRE - International Journal of Research in Electronics ISSN: X required flow of water into the conical tank and outflow is considered as constant. There is a continuous flow of water in and out of the conical tank. B. Process Model of conical Tank System The structure of non- interacting conical tank system is shown in Fig. 2 in which tank- inlet F in being the inflow rate(m 3 /s) and outlet is F in2 which is the fluid level(m). H reresents the total height of the tank and h reresents the level of the tank-. Similarly, the inlet flow of tank-2 reresents the F in2 and outlet flow of the tank-2 reresents the F in3. H 2 reresents the total height of the tank-2 and h 2 reresents the level of the tank-2. MV, MV3, MV2 reresents rotameter. A. Descrition of the Conical Tank System The exerimental setu of conical tank system is shown in Fig. which is designed by interacting and noninteracting tye. The system consists of conical tank, reservoir tank, centrifugal um, differential ressure transmitter (DPT), air regulator, (I/V) converter, electro neumatic converter (I/P), LabVIEW card. Fig. 2. Process Model of Non-interacting Conical Tank System 3. MATHEMATICAL MODELING Using mass balance equation, the mathematical modeling for two tank non-interacting conical tank system is derived below, Rate of accumulation of mass in the tank Mass of inlet flow rate - Mass of outlet flow rate The transfer function of the two tank non-interacting conical tank is given by, Fig.. Exerimental Setu of Conical Tank System The level in the tank which is measured by using DPT and the signals can be transmitted in the form of (4-2mA) to the (I/V) converter. The LabVIEW card was interfaced to the Personal Comuter (PC). After, designed the controllers in the PC, the control signals are transmitted in the form of current signal (4-2mA) to the (I/P) converter then it asses the air signal to the neumatic control valve. The control valve which is actuated by this signal to roduce the Y2 U kk ( τ s + )( τ s + ) 2 To obtain the transfer function of the roosed system, by considering the following secifications as follows, i) R To radius of the conical tank 7cm ii) H Maximum height of tank and tank 2 7 cm iii) F in & F in2 Maximum inflow to tank and tank 2 LPH iv) C v & C v2 Valve coefficient of MV & MV 2 4 ( inch) v) C v2 Valve coefficient of MV 2 (3/4 inch) Hence, the transfer function of two conical tank noninteracting system is given by, () Research scrit IJRE Volume: 4 Issue: 2 27 Researchscrit.com 2
3 Y U s s + (2) A. Real Time Data Logging The two conical tank non- interacting system inutoutut data are required which are collected in real time setu of conical tank system is shown in Fig. 2. From this, the level of the tank reresented as h and the level of the tank 2 reresented as h 2.The various inut-outut data are collected from two conical tank non- interacting system and among some are resented in Table I. TABLE I. INPUT-OUTPUT DATA COLLECTION Fin LPH Fin 2 62 LPH Fin2 (LPH) h (cm) h2 (cm) Fin (LPH) h (cm) h2 (cm) 4. CONVENTIONAL PID CONTROLLER Conventional PID controllers have been widely used in many rocess control industries. It has a simle structure and accetable erformance. The transfer function of two conical tank non-interacting system has derived, the controller has to be designed for maintaining the system to the desired set oint. This can be obtained by roerly selecting the tuning arameters which are K P, T I and T D for a conventional PID controller. The required gain values of PID controller are obtained by using cohen and coon tuning recommentations. Fig 3 shows the resonse of Conventional PID controller and the tuning arameters are K P , K I.44 and K D Fig. 4. Real Time Resonse using PID Controller- Set oint2 cm Fig.. Real Time Resonse of PID Controller using Data Logging- Setoint2 cm Time(min) Setoint. INTERNAL MODEL CONTROLLER Internal model control is model based controller. The Fig. 6 shows the IMC structure which makes use of a rocess model to identify the effect of immeasurable disturbance on the rocess outut and then counteracts that effect. Internal model controller is based on the control system, which holds some model of the rocess to be controlled then a faultless control can be attained in the conical tank system. Fig. 6. Block Diagram of IMC Fig.3. Resonse of Conventional PID Controller Fig. 4 shows the real time resonse using PID controller it reaches the level in a tank at 2 cm and also Fig. shows the resonse of PID controller using data logger values. * In this diagram, G is the rocess lant, G is the model of the rocess, Qc, is an controller, to control the * rocess, d is an unknown disturbance affecting the system. The maniulated inut u is introduced to both the rocess and its model. The rocess outut, Y is comared with the outut of the model, resulting in a signal d *. IMC is designed for the conical tank system by the transfer function given in equation (3) Research scrit IJRE Volume: 4 Issue: 2 27 Researchscrit.com 3
4 G s s + (3) From this, IMC is designed by the given equation (4) G Q G IMC c f where, Q c (s) inverse of the model of the rocess (s) low ass filter G f (4) The transfer function of the low ass filter is given below τ s + τ 2s + () G f The model is an exact reresentation of the rocess, G G. The closed loo outut signal for the IMC is, therefore Y G u + d. The closed loo resonse is obtained using IMC. This imroves the robustness of the system, the resonse using IMC is shown in Fig. 7. Fig. 9. Resonse of Servo Oeration for IMC A sudden disturbance is given by ouring water into tank 2 while the system becomes stable. The leakage of some amount of water from tank 2 is considered as the error introduced to the system. Fig. shows the regulatory resonse obtained at different set oints from 2 cm to 42 cm by introducing disturbance and the error in the tank2. Fig. 7. Resonse of Internal Model Controller Fig. 8 shows the real time resonse of IMC controller using LabVIEW and it reaches the setoint in 2 cm at 3 secs. Fig.. Resonse of Regulatory Oeration for IMC After the tuning rocedures are done through the controllers of conventional PID and IMC control techniques, the resonses are analysed to a ste inut. The resonses of conventional PID and IMC controllers are comared, which is shown in Fig.. Fig. 8. Real Time Resonse of IMC Controller The servo resonse was also obtained for changing set oint rofile from 2 cm to cm without an influence of any external disturbance. Fig. 9 shows the set oint tracking for different changing set oints of level in tank 2. Fig.. Comarative Resonses for PID and IMC In the time domain, secifications for a control system design involve certain requirements associated with the time resonse of the system. A comarative study of their erformance has been in the Table II. Research scrit IJRE Volume: 4 Issue: 2 27 Researchscrit.com 4
5 Table II. Comarison of Time Domain Parameters 2 2 S.NO TIME DOMAIN PARAMETERS PID IMC Setoint. Settling Time(sec) 2 2. Overshoot 4 The requirements are often exressed in terms of the standard quantities on the rise time, settling time, overshoot, eak time, and steady state error of a ste resonse. From the above observation, IMC controller shows the better settling time and there is no overshoot in the two conical tank non- interacting system. 6. METHODS OF FAULT DETECTION Associated with an increasing demand for high erformance and additionally for more safety and deendability of dynamic systems, and a characteristic attern toward system automation, fault detection and diagnosis is becoming a strategic necessity as a result of increasing economic and natural requests. Early detection and diagnosis of rocess faults while the lant is as yet working in a controllable district can hel kee away from abnormal event rogression and reduce roductivity loss. A fault can be defined as an unforeseen change of the system functionality which may be related to a failure in a hysical comonent or in a system sensor or actuator. Fig. 2 shows the general comonents of fault diagnosis framework. Time(min) Fig. 3. Real Time Resonse by Varying the Suly Pressure in Air Regulator at kg/cm 2 Fig. 4 shows the real time resonse by varying the suly ressure in air regulator using PID controller. It reaches the desired setoint in 7.8 mins. Because, the control valve of a tank gets fully oened condition. 2 2 Setoint Time(min) Fig.4. Real Time Resonse by Varying the Suly Pressure in Air Regulator at 2kg/cm 2 In non-interacting conical tank sytem, reaches the setoint in the inlet flow rate is setted at 2 LPH and outlet flow rate is 38 LPH and then observed the resonse that is shown in the Fig Setoint Fig.2. Comonents of Fault Diagnosis By varying an suly ressure in the air regulator, atmost 7% of oenings in the control valve. Fig. 3 shows the real time resonse by varying the suly ressure in air regulator using PID controller and also it takes mins time to reaches the set oint at 2 cm. Time(min) 2 3 Fig.. Real Time Resonse under Normal Condition After, the tank reaches the setoint by adding 3 LPH in the inlet flow rate and then observed the reonse using PID controller that is shown in Fig.6. Research scrit IJRE Volume: 4 Issue: 2 27 Researchscrit.com
6 2 2 Set Point [] T.Pushaveni, S.Srinivasulu Raju, N.Archana, M.Chandana (23), Modeling and Controlling of Conical tank system using adative controllers and erformance comarison with conventional PID, International Journal of Scientific & Engineering Research, Vol. 4(), [] L. Ren, Z. Y. Xu, and X. Q. Yan(2), Single-Sensor Inciient Fault Detection, IEEE sensors journal, vol. (9), Time(min) 2 3 Fig. 6. Real Time Resonse by Indroducing Disturbance in Rotameter 7. CONCLUSION In this roosed work, two conical tank of noninteracting tye is taken as a non-linear system. For which, a conventional PID controller is designed to achieve the level control in conical tank system. But due to the unsatisfactory erformance of the conventional PID controller, a model based controller of IMC is designed and laced in the forward ath of the system. From the comarative results, it is found that the settling time and the overshoot of conventional PID controller such as secs and 4 % are higher than the IMC controller. Various faults are introduced into the conical tank system and observed the resonses using PID controller in real time. Simulated studies have also roved that IMC control technique has good servo tracking and disturbance rejection caability. REFERENCES [] P.Aravind, M.Valluvan, S.Ranganathan (23), Modeling and Simulation of Non Linear Tank, International Journal of Advanced Research in Electrical, Electronics and Instrumentation Engineering, Vol. 2(2), [2] D.Hariharan and S. Vijayachitra(23), Modeling and Real Time Control of two conical tank systems of Non-Interacting and Interacting tye, International Journal of Advanced Research in Electrical, Electronics and Instrumentation Engineering, Vol. 2 (), [3] George Stehanooulos (984), Chemical Process Control, Prentice-Hall Publication, New Jersey, Eastern Economy Edition. [4] Arutha Vijayaselvi J, Rathakirushnan TK, Sundaram S. (27) Performance assessment of PID and IMC tuning methods for a mixing rocess with time delay, ISA Transaction, Vol. 47(3), [] Jeffrey E. Arbogast, Douglas J. Cooer (27), Extension of IMC tuning correlation for non-self egulating (integrating) rocess, ISA Transactions, Vol.46(3), [6] D. Angeline Vijula, K.Vivetha, K.Gandhimathi and T. Praveena (24), Model based Controller Design for Conical Tank System, International Journal of Comuter Alications, Vol. 8(2),. 8-. [7] E. Kesavan, Agalya, P. Palandian and S. Manoharan, (26), Performance Analysis and Comarison of Different Tuning Strategies of PI Controller in Conical Tank, Indian Journal of Science and Technology, Vol. 9(),. -6. [8] S. Vadivazhagi and N. Jaya,(2), Control of Two Tank Conical Interacting Level System using Relay Auto Tuning,Indian Journal of Science and Technology, Vol. 8(2),. -6. [9] P. Suganthini, P. Aravind, and S. M. Girirajkumar(24), Design of Model Based Controller for a Non-Linear Process, International Journal of Comuter Alications, Vol. 8(2), Research scrit IJRE Volume: 4 Issue: 2 27 Researchscrit.com 6
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