International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181
Vol. 4 Issue 06, June-2015

Modelling and Control of Coupled Tank Liquid

Level System using Backstepping Method

Jiffy Anna John Dr. N. E. Jaffar Prof. Riya Mary Francis

Industrial Instrumentation and Control Department of Chemical engineering, Industrial Instrumentation and Control
Department of Electrical and Electronics TKM college of engineering, Department of Electrical and Electronics
engineering, Kollam, India engineering,
TKM college of engineering, TKM college of engineering,
Kollam, India Kollam, India

Abstract- The level and flow control in tanks are the heart of all actual design are usually defined by overshoots, rising time,
chemical engineering system. The control of liquid level in tanks settling time, steady state error etc.
and flow between tanks is a basic problem in the process
industries. Many times the liquids will be processed by chemical Various attempts in controlling liquid level of
or mixing treatment in the tanks, but always the level of fluid in coupled tank system were proposed. The design of PI
the tanks must be controlled and the flow between tanks must
controller using Characteristics Ratio Assignment method for
be regulated in presence of non-linearity, disturbance and time
varying system parameters. This work introduce the approach linear modelled coupled tank SISO process was proposed by
of modelling and compute a level backstepping control strategy M. Senthilkumar et al [1].The mathematical modelling and
with pure feedback form for non-linear modelled coupled tanks designing of Sliding Mode Control for a liquid level control
system.The goal of the control algorithm is to track the desired system when tanks are coupled by using baffles was
level of liquid in second tank by using flow rate of liquid into proposed by Hur Abbas et al [2] and a fuzzy logic controller
first tank as the manipulated variable. The designed non-linear for liquid level control introduced by Abdelelah et al
controller is capable of tracking the desired water level for all [3].Muhammad Nasiruddin Mahyuddin et al proposed a
set points with high degree of accuracy, maximally fast and Direct Model Reference Adaptive Control for Coupled Tank
without significant overshoot.
System [4] and Comparison between PI and MRAC on
coupled tank system done by M. Saad et al [5].
Keywords---Backstepping, Coupled tank, Non-linear model,
Process control This paper presents the mathematical modelling of
non-linear coupled tank system andintroduce a level
backstepping control strategy with pure feedback form for
coupled tank liquid level system and the results are compared
I. INTRODUCTION with conventional PID controller.
The liquid level control in Coupled Tank System is a The structure of this paper is as follows. Section 2
classical benchmark control problem. Level control is one of deals with the system description.The non-linear modelling
the control system variable which are more important in of the coupled tank system is explained in section 3. Section
process industries. The process industries requires liquid to 4 highlights the Backstepping control designs. Simulation
be pumped as well as stored in tanks and then repumped to results with PID and Backstepping method is given in section
another tank. Many times the liquids will be processed by 5. Conclusion is discussedin section 6.
chemical or mixing treatment in the tanks, but always the
level of fluid in the tanks must be controlled and the flow
between tanks must be regulated. The quality of the product
of the mixture depends on the level of the reactants in the II. SYSTEM DESCRIPTION
mixing tank. Tank level control systems are used frequently
in different processes. All of the pharmaceutical industries, The coupled tank system includes two tanks
petrochemical plants, food/beverage industries and nuclear mounted above a reservoir, which function as a storage for
power plants depend upon tank level control systems. It is liquid. It has an independent pump to pump liquid from
essential for control system engineers to understand how reservoir to tanks. The two tanks are connected in an
tank control systems work and how the level control problem interactive manner. When two tanks are coupled, the liquid
is solved. The liquid level system has time varying system in two tanks interact and exhibit a non-linear behavior. The
parameters and non-linear characteristics in the complex liquid meets resistance when flowing through a conduit such
industrial process. Most of the control performances in the

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 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 4 Issue 06, June-2015

as a pipeline. If a liquid flow through the pipe is under 𝑎12 be the cross sectional area of interaction pipe
turbulent flow condition, the outlet flow rate being function between tank 1 and tank 2 (𝑐𝑚2 )
of the square root of the tank height. The discharge 𝛽12 be the valve ratio of interaction pipe between tank 1
coefficient of liquid flowing out of tank can vary by using and tank 2
valves. 𝛽2 be the valve ratio of outlet pipe of tank 2
g be the acceleration due to gravity

Figure 2: The Coupled tank SISO Process

It is assumed that the liquid used is non-viscous,

incompressible. The nonlinear equation of the coupled tank
system can be obtained by mass balance equation and it is
given by,
Figure 1: Block Diagram of Coupled Tank System
Rate of change of mass in the tank = Mass flow in - Mass
Both tanks are identical in cross section and is flow out
represented as A(𝑐𝑚2 ). The inlet flow 𝑄𝑖𝑛 is given to the
tank 1 and the outlet flow 𝑄𝑜𝑢𝑡 is taken from tank 2. A 𝐴𝑑𝑕
ie, = 𝑄𝑖𝑛 − 𝑄𝑜𝑢𝑡
𝑑𝑡
manual valve is available between tank1 and tank2 which
can be used to change the interaction between the tanks. The
The dynamic equations for tank 1:
change in water level 𝑕1 (cm) in tank1 affects the water level
𝑕2 (cm) in tank 2. The water level variation in tank1 and 𝑑𝑕 1 (𝑡)
𝐴1 = 𝑄𝑖𝑛 - 𝛽12 𝑎12 2𝑔[𝑕1 𝑡 − 𝑕2 (t)]
𝑑𝑡
tank2 depends on the inlet and outlet flows. The liquid level
in second tank ie, 𝑕2 (cm)is maintained at some desired value U(t) = 𝑄𝑖𝑛
3
by using flow rate of the liquid into first tank 𝑄𝑖𝑛 (𝑐𝑚 𝑠𝑒𝑐 ) 𝑑𝑕 1 (𝑡) 𝑢(𝑡) 𝛽 12 𝑎 12
= - 2𝑔[𝑕1 𝑡 − 𝑕2 (t)]
as the manipulated variable. 𝑑𝑡 𝐴1 𝐴1

(1)
The control of liquid level in tanks presents a
challenging problem due to its non-linear behavior which is The dynamic equations for tank 2:
due to the interacting characteristics. In interacting process,
𝑑𝑕2 𝑡
dynamics of tank1 affects the dynamics of tank2 and vice 𝐴2 = 𝛽12 𝑎12 2𝑔[𝑕1 𝑡 − 𝑕2 t
versa because flow rate depends on the difference between 𝑑𝑡
the liquid levels. -𝛽2 𝑎2 2𝑔𝑕2 (t)
III. MATHEMATICAL MODELLING OF
𝑑𝑕 2 (𝑡) 𝛽 12 𝑎 12
COUPLED TANK SYSTEM = 2𝑔[𝑕1 𝑡 − 𝑕2 (t)]
𝑑𝑡 𝐴2

Let, 𝛽2 𝑎 2
- 2𝑔𝑕2 (2)
𝑕1 and 𝑕2 be the height of liquid in tank 1 and tank 2 𝐴2
respectively (cm) At equilibrium, for constant water level setpoint, the
𝐴1 and 𝐴2 be the cross-sectional area of tank 1 and tank derivatives must be zero ie, 𝑕1 = 𝑕2 = 0. In addition, for the
2 respectively (𝑐𝑚2 ) case when 𝑕1 = 𝑕2 , the system model is decoupled. So
3
𝑄𝑖𝑛 be flow rate of liquid into tank 1(𝑐𝑚 𝑠𝑒𝑐 ) 𝑕1 > 𝑕2 .
3
𝑄𝑜𝑢𝑡 be flow rate of liquid out of tank 2(𝑐𝑚 𝑠𝑒𝑐 )

𝑎2 be the cross sectional area of outlet pipe in tank 2

(𝑐𝑚2 )

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 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 4 Issue 06, June-2015

Parameters Value bc z1 z2 c2 ab
𝑥2 = − + - b2 + u(11)
2 z2 z1 2 2 z2
𝐴1, 𝐴2 (𝑐𝑚2 ) 154
Where the values of 𝑧1 and 𝑧2 in above equation are function
𝑎2, 𝑎12 (𝑐𝑚2 ) 0.5
of 𝑥1 and 𝑥2 as given in eqn (7) and (8).
β12 1.5315195
Hence dynamic model of the system can be written as:
β2 0.6820043
𝑥1 = 𝑥2 (12)
981
( 𝑐𝑚2 𝑥2 = 𝑓 + ø𝑢 (13)
g sec⁡
)
y = 𝑥1 (14)
bc z1 z2 c2
Where, f = − + - b2
2 z2 z1 2

Table 1: Parameters of Coupled Tank System 𝑎𝑏

ø=
Let, 2 𝑧2

𝑧1 = 𝑕2 > 0 and 𝑧2 = 𝑕1 - 𝑕2 > 0 The dynamic model in eqn (12), (13), (14) will be used to
design backstepping control techniques for the coupled tank
𝑧1
z= , u = q (t) system.
𝑧2
and
IV. CONTROLLER DESIGN
𝛽 12 𝑎 12 𝛽2 𝑎 2 1
b= 2𝑔, c = 2𝑔 , a =
𝐴2 𝐴2 𝐴1
In this section, we will define a controller design using
The output of the coupled tank system is taken to be the level backstepping method which is in pure feedback form for the
of the second tank. Therefore, the dynamic model of coupled coupled tank system.Backstepping control design is based on
tank in eqs. (1) and (2) can be written as: Lyapunov theory. The objective is to construct a control law
that brings the system to some desired state. This is to say,
𝑧1 = b 𝑧2 - c 𝑧1 (3) we wish to make this state a stable equilibrium of the closed
𝑧2 = au -2b 𝑧2 + c 𝑧1 (4) loopsystem.
Consider the system affine in the control input:
y = 𝑧1 𝑥 = 𝑓 𝑥 + 𝑔(𝑥)𝑢
The objective of the control scheme is to regulate the output Where x Ԑ 𝑅𝑛 and u Ԑ R represent respectively the state
y (t) = 𝑧1 𝑡 = 𝑕2 (𝑡) to a desired value 𝑕2 (𝑑𝑒𝑠) . The variables and the control input of the system. Firstly, „u‟ is
dynamic model of the coupled tank system is highly non- regarded as the control input for the x-subsystem. „u‟ can be
linear. Therefore, we will define a transformation so that the chosen in any way to make the x-subsystem globally
dynamic model of the coupled tank system can be asymptotically stable. The choice is denoted 𝑢 𝑑𝑒𝑠 (𝑥) and is
transformed into a form facilitates the control design. called a virtual control law. First we define the control error
𝑒1 such that :
𝑥1
Let,x= and define the transformation 𝑒1= 𝑥1 − 𝑥1 (𝑑𝑒𝑠)
𝑥2
x = T(z) such that 𝑥1 (𝑑𝑒𝑠) is the desired set point and we select the
following Lyapunov candidate function :
𝑥1 = 𝑧1 (5)
1
𝑥2 =b 𝑧2 - c 𝑧1 (6) 𝑉1 𝑒1 = 𝑒1 2 , which is a positive definite function
2
The inverse transformation z = 𝑇 −1 (𝑥) is such that and its derivative must be a negative definite function.
ie, 𝑉1 (𝑒) ≤ −𝑊 𝑥 ≤ 0 , [where 𝑊 𝑥 must be positive
𝑧1 = 𝑥1 (7) definite] then we can say that the system is globally bounded.
𝑐 𝑥 1 +𝑥 2
2 So the control input „u‟ ensures the objective of stability and
𝑧2 = (8) asymptotic performance.The control objective is to regulate
𝑏
the output y (t) = 𝑥1 (𝑡) = 𝑕2 (𝑡) to a desired value 𝑕2 (𝑑𝑒𝑠)
It can be checked that we can write the dynamic model of [ 𝑕2 𝑑𝑒𝑠 = 𝑥1 (𝑑𝑒𝑠)] . The time derivative of above
coupled tank system in eqn (5) and (6) can be written as: Lyapunov candidate function is given by :
𝑥1 = 𝑥2 (9)
bz 2 cz 1
𝑉1 (𝑒1 ) =𝑒1 𝑒1
𝑥2 = − (10) = 𝑒1 𝑥1 = 𝑒1 𝑥2
2 z2 2 z1
Where 𝑥2 chosen such that 𝑉1 (𝑒) must be a negative definite.
Substitute the values of 𝑧1 and 𝑧2 in eqn (10), we get
𝑥2 𝑛𝑒𝑤 = −𝑐1 𝑒1
Due to 𝑥2 𝑛𝑒𝑤 a second error generate which is given by,

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 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 4 Issue 06, June-2015

𝑒2 = 𝑥2 (𝑛𝑒𝑤) − 𝑥2 the set point consecutively during the operation, which is

𝑒2 = 𝑥2 (𝑛𝑒𝑤) − 𝑥2 shown in figure 4. The set point change is done at 60 second
by a magnitude of 30 cm height in water level. It can be seen
Let us now consider the second Lyapunov function to ensure that the level backstepping control strategy tracks the set
that the system become globally asymptotically stable, point changes in water level accurately. The results obtained
from backstepping method is compared with conventional
1 PID controller. Zeigler– Nichols open loop method of tuning
𝑉2 𝑒2 = 𝑉1 𝑒1 + 𝑒2 2
2 is used to obtain the parameters of PID controller. The PID
controller exhibit inconsistent transient response
1
= [ 𝑒1 2 + 𝑒2 2 ] performance with a peak overshoot and approximately 35 sec
2
take to settle. The proposed backstepping control strategy
Which should a positive definite function and its derivative with pure feedback form provide better transient response
should be negative definite function. with no overshoot and the settling time reduces to 30 sec as
compared to PID controller.
𝑉2 (𝑒2 ) =𝑒2 𝑒2 = 𝑒2 [𝑥2 𝑛𝑒𝑤 − 𝑥2 ]
70
=𝑒2 [𝑥2 𝑛𝑒𝑤 −{ 𝑓 + ø𝑢}]
60
To make 𝑉2 (𝑒2 ) a negative definite function, the control law

Water level in tank 2 ( cm)

should be such that: 50

x new − f + C 2 e 2
u (t) = 2 where 𝐶2 > 0 40
ø
Where,
30
𝑏𝑐 𝑧1 𝑧2 𝑐2 2
f= − + -𝑏
2 𝑧2 𝑧1 2 20
𝑎𝑏
ø= 10
2 𝑧2
Where the values of 𝑧1 and 𝑧2 are function of 𝑥1 and 𝑥2 as 0
0 10 20 30 40 50 60 70 80 90 100
given in eqn (7) and (8).The values of f and øin terms of Time (seconds)
𝑥1 and 𝑥2 is given by,
Figure 3: Response of the system for different operating level

𝑏𝑐 𝑏 𝑥1 𝑐 𝑥 1 +𝑥 2 𝑐2 70
f= − + - 𝑏2
2 𝑐 𝑥 1 +𝑥 2 𝑏 𝑥1 2

𝑎𝑏 2 60
ø=
2[𝑐 𝑥1 + 𝑥2 ] 50
plant response with backstepping
commanded set point
So the control law becomes,
Water level in tank 2 ( cm)

40
u (t) =
bc b x1 c x 1 +x 2 c2 30
x 2 new −{ − + − b2} + C2e2
2 c x 1 +x 2 b x1 2
ab2
Where𝐶2 > 0
20
2[c x 1 +x 2 ]

10
V. RESULTS AND DISCUSSION
0
The response of the system for different 0 20 40 60 80 100 120
Time (seconds)
operating level and set point tracking performance of
the system with designed level backstepping control
Figure 4: Set point tracking performance of the system
strategy in pure feedback form are observed. The
obtained result with backstepping method is compared
with conventional PID controller.

In figure 3, the response of the system for different

operating level is shown. The system achieves consistent
performance and maintains the desired transient response
characteristic throughout all operating points [at 20 cm, 40
cm, 60 cm]. The set point tracking test consist of changing

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 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 4 Issue 06, June-2015

Engineering, Vol. 3, ISSN 2250-2459, ISO9001:2008, August

70 2013
[7] Aditya Karthik and J Supriyanka“Design of self tuning PID
controller using Fuzzy Logic for Level Process”. International
60
journal of Engineering science and research technology,
with pid ISSN:2277-9655
Water level in tank 2 (cm)

50 with backstepping [8] Pankaj A Valand, Amit Patel and Hetal Solanki “An analysis
commanded setpoint of self tuning Fuzzy PID-IMC for coupled water two tank
system”. International journal of Engineering development
40
and research, ISSN:2321-9939,January 2014

30

20

10

0
0 20 40 60 80 100 120
Time (seconds)
Figure 5: Comparison of Backstepping method with conventional PID

VII CONCLUSIONS

It can be shown that the level backstepping control

strategy can cope with the coupled tank non-linear
characteristics at all operating points (water level or height in
tank 2). PID controller exhibit inconsistent transient
performance at all set point changeand this shows that fixed
controllers are not able to sustain the predefined transient
response at all operating points. The designed non-linear
controller is able to sustain the desired transient response
throughout the set point changes without significant
overshoot, maximally fast and with high degree of accuracy

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