Control of Multi Tank System and Their

Performance analysis

A THESIS SUBMITTED IN PARTIAL FULFILMENT

OF THE REQUIREMENTS FOR THE DEGREE OF

Master of Technology

In

Electronics & Instrumentation

by

ASHISH KUMAR SINGH

Roll No: 212EC3161

Department of Electronics & Communication Engineering

National Institute of Technology
Rourkela
MAY 2014
Control of Multi Tank System and Their
Performance analysis

A THESIS SUBMITTED IN PARTIAL FULFILMENT

OF THE REQUIREMENTS FOR THE DEGREE OF

Master of Technology
In
Electronics & Instrumentation

by

ASHISH KUMAR SINGH

Roll No: 212EC3161

Under the guidance of

Prof. Tarun Kumar Dan

Department of Electronics & Communication Engineering

National Institute of Technology
Rourkela
MAY 2014
 National Institute Of Technology
Rourkela

CERTIFICATE

This is to certify that the thesis entitled, “Control of Multi Tank System and Their
Performance analysis” submitted by ASHISH KUMAR SINGH in partial fulfilment of the
requirements for the award of Master of Technology degree in Electronics and
Communication Engineering with specialization in “Electronics & Instrumentation”
during session 2012-2014 at National Institute of Technology, Rourkela and is an authentic
work by him under my supervision and guidance.

To the best of my knowledge, the matter embodied in the thesis has not been submitted to
any other university/institute for the award of any Degree or Diploma.

Date: Prof. Tarun Kumar Dan

Dept. of ECE
National Institute of Technology
Rourkela-769008
Email: [email protected]
Dedicated to my Respected Parents
and Faculties and Beloved Friends
 Acknowledgement

I would like to express my gratitude to my thesis guide Prof. Tarun Kumar Dan for his
guidance, advice and constant support throughout my thesis work. I would like to thank him
for being my advisor here at National Institute of Technology, Rourkela.

Next, I want to express my respects to Prof. U. C. Pati, Prof. K. K. Mahapatra, Prof. S.K.
Patra, Prof. S. Meher, Prof D. P. Acharya, Prof. Poonam Singh, Prof. Samit Ari,Prof A. K.
Swain and Prof A. K. Sahoo for teaching me and also helping me how to learn. They have
been great sources of inspiration to me and I thank them from the bottom of my heart.

I would like to thank all faculty members and staff of the Department of Electronics and
Communication Engineering, N.I.T. Rourkela for their generous help in various ways for the
completion of this thesis.

I would like to thank all my friends and especially my classmates for all the thoughtful and
mind stimulating discussions we had, which prompted us to think beyond the obvious. I’ve
enjoyed their companionship so much during my stay at NIT, Rourkela.

I am especially indebted to my parents for their love, sacrifice, and support. They are my first
teachers after I came to this world and have set great examples for me about how to live,
study, and work.

ASHISH KUMAR SINGH

Roll No: 212EC3161

Dept. of ECE

NIT, Rourkela
 Abstract

A multi tank level control system has an example of interacting and non-interacting

system. In this system, we have considered three tanks each having equal cross section area

and each tank can be assumed as a first order system which are connected in interacting and

various non-interacting mode. The control system is intended to maintain the level of the

third tank at some predefined value irrespective of changes of inflow of first tank.

Conventional PID controller is a powerful controller used in process industries to regulate

and control process variables. In this work, we also consider the effect of the disturbance on

the response of the system. According to these disturbances, we need to implement feed

forward controller with better tuning algorithm. Thus, we implement transfer function of

above system and behavior is observed with step input.

Control of the level in the tank and flow in between them is basic problem in process control

industries almost all the chemical industries are connected in cascade for storage of liquid and

for other chemical processes. all the tank have their own manipulated variable to control

liquid level inside the tank so in this section we are analyze the response of various type of

tank, like conical, rectangular etc. the response of these tank which are connected in

interacting and non interacting mode are observed with applying step input and response

these system is improved by designing various type of controller like feedback controller and

feed-forward controller. Effect of interaction is also observed and the effect of this interaction

is minimized by designing a de-coupler circuit.

i
 TABLE OF CONTENTS

Page No.

ACKNOWLEDGEMENT ...…………………………………………....………….…….......i
ABSTRACT ……….……………………………………………………....…………….…...ii

TABLE OF CONTENT ………………………………………………………………...…..iii

LIST OF FIGURES ………………………………………………………………..……......v

Chapter 1
INTRODUCTION....................................................................................................................1
1.1 Background..........................................................................................................................2
1.2 Literature Review ................................................................................................................3

Chapter 2
CONTROLLER DESIGN AND TUNING............................................................................4
2.1 Feedback control system.....................................................................................................5
2.2 Feed forward control system ...............................................................................................5
2.3 Tuning of PID controller......................................................................................................6
2.3.1 Ziegler – Nichols Tuning Method.....................................................................................6
2.4 Tuning of Feed Forward Controller....................................................................................7
2.5 Block diagram of feed forward controller...........................................................................8
2.5.1 Calculation of coefficient of feed forward controller.......................................................9
Chapter 3
MULTIVARIABLE CONTROL
3.1 Multivariable Control System............................................................................................11
3.2 Relative gain array..............................................................................................................12
3.3 Selection of control loop using RGA matrix....................................................................15
3.4 De-coupler design for two tank interacting system..........................................................16

ii
Chapter 4

PERFORMANCE ANALYSIS AND COMPARISION

4.1 Performance Analysis of three tank level control using feedback and feed forward
feedback controller.............................................................................................................28
4.2 Non-Interacting Three tank system ...................................................................................28
4.2.1 Mathematical modelling of Three tank Non-Interacting system............................. 29
4.3 Interacting Three tank system case (1)..............................................................................31
4.4 Interacting three tank system case (2)...............................................................................32
4.5 Disturbance analysis of three tank non-interacting system..............................................33
4.6 Disturbance analysis of three tank interacting system (case1).........................................33
4.7 Disturbance analysis of three tank interacting system (case2)..........................................33
Chapter 5

IMPLEMENTATION AND RESULTS..............................................................................34

5.1 MATLAB Implementation and Results............................................................................35
5.2 Feedback and Feed Forward- Feedback Controller for three tank system........................37
5.2.1 Three tank Non-Interacting System.........................................................................37
5.2.2 Three tank interacting system (case1)......................................................................40
5.2.3 Three tank interacting system (case2)......................................................................40
Chapter 6
6.1 CONCLUSIONS..............................................................................................................49
6.2 FUTURE SCOPE............................................................................................................49

BIBLIOGRAPHY………………………………………………….……………….............50
DISSEMINATION OF RESEARCH WORK………………………….………..…..........51

iii
ii
List of Figures Page No.

Fig.1.1 Three tank Non-Interacting system................................................................................2

Fig.2.1 Block diagram of feedback control system....................................................................5

Fig.2.2 Block diagram of Feed forward controller.....................................................................6

Fig.2.3 Feed forward- feedback control system.........................................................................8

Fig.3.1 Interacting two tank system.........................................................................................16

Fig.3.2 Interacting two tank system.........................................................................................18

Fig.3.3 decoupled two tank interacting system........................................................................19

Fig.3.4 Block diagram of two input two output system...........................................................21
Fig.3.5 General block diagram of TITO system.....................................................................23

Fig.3.6 two tank conical interacting system.............................................................................24

Fig.4.1 Three tank Non-Interacting system..............................................................................28

Fig.4.2 interacting three tank systems.....................................................................................31

Fig.5.1 Decentralized PI Controller for TITO Process............................................................35

Fig. 5.2 Output response of the first tank using De-coupler with Step Input..........................36

Fig. 5.3 Output response of the second tank using De-coupler with Step Input.....................36

Fig.5.4 Feedback controller for three tank non interacting system.........................................37

Fig.5.5 Output response of feedback controller for three tank non interacting system...........38

Fig.5.6 Fee back controller for three tank non interacting system with disturbance...............38
Fig.5.7 Output response of feedback controller for three tank non interacting system with
disturbance...............................................................................................................................39
Fig.5.8 Feedback and feedback-feed forward controller for three tank non interacting system
with disturbance.......................................................................................................................39

Fig.5.9 Output response of feedback and feed forward-feedback controller for three tank non
interacting system with disturbance.........................................................................................40

Fig.5.10 Feedback controller for three tank Interacting system (case1) .................................41

Fig.5.11 Output response of feedback controller for three tank Interacting system (case1)....41
Fig.5.12 Feedback controller for three tank Interacting system (case1) with disturbance.......42

iv
Fig.5.13 Output response of feedback controller for three tank Interacting system (case1) with
disturbance.............................................................................................................................. .42

Fig.5.14 Feedback and feedback-feed forward controller for three tank Interacting system
(case1) with disturbance...........................................................................................................43
Fig.5.15 Output response of feedback and feed forward-feedback controller for three tank
Interacting system (case1) with disturbance............................................................................43
Fig.5.16 Feedback controller for three tank Interacting system (case1)..................................44
Fig.5.17 Output response of feedback controller for three tank Interacting system (case2)....45
Fig.5.18 Feedback controller for three tank Interacting system (case2) with disturbance.......45
Fig.5.19 Output response of feedback controller for three tank Interacting system (case2) with
disturbance..............................................................................................................................46
Fig.5.20 Feedback and feedback-feed forward controller for three tank Interacting system
(case2) with disturbance...........................................................................................................46
Fig.5.21 Output response of feedback and feed forward-feedback controller for three tank
Interacting system (case2) with disturbance............................................................................47

List of Tables
Table 2.1 tuning rule for feed forward controller....................................................................9
Table 3.1 various operating parameters of two tank conical interacting system....................24

v
 INTRODUCTION

1|Page
1.1 Background
Multi tank systems are widely used in chemical and petroleum industries so as to control the

liquid level in the tank. It is the challenging task as it may affect both pressure and flow of the

process so it is important to maintain level at set point. In this project the transfer function of

the three tank system has been formulated. Three tank system is shown below

Fig. 1.1 Three tank Non-Interacting system

Various type of feedback controller can be used to control the liquid level in the tank but

biggest problem is when disturbance come in to the picture. To nullify the effect of the

disturbance we have to implement feed forward controller. To maintain liquid level at desired

set point combination of feedback and feed forward-feedback controller is used.

2|Page
1.2 Literature Review

Control of liquid level in any process control is challenging task. There are many different
connection of tanks possible in the plant like Interacting and Non-Interacting. Many type of
disturbances are possible which can affect the performance of the system. designing of
controller for these type of process is challenging task in process control industries.

In paper [1]V.R.RAVI, proposed idea of Decentralized PID controller for interacting non
linear system in which they are designed decoupling circuit for Two input two output
process.

In paper [2] V.R.RAVI, proposed idea of adaptive control technique for non linear system in
which they are represented as piecewise linear regions and for each linearized region, they
tuned the PI controller.

In paper [3] V.R.RAVI, proposed idea of gain scheduling adaptive model predictive
controller for two tank interacting system in which they are designed multiple linear MPC
controller.

In paper [4] Parag, proposed the idea of decoupling design for two tank interacting system In
which they are considered as two tank system as two input and two out process and then
relative gain array is calculated and then corresponding pairing is done.

3|Page
 CONTROLLER DESIGN AND
TUNING

4|Page
2.1 Feedback control system

There are mainly two types of control loop existed in the industry namely negative feedback
control and positive feedback control. In the positive feedback control the input and output
values are added. In a negative feedback control the input and output values are subtracted.
Generally negative feedback control systems are more stable than positive feedback control
systems. By using Negative feedback the effect of random variations in values of component
and inputs is minimized. There are many controllers which is used in industry i.e P, P+I, and
P+I+D.[8]

Block diagram of feedback control system is shown in figure 2.1

Fig.2.1 Block diagram of feedback control system

2.2 Feed forward control system

Feed forward controllers are used whenever there are major disturbances in the plant if we
used feed-forward and feedback controller in combination the effect of disturbances at output
of plant is minimized significantly. In ideal situation feed-forward controllers are capable to
reduce the effect of measured disturbance to zero at output of process.
Feed-forward controllers are always used along with feedback controller feedback controller
are used to tracking the change in set point and also to minimized the effect of disturbances

5|Page
which is unmeasured in the nature and such type of disturbances are always present in the
real plant.[5-6]
Block diagram of feed forward control system is shown in fig. 2.2

Fig.2.2 Block diagram of Feed forward controller

2.3 Tuning of PID controller

PID controllers are most widely used in process control industries so we have to tune PID
controller in order to obtain desired response these methods are discussed below

2.3.1 Ziegler – Nichols Tuning Method

How to calculate the coefficient of P,I and D if the dynamic model of system is known and
the dynamic model of system in not known[8-9].

6|Page
2.3.1.1 If the dynamic model of system is not Known

If the dynamic model of system is not known then we have to test open loop response of the
system experimentally by making feedback loop open and apply a step input to the process if
the response is the s- shaped then Ziegler Nichols tuning method is applicable to the such
type of the process otherwise it is not applicable the s type curve have two constant namely
dead time and time constant of system these values are calculated by simply drawing a
tangent.
This type response mathematically modelled as first order system having time constant and
delay L

And then coefficient of P,I and D are calculated as follows

(2.1)

(2.2)

(2.3)

2.3.1.2 If dynamic model of process is known

If dynamic model of process is known then to calculate the coefficient of P,I and D using the
Ziegler Nichols tuning method by connecting only proportional gain in closed loop and vary
the gain of controller till the oscillation is not observed in the output .
Gain at which oscillation is observed at output is called as critical gain of the system and
using this critical gain we can calculate critical time period or ultimate time period and then
PID controller can be tune by following formulae

(2.4)
(2.5)
(2.6)
2.4 Tuning of Feed Forward Controller
In practical cases of feed forward controller we do not have neither block diagram of process
nor transfer function of plant for these situation we can still tune the feed forward controller
by making a step change as disturbance and then applying tuning rule for such type of system
To describe these rules we are assuming that its transfer function is in lead lag form

7|Page
 
 S  1 
   1
 (2.7)
G K
f f

 2
S 1 


Where,

K f
- DC gain of the controller

 ,
1 2
- are the time constant of the controller

2.5 Block diagram of feed forward controller

Block diagram of feed forward controller is shown in fig.2.3 in which disturbance is added
through the path (G1)and effect of this disturbance is minimized by using feed forward
controller (Gf).[7]

Fig.2.3 Feed forward- feed back control system

Where,

G - transfer function between output and disturbance

1

G - transfer function of feed forward controller

f

G - transfer function of PI controller

c

G - transfer function of plant

p

2.5.1 Calculation of coefficient of feed forward controller

8|Page
First make fee back path open and then step change in the disturbance input and observe the
transient behaviour of output which may be lead dominant or lag dominant by identifying

whether it is lead dominant or lag dominant we can calculate the value of  ,

1 2
by using

formulae given in the table

Table 2.1 Tuning rule for Feed-forward controller.

Sr.No Mode
 1  2

1. Lead 1.5 peak time 0.7 peak time

2. Lag 0.7 peak time 1.5 peak time

9|Page
 Multi Variable Control

10 | P a g e
3.1 Multivariable Control System

If the process have only one output may be controlled by single manipulated variable these
type of process classified as single input single output system while in process control
industries each process requires more than one control variables and hence minimum two
loops are connected with it. Any system having more than one control loops are known as
multi input multi output or multivariable system.
There are mainly two types of loop interaction namely p-canonical and v- canonical it is clear
from diagram p-interaction represent feed forward control while v- interaction represent
feedback control
P- canonical representations
On the loop basis input and output can be related as following equation

y 1
 u * g
1 11
u2* g
12
 (3.1)

y 2
 u * g
1 21
u2* g
22
 (3.2)

Where,

y ,y
1 2
- is the output of the system

u ,u
1 2
- is the manipulated variable

The above relationship can be represented in more generalized in matrix form

Y= g*u (3.3)
V- canonical representations-
Mathematical model for v- canonical representation

y 1
  y *g
2 12
 u 1*g
11
(3.4)

y 2
  y *g
1 21
 u 2 *g
22
(3.5)

In matrix form it can be written by


y  I  G m G i  * G mU (3.6)

11 | P a g e
3.2 Relative gain array

Relative gain array is not only important tool for pairing manipulated variable and control
variable but also used to predict the response of the system. for (2  2) relative gain matrix are
constructed as follows:

Let us consider the Kij is the gain of transfer function Gij assume manipulated variable u 2
is

constant and if we make step change in manipulated variable u 1

of magnitude  u 1
it will

produce a change of  y in the y

1 1

So the gain between y 1

and u 1
when manipulated variable u 2
is kept constant

y
K 11 at constant u 2
=
u 1
1
at constant u 2

In place of manipulated variable u 2

if we consider the y 2
is constant then step change in

manipulated variable u 1
of magnitude  u 1
it will produce another change in y.1

Gain in this condition is written by

y
K 11 at constant y 2
=
u 1
1
at constant y 2

Relative gain

 y 
 2 
 u 2 
 22

 y 
u1 (3.7)
 2 
 u 2  y
1

 11
is dimension less, and it is ratio of output y to input u
1 1
and it gives following

information.

3.2.1. If  11
= 0 then chance in the manipulated variable u 2
does not influence output y 1

and hence it should not be used for control of y.1

12 | P a g e
3.2.1. If  11
=1 it means the  K u11
2
and K y 11
2
have the same value therefore gain

between output y 2
and input u 1
does not affected by the loop between output y 2
and

input u 2

For a (2  2) there are three more relative gain i.e

 y 
 1 
 u 2 u
 12

 y 
1
(3.8)
 1 
 u 2  y2

 K u
 21 
21
2
(3.9)
K y
21
1

 y 
 2 
 u 1u
 21

 y 
2
(3.10)
 2 
 u 1 y
1

 K u
 22 
22
1
(3.11)
K y 22
1

 y 
 2 
 u 2 u
 22

 y 
1
(3.12)
 2 
 u 2  y
1

From above expressions it seems Determination of relative gain array is very difficult task
but in general it not much difficult task because element of relative gain array has following
property.

13 | P a g e
 (1) The sum of element in each column is unity
(2) The sum of element in each row is unity
Thus for two input two output system if we calculate one element of relative gain
array then all other three can calculated easily by relation.

  1 
12 11
(3.13)

  21 12
(3.14)

And  22
  11 (3.15)

The above procedure to determine the element of RGA is experimentally. however if

we have steady state model of system then it can calculated analytically.
For

y  K u K u 
2 21 1 22 2
(3.16)

And y  K u K u 
2 21 1 22 2
(3.17)

Where,

K ,K ,K
11 12 22
and K 21
are steady state gain of system

Eliminating u 2
from above equation we have

K  y 2 K u 
y  K u  
21 21 1
11 1
(3.18)
1
K 22

Differentiating above equation with respect to u 1

we get

 y 
K y 11
 1
 u 1 
(3.19)
 y
2


 K 11 K K  21 12
(3.20)
K 22

Thus the relative gain  11

is given by

 K u

11

K y
11
2
(3.21)
11
2

14 | P a g e
 1
= (3.22)

1 K K

K K 
12 21

11 22

3.3 Selection of control loop using RGA matrix

If RGA is constructed then the following case may be arise

3.3.1 If  11
=0 , this means the value of diagonal element is zero and non diagonal element

value is unity. And system can control by pairing y 1

with u 2
and y 2
with u 1
and

resulting system in non- interaction with each other.

3.3.2 If  11
= 1, this means system is non interaction with each other and pairing can be

done like y1u 1

and y u 2 2
and neither u 1
can be used to control y 2
nor u 2
can

be used to control y1 .

3.3.3 If  11
=0.5, this is the worst case and in this case both manipulated variable u 1
and

u 2
affect the by same factor and degree of interaction in this case will be same .

3.3.4 If  11
in the range between 0 to 0.5 (let 0.25) it means the value of diagonal

element is 0.25 while the value of non diagonal element have 0.75 so more suitable

pairing is y 1
with u 2
and y 2
with u 1
.

3.3.5 If  11
in the range between 0.5 to 1 (let 0.75) it means the value of diagonal

element is 0.75 while the value of non diagonal element have 0.25 so most suitable

pairing is y1u 1
and y u
2 2
.

3.3.6 If  11
is greater than 1 it means non diagonal element have negative value, this

means change in y1 due change in first manipulated variable is reduce if loop

between second output and second manipulated variable is closed and controlled
response is affected by this interaction larger the of this means larger the effect of
interaction .

15 | P a g e
3.4 De-coupler design for two tank interacting system
Dynamic behaviour of two tank interacting system can be studied by step change in flow rate
and by observing the response of the system by developing a mathematical model of system.
Mathematical model of two tank interacting system-
Two tank interacting system is shown below the mathematical model is derived by assuming
that
(1) Flow resistance is linear
(2) Both tank have equal and uniform cross section area
(3) And fluids are incompressible i.e density of fluid is constant.
Level of Tank 1 is depends on tank 2 level and level of tank 2 is depend upon level of
tank 1 as a result of the interconnecting stream with flow rate . The term intaracting
is referred as loading. The second tank of Fig.3.1 is said to load the first tank.

Fig3.1. Interacting two tank system

Applying mass balance around tank 1 we get

= (3.23)

Applying Mass balance around tank 2:

= (3.24)

16 | P a g e
where:

, - is the cross section area of the tank

- is the input flow to the first tank

– is the output flow of the first tank and input flow to the second tank

– is the output flow of first tank

= (3.25)

and = (3.26)

Then the equation 3.23 and 3.24 reduce to

dh  h1  h 2  (3.27)
AR 1 1
dt
1
RQ 1 i

dh  R  h R h (3.28)
AR  1 2 2
 2
0

2 2
dt  R  1
2
R 1
1

h h
1 2
 R1Q
i
(3.29)

 R  h R h (3.30)
 1 2
 2
0

 R  1
2
R 1
1

From the equation (3.26) and (3.27) steady state equivalents are

dh '  h '1  h '2  (3.31)

AR1 1
dt
1
R Q' 1 i

dh '  R  h ' R h' (3.32)

AR 2
 1  2
 2
0

2 2
dt  R 1
2
R1
1

Where

Q '  (Q  Q ) (3.33)
i i i, s

17 | P a g e
 h 2
' h  h 2 2, s
(3.34)

Taking the laplace transform of equation (3.30) and (3.31) we get:

 A R R s  R  R  (3.35)
H ' (s)  Q
2 2 1 2 1

S A R A R  A R  A R  A R  S 1
1 2 i (s)
1 1 2 2 1 1 2 2 1 2

H ' (s) 
2
R  2 (3.36)
S A R A R  A R  A R  A R  S 1
2
Q i (s) 1 1 2 2 1 1 2 2 1 2

H ' (s) 
2
R  2 (3.37)
S      A R  S  1

2
Q' (s)
i 1 2 1 2 1 2

where:

and

Consider a two tank interacting system as shown in figure below in which we have two
manipulated variable r 1
and r 2
and now we have to calculate gain of each manipulated

variable for each controlled variable Y 1 and Y2 therefore we have to calculate four gain.

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 Fig. 3.2 Interacting two tank system

The gain of each manipulated variable for each controlled variable

 
  h
 11  q 
1
(3.38)
 i q
2

 
  h
 12  q 1
(3.39)
 2 q
i


h 2 
 21  q 
  (3.40)
 i q
2

 
   h 2  (3.41)
22
 q 
 2 q
i

De-coupler design for two tank interacting system

Block diagram decoupled two tank system is shown in figure below in which Gc1 and Gc2 are
controller. d11, d12, d21 and d22 are coefficient of de-coupler

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 Fig.3.3 decoupled two tank interacting system

One of the important characteristics of the De-coupler circuit is that it change the
manipulated variable irrespective of the other loop. The de-coupler work as feedback
controller for first tank and work as feed forward controller for the second tank. To reduce
the interaction between the two tank we have to implement two de-coupler circuit having
Transfer functionD12(s) and D21(s). Transfer function of decoupled system is given below.

  G 2(s)* G12(s)
D12 (s) (3.42)
G1(s)* G11(s)

(s)   G 1
(s)* G 21(s)
D 21
(3.43)
G 2(s)* G 22(s)
Decentralized PID controller for two tank interacting non linear system

Most of industrial process basically a multi input multi output system for such type of system
loop interaction may be arise and to solve such type of problem we have to design de-
coupler.
Relative gain array
The biggest advantage of relative gain array matrix is it is requires the minimal knowledge of
plant or physical system like steady state gain another important advantage is independency

of result on physical units and variable of process. The relative gain for ith manipulated

variable and jth controlled variable is defined as

 ij
=

Decoupling design for non linear two tank interacting system

Decoupling design is to calculate the coefficient which cancel the effect of interaction and
allowing us to independent control loop in decentralized control objective is not to eliminate
interaction but take it to consideration . objective in decoupling design is to compensate the
effect of interaction which is come in to picture due to cross coupling of the process variable.

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Basic block diagram of two input two output system is shown in figure below

y    Gc1 0   r1  y 
 1   G 11 G 12
 
1
(3.44)
 y  G 21 G 22   0 Gc 2  r 2  y 
 2 2

Fig.3.4 Block diagram of two input two output system

In this system interactions G 12 and G 21 is not zero we have to manipulate controller in this

way that the effect of G 12

and G 21
is appears zero . this means output of controller is

transformed with matrix which is contains decoupling function and thus manipulated variable
is given by

 u 1   d 11 d  Gc1 0   r1  y 
    
12 1
(3.45)
u 2   d 21 d 22   0 Gc 2  r 2  y 
2

And the coefficient of the d d d 11, 12, 21

and d 22
is given by

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  G 22 H 1  (3.46)
d  
11   
 G 11G 22 G 21G 12 

   G 12 d 22 
 
d (3.47)

12
 G11 

 G11 H 2  (3.48)
d  
 
 G 11G 22  G 21G 12 
22

   G 21d 11 
And   (3.49)
d 
21
 G 22 
Assume
  G 22 G 11   G 21G 12   (3.50)
H  
1
 G 22 
 

 G 22 G11   G 21 G12   (3.51)

H  
2
 G11 
 

The element of the two input two output system for decoupling matrix which is try to
eliminate the effect of interaction from loop is given by

  G 12(s)   (3.52)
d (s)    
12  G 11(s) 
 

 G 21(s)  
(s)     (3.53)
d 21  G 22(s) 
 

And d (s) = d 22 (s) =1

11

General block diagram of two input two output system with decoupling and controller for a
single loop is shown below.

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 Fig. 3.5 General block diagram of two input two output system with decoupling and
controller for a single loop.

Mathematical modelling of two tank conical interacting system

Two tank interacting conical system is shown in figure below it is consist of two identical
conical tank each having equal area and equal height in this system two pump which
independently deliver flow Fin1 and Fin2 two the tank 1 and tank 2 respectively through the
control valveCV1 and CV2 both of the tank connect through manual control valve MV12 at
bottom as shown in figure below

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 Fig 3.6 two tank conical interacting system
Table 3.1 Various operating parameter of two tank conical interacting system.

In this system two tank conical interacting system is considered as two input two output
process in which level in first and second tank is considered as controlled variable while flow
in first and second tank is considered as manipulate variable. The mathematical model of two
tank conical interacting system is given by

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 


dA(h1)    1 h 1   sign(h  h )   h  h  
1 2 12 1 2

dh1   Fi1 h1 dt 

(3.54)
2
 r 
2
dt

h1 
2
 3H 

 
 dA  h 2  
dh 2   Fi 2  sign  h1  h 2   12
h  h   
1 2 2 h 2  h 2 dt 

(3.55)
2
  r h2 
2
dt
 2 
 3H 

Where

Gc is the area of first tank at given height h1 (cm2)

2  
A h 2   is the area of first tank at given height h 2 (cm2)  
h1 = is the height of liquid level in first tank (cm)

h 2
= is the height of liquid level in second tank (cm)

To model the two tank conical interacting system transfer function matrix model is taken and
it can be given as

Where G ij
is considered as first order system with delay the generalized form can be given

as
 sTd
ke
G (s) 
ij
(3.56)
ij
S  1 ij

The transfer function parameter for two tank interacting system is given below

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The relative gain array matrix for two tank conical interacting system is given below

From the above calculation it is clear that the dominant variable that are to be paired as input
flow to first tank as level of first tank and input flow to second tank as level in second tank
The coefficient of de-coupler for two tank interacting system is given below

d (s) =
11 d 22
(s) =1

Tuning of two tank conical interacting non linear system is done using Ziegler Nichols tuning
method and the coefficient of controller is given table below

S.No Controller
K p  i  d

1.
Gc 1
4.98 235 292.75
2.
Gc 2 5.4 317 79.25

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 PERFORMANCE ANALYSIS AND
COMPARISION OF THREE TANK
SYSTEM

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4.1 Performance Analysis of three tank level control using feedback and feed forward-
feedback controller
Control of liquid in process control industries is important in order to provide desired
performance because level of system can affect the pressure and rate of flow in the industry
So it is important to maintain level at desired set point. in this section we are considering
three tank system which are connected in different configuration like interacting and non
interacting
4.2 CASE (1) - Non-Interacting Three tank system
Non-Interacting three tank system is shown in figure below in which manipulated variable is
input flow rate to the first tank and controlled variable is level in the third tank in this system
we are also considering the effect of disturbance on the response of the system. To minimize
the effect of these disturbances we have to implement Feed-forward controller with suitable
tuning parameter

fig.4.1 Three tank Non-Interacting system

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in this system output flow of first tank is input flow of second tank and similar way second
tank is connected to third tank.
4.2.1 Mathematical modelling of Three tank Non-Interacting system
Applying Mass Balance around first tank we have

dh1
A1   Qi  Q1  (4.1)
dt

From Valve relation we have

H 
Q1   1  (4.2)
 R1 

Where,

Qi - is the inlet flow rate to first tank ( m3 s)

Q1 - is the outlet flow rate of first tank ( m3 s)

R1 - is Outlet flow rate resistance of first tank ( m m3 s )

A1 - is the area of first tank ( m2 )

H1 - is the Actual liquid level in first tank ( m )

Mass Balance around tank 2

dh2
A2   Q1  Q2  (4.3)
dt

From the Valve relationship we have

H  (4.4)
Q2   2 
 R2 

Where,

Q1 - is the outlet flow rate of first tank and inlet flow rate to second tank ( m3 s )

Q2 - is the outlet flow rate of second tank ( m3 s )

29 | P a g e
R2 - is the flow resistance of second tank ( m m3 s )

A2 - is the Area of second tank ( m2 )

H2 - is the Actual liquid level in the second tank ( m )

Applying Mass Balance around the third tank

dh3
A3   Q2  Q3  (4.5)
dt

From the Valve relationship we have

H  (4.6)
Q3   3 
 R3 

Where,

Q2 - is the third Tank input flow ( m3 s)

Q3 - is the third Tank output flow ( m3 s)

R3 -is the flow resistance of third tank ( m m3 s )

2
A3 -is the Area of third tank ( m )

H3 - is the liquid level in the third tank ( m )

Transfer function of three tank system is calculated by rearranging all above equation (4.1)
to equation (4.6),

H 3 (s) R3
 (4.7)
Qi (s) (A3 R3 s  1)( A2 R2 s  1)(A1 R1 s  1)

By Assuming,

R1  R2  R3  A1  A2  A3 = 1.

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Equation (4.7) is reduced to

H 3 (s)  1  (4.8)

Qi (s)  (s  1) 3 

4.3 Interacting Three tank system case (1)

Interacting three tank system is shown in figure below in which tank 1and tank 2 are in
interaction with each other while tank 2 and tank 3 are non interaction with each other

Fig.4.2 Interacting three tank system (case1)

By applying mass balance and valve relation to all three tank and rearranging them we get
transfer function
H 3 (s) R1 R2 R3
 (4.9)
Qi (s) ((S 1  1)(S 2 R1  R1  R 2 )  R 2 )(S 3  1)

By assuming,
R1  R2  R3  A1  A2  A3 =1

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Above equation reduce to

H 3 (s) 1
 (4.10)
Qi (s) ((S 1)(S 2)  1)(S 1)

4.4 Interacting three tank system case (2)

Interacting three tank system is shown in figure below in which tank 1 and tank 2 are non
interaction with each other while tank 2 and tank 3 are interaction with each other

Fig.4.3 Interacting three tank system (case2)

By applying mass balance and valve relation to all three tank and rearranging them we get
transfer function

32 | P a g e
 C(s) R1 R2 R3
 (4.11)
R(s) ((S 2  1)(S 3 R2  R2  R 3 )  R 3 )(S 1  1)

By assuming
R1  R2  R3  A1  A2  A3 =1
Above equation reduce to

H 3 (s) 1
 (4.12)
Qi (s) ((S 1)(S 2)  1)(S 1)

4.5 Disturbance analysis of three tank non-interacting system

In this case we are considering the disturbance is applied to second tank and transfer function
between level of third tank and input disturbance to second tank is calculated
H 3 (s) R3
 (4.13)
Ci (s) (A 3 R3 s  1)(A 2 R2 s  1)

4.6 Disturbance analysis of three tank interacting system (case1)

H 3 (s) R3
 (4.14)
Ci (s) (A 3 R3 s  1)(A 2 R2 s  1)

4.7 Disturbance analysis of three tank interacting system (case2)

H 3 (s) R2
 (4.15)
Ci (s) A1 R1 A2 R2 s  ( A1 R1  A2 R2  A1 R 2 ) s  1
2

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 Implementation and Result

34 | P a g e
5.1 MATLAB Implementation and Results

Response of two input two output process is shown in figure below in which relative gain
array is calculated to obtain suitable pairing. After calculating relative gain the suitable
pairing for two input two output process is level of first tank is controlled by first
manipulated variable while level of second tank in controlled by second manipulated
variable. after pairing we are designed the suitable de-coupler circuit to eliminate the effect
of interaction in two input two output process. Finally two single loop controller is designed.

Fig.5.1 Decentralized PI Controller for Two input Two output process using Simulink.

35 | P a g e
 Fig. 5.2 Output response of the first tank using De-coupler with Step Input.

Fig. 5.3 Output response of the second tank using De-coupler with Step Input.

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5.2 Feedback and Feed Forward- Feedback Controller for three tank system

5.2.1 Three tank Non-Interacting System

Response of Three Tank non-interacting system is shown in figure below in which transfer
function between level of third tank and input flow rate is calculated and then corresponding
PI controller is designed then disturbance is applied to second tank and transfer function
between level of third tank and input disturbance is calculated then corresponding feed-
forward controller is designed and finally response is observed with step input in simulink.

Overall transfer of three tank non interacting system is given below

H 3 (s) R3
 (5.1)
Qi (s) (A3 R3 s  1)( A2 R2 s  1)(A1 R1 s  1)

Transfer function with respect to disturbance

H 3 (s) R3
 (5.2)
Ci (s) (A 3 R3 s  1)(A 2 R2 s  1)

Fig.5.4 Feedback controller for three tank non interacting system.

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 Fig. 5.5 Output response of feedback controller for three tank non interacting system.

Fig. 5.6 Fee back controller for three tank non interacting system with disturbance.

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 Fig.5.7 Output response of feedback controller for three tank non interacting system with
disturbance.

Fig. 5.8 Feedback and feedback-feed forward controller for three tank non interacting system
with disturbance

39 | P a g e
Fig.5.9 Output response of feedback and feed forward-feedback controller for three tank non
interacting system with disturbance

5.2.2 Three tank interacting system (case1)

Response of Three tank interacting system is shown below in which first tank and second
tank are connected in interacting with each other while second tank third tank are non
interaction with each other the transfer function between level of third tank and input flow to
the first tank is calculated and then corresponding PI controller is designed then disturbance
is applied to the second tank and transfer function between level of third tank and input
disturbance is calculated and Feed forward controller is designed.

40 | P a g e
 Fig.5.10 Feedback controller for three tank Interacting system(case1).

Fig.5.11 Output response of feedback controller for three tank Interacting system (case1).

41 | P a g e
 Fig.5.12 Feedback controller for three tank Interacting system (case1) with disturbance.

Fig.5.13 Output response of feedback controller for three tank Interacting system(case1) with
disturbance.

42 | P a g e
 Fig. 5.14 Feedback and feedback-feed forward controller for three tank Interacting system
(case1) with disturbance.

Fig. 5.15 Output response of feedback and feed forward-feedback controller for three tank
Interacting system (case1) with disturbance.

43 | P a g e
5.2.3 Three tank interacting system (case2)-

Response of Three tank interacting system is shown below in which first tank and second
tank are connected in non- Interacting with each other while second tank third tank are
connected in Interaction with each other the transfer function between level of third tank and
input flow to the first tank is calculated and then corresponding PI controller is designed then
disturbance is applied to the second tank and transfer function between level of third tank and
input disturbance is calculated and Feed forward controller is designed.

Fig. 5.16 Feedback controller for three tank Interacting system(case1) .

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 Fig. 5.17 Output response of feedback controller for three tank Interacting system (case2).

Fig.5.18 Feedback controller for three tank Interacting system (case2) with disturbance.

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 Fig. 5.19 Output response of feedback controller for three tank Interacting system (case2)
with disturbance.

Fig.5.20 Feedback and feedback-feed forward controller for three tank Interacting system
(case2) with disturbance.

46 | P a g e
 Fig.5.21 Output response of feedback and feed forward-feedback controller for three tank
Interacting system (case2) with disturbance.

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 Conclusions and Future Scope

48 | P a g e
6.1 Conclusion

Response for various types of connections of the multi tank system which is connected in

Interacting and non Interacting mode has been analyzed. Then the response is analyzed by

designing various types of controller like feedback, feed forward and combination of feed and

feed forward.

In interacting two tank system, first we calculate the relative gain array and then the

decoupling circuit is designed and finally response is observed by designing a PI controller

with step input.

For Interacting and Non Interacting system, first we observe the response without applying

the disturbance to the system and then we are applying the disturbance to the second tank.

By applying the disturbance to the system peak overshoot of the system increased. To reduce

the effect of these disturbances we are designing the feed forward controller. By using

combination of feedback and feed forward- feedback controller, peak overshoot of the system

is minimized.

6.2 FUTURE SCOPE

1. Feedback and combination of feed forward- feedback controller can be used for
observing the response of four tank order tank.
2. Controller design for recycling application.
3. Decoupling design for three tank four tank system.

49 | P a g e
 Bibliography

[1] Ravi V R, Thyagarajan T, "A De-centralized PID Controller for Interacting Non
linear Systems," Proc. of IEEE international Conference on Emerging trends in
Electrical and Computer Technology, pp. 297-302, 2011.
[2] Ravi V R, Thyagarajan T, "Application of Adaptive Control technique for Interacting
Non linear Systems," Proc. of IEEE 3 rd international conference on Electronics
Computer Technology (ICECT), pp. 386- 392, 2011.
[3] Ravi V R, Thyagarajan T, “Gain scheduling Adaptive Model Predictive Controller for
Conical Tank Interacting Level system” proc. of IEEE international conference on
computing communication and network technologies, pp. 1-7, 2012.
[4] Parag Joshi, “Design of De-coupler for an interacting tanks system” IOSR Journal of
Electrical and Electronics Engineering, vol.7, issue 4, pp. 48-53, 2013.
[5] Surekha Bhanot, “Process Control Principles and Applications”, India: Oxford
University Press, 2008.

[6] B, Wayne Bequette, “Process Control Modeling design and simulation”, PHI

Publication,2003.

[7] Donald R.Coughanower, “Process systems Analysis And Control”,2 nd ed.McGraw

Hill international edition
[8] I.J. Nagrath., M. Gopal, “control system engineering”, 5th ed. New age International
Publishers,2010
[9] Gude. J.J, “Modified Ziegler-Nichols method for fractional PI controllers”,
international conference on Emerging Technologies and Factory Automation (ETFA),
2010, pp.1-5

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 Dissemination of the Research Work
[1] Ashish Kumar Singh and Sandeep kumar “ Comparing the Performance Analysis of
Three Tank System using Feedback and Feed forward- Feedback configuration”, proc. of
IEEE international conference on Advance Communication, control and computing
technologies (ICACCCT), may- 2014, Tamilnadu, india.

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