ISA Transactions 50 (2011) 529537

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ISA Transactions
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Parameter estimation of integrating and time delay processes using single relay
feedback test
Rames C. Panda a, , V. Vijayan a , V. Sujatha a , P. Deepa a , D. Manamali b , A.B. Mandal a
a

Chemical Engineering Department, CLRI (CSIR), Adyar, Chennai 600 020, India

Department of Instrumentation, Anna University, MIT Campus, Chrompet, Chennai 44, India

article

info

Article history:
Received 25 January 2011
Received in revised form
16 April 2011
Accepted 21 June 2011
Available online 20 July 2011
Keywords:
Relay feedback
Identification
Autotuning
Integrating process
PID controller

abstract
Autotuning using relay feedback is widely used to identify low order integrating plus dead time (IPDT)
systems as the method is simple and is operated in closed-loop without interrupting the production
process. Oscillatory responses from the process due to ideal relay input are collected to calculate ultimate
properties of the system that in turn are used to model the responses as functions of system model
parameters. These theoretical models of relay response are validated. After adjusting the phase shift,
input and output responses are used to find land mark points that are used to formulate algorithms for
parameter estimation of the process model. The method is even applicable to distorted relay responses
due to load disturbance or measurement noise. Closed-loop simulations are carried out using model based
control strategy and performances are calculated.
2011 ISA. Published by Elsevier Ltd. All rights reserved.

1. Introduction
Processes with long time delays are found in many chemical and
biochemical processes. Chemical and biochemical process systems
with a huge storage facility using inlet/exit valves can be approximated as IPDT [1] systems for designing model based control systems. Recently, these systems have drawn much attention as their
openloop step responses show increasing behavior and need to be
controlled for safe operation. Liquid level with a surge tank, water
level in steam boiler drum and pressure of boiling liquid are examples of such processes. Many researchers have attempted controller design for such processes. Tyreus and Luyben [2] presented
PI tuning rules of IPDT systems and in a separate attempt [3] discussed temperature control of an openloop unstable reactor. Ho
et al. [4] obtained stabilized response by using a derivative block
before IPDT process. Rice and Cooper [5] designed tuning rules exclusively for self-regulating systems to improve closed-loop performance. Scali and Rachid [6], Zhang et al. [7], Chien et al. [8],
Dwyer [9] also discussed control techniques for integrating systems. Kaya [10] considered parameter estimation using relay response under load disturbances. Recently, Liu and Gao [11] derived
theoretical models for relay responses of IPDT systems using biased/unbiased relay. Their presentation did not include IPDT systems with a zero in the numerator, relay identification under load

Corresponding author. Fax: +91 44 24911589.

E-mail address: panda@clri.res.in (R.C. Panda).

variation and they used IMC strategy for control. Many practical
systems have drawn much attention as they behave as an IPDT system with a zero in the numerator. Generally, the presence of an
integrator term

(s) with Laplace variable, s, in the process model

GP =

KP eDs
s

makes the system difficult to control. Moreover,

with the presence of a zero in the transfer function, IPDT process

shows inverse response that gives rises to irregular and undesirable characteristic (inverse response or overshoot) to the system.
Due to the presence of two (or more) competing dynamics (with
different time constants in numerator and denominator) the process initially shows inverse step response that makes the controller
blind to act. Addition of a zero in the transfer function has its implication both theoretically and practically on the response of the system that has not been discussed by earlier researchers and needs
to be addressed. A system is characterized by its poles and zeros. A
zero in the numerator of transfer function means that the output
at that frequency is zero while a pole in the denominator means
that the output at that frequency is zero. The presence of a zero affects the transient response of the system, either by producing an
inverse response (RHP zero) or by adding an overshoot (LHP zero)
in the response of the system. Control of a real non-minimum
phase (NMP) system becomes difficult when the controller is designed by neglecting the inverse dynamic part of the system. Thus
this paper aims mostly with 2nd/3rd order systems with RHP
zeros that are often encountered in the process industries (for example, liquid level control in boiler). Identification of process parameters using relay feedback of such systems are either rare or

0019-0578/$ see front matter 2011 ISA. Published by Elsevier Ltd. All rights reserved.
doi:10.1016/j.isatra.2011.06.004

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R.C. Panda et al. / ISA Transactions 50 (2011) 529537

Fig. 1. Schematic diagram of relay feedback approach.

are not clearly explained/understood in earlier research. Hence integrating plus dead time systems need to be studied for safe operation and control of process. In order to get desired performances
of the process output, a well-designed and properly tuned controller is needed. Any controller that is designed nearer to its ultimate frequency gives better performance. Model based controllers
require exact model parameters for controller tuning. Autotuning
can be used to identify model structures [12] and estimate for tuning controller parameters. It has got two steps, identification and
controller design phase. In this paper relay feedback approach is
used to identify model parameters of integrating processes from
which controller parameters are calculated using proper model
based tuning rules. Three typical model structures for integrating
systems, namely, integrator plus dead time (IPDT ), Integrating second order plus dead time (ISOPDT ) and Integrating second order
plus dead time with a zero (ISOPDTZ ), are considered for autotuning in this work. Emphasis has been given on ISOPDTZ type systems
as they pose many difficulties during control. The entire paper is
organized as follows: at first, mathematical models for relay responses are developed in Section 2. The relay responses obtained
from theoretical equations are validated against experimental response and parameter estimation algorithms are formulated using
land mark points from response curves in Section 3. In Section 4,
PID tuning algorithm is presented and discussed. In Section 5, typical examples are considered whose relay response models are derived, validated, identified and are treated for closed-loop control
using the autotuning theory developed in previous sections.
2. Development of analytical expressions
According to Astrom and Hagglund [13] and Yu [14], when a
process is subjected to relay inputs (height, h), the closed-loop
process output starts oscillating around its steady operating state
and lags behind the input by radians. The oscillatory response
can be used to calculate ultimate properties of the system (ultimate
gain, Ku = 4ha ; where, a = amplitude of response and ultimate

frequency, u = 2P ). Based on the theory developed by Panda and

u
Yu [12,15], analytical expressions are developed for relay feedback
responses of integrating systems in this section. It is assumed
that ideal relay input signals (steps) (composed of infinitely small
steps) are introduced to integrating process, (GP ) (Fig. 1) with
time delay (DP ) and Load, L, when the actual relay output lags
the input by amount DP . The input signals thus obtained can be
synchronized with output by shifting it behind the output by
amount uDP . (i.e., output lags behind input, Fig. 2). After elapsing
a period of DP from t = 0, the relay response starts increasing
and consequently proceeds two to three cycles, after which the
limit cycles
stabilizes in amplitude and period.Hence it is evident
in Fig. 2 response for CEx-2 =

0.25(s+1)e1.0s
s(2.0s+1)

that as soon as a

segmental change in input (u) is given in the system at time t3 , the

response starts after a time delay (DP ) from point A (can be seen
in the zoomed portion of the figure; tm is time for model while t is
time for experiment) and then the model follows point BCD.
For modeling purpose, as shown in Fig. 2, that each period is
considered as one half cycle or from, t = 0 to t = Pu /2. As time

Fig. 2. Development of theoretical modeling validation of formulated model:

theoretical response (solid line segment) is matched with actual relay response
(dashed line) of the systems for CEx-2.

changes from t = 0 to t = DP , the response y1 is produced due

to step change u1 . In the 2nd interval, time changes from t =
DP to t = DP + Pu /2, when response y2 results due to combined
effect of instant step changes u1 and u2 . Similarly, y3 is produced
due to effects of u1 , u2 and u3 . Thus, after proceeding in this way
up to even values of n, y2n , ascending half of the cycle is found to
appear. Let us think that the descending part of the response, y2n+1 ,
is formed by odd values of n. It can be observed that the generalized
response forms an infinite series that can be summed up to a closed
compact form as described below.
2.1. Integrating second order plus dead time systems with a zero
The transfer function for an ISOPDTZ type of system can be
K ( s+1)eDP s

written as GP = P sPz( s+1)

where KP is the steady state gain, P
P
is the time constant, DP is time delay and PZ is a numerator zero
of the process. The original step response for this transfer function
can be given as
y = KP [t a1 P (1 et /P )]

(1)

where a1 = P Pz .
P
After shifting the input signal and synchronizing with the
output signal (Fig. 2), the 1st segment of the relay response is the
step response without time delay and can be given as
y1 = KP [uDp + t a1 P (1 et /P )].

(2)

The 2nd segment of relay response can be obtained by introducing

the delay, DP , as
y2 = KP [uDP + (t + DP ) a1 P (1 a1 e(t +DP )/P )]

2KP [t a1 P (1 et /P )]
= KP [uDP + (1 2)t
DP a1 P {(1 2) et /P (eDP /P 2)}].

(3)

At the 3rd interval, the relay response lags by an amount DP +

Pu /2 from the input. Thus after introducing the time shift, Eq. (3)
becomes

y 3 = KP

uDp + t + DP +

Pu
2

a1 P 1 e

(t +DP +0.5Pu )/P

Pu
2KP t +
a1 P 1 e(t +DP )/P
2

+ 2KP t a1 P 1 et /P

R.C. Panda et al. / ISA Transactions 50 (2011) 529537

= KP uDp + (1 2 + 2)t + DP +

Pu
2

Pu

a1 P ((1 2 + 2) 2e(t +DP +0.5Pu )/P

+ 2e

(t +DP )/P

t /P

2e

(4)

It can be observed that the terms inside the brackets of RHS of

above Eq. (4) are forming a series. Thus proceeding for nth interval
the series becomes

Pu

ym = KP uDP + t DP
where c =

2
1 + ePu /2P

a1 P 1 et /P .c

(5)
(6)

Generally, uDP is taken to be zero and substituting t = 0, Pu /2

and other parameters in RHS of Eq. (5) it is possible to compute
theoretical relay responses.
Similarly, for an IPDT system, GP =
model can be derived as

yn = KP uDP + t + DP + (1)n

Pu

KP eDP s
,
s

the relay response

with n = even.

(7)

K eDP s

For ISOPDT system, GP = s(P s+1) , the relay response equations can
P
be formulated as

yn = KP uDP + t + (1)n P DP

+ P et /P

2
1+

ePu /2P

Model structure

Relay response equations

KP eDP s
s
K eDP s

yn = KP h[uDp + t + DP Pu /2]

2et /P1
1+ePu /2P1
2et /P1
(1+ePu /2P1 )

s(P1 s+1)

yn = KP h uDp + t DP Pu /2 P1 1

KP (P3 s+1)eDP s
s(P1 s+1)

yn = KP h uDp + t DP Pu /2 a1 P1 1

) .

531

Table 1
Analytical expressions for relay responses.

simulated for time from t = 0 to t = Pu /2, and generated response

is plotted. The process input and outputs are plotted in the same
figure or graph. Cycle time for inputs and outputs are found to
be increasing slowly and settling after 3rd or 4th cycle onwards.
Model response is computed and is matched /synchronized with
the experimental response curve by shifting it along time and y axis
as shown in Fig. 2. The total amount of adjustments done in this
way is added to the model. It is observed from the responses that
for IPDT systems, response starts (tm = 0) from bottom (or top)
corner and ends at the next top (or bottom) peak. Here t represents
experimental or real time whereas tm is the time considered for
computation of model. In case of ISOPDT , the response starts
from midpoint of the lower or upper trend and with increase in
time delay values of models, the starting point shifts toward right
reaching to the peak/bottom. In the case of ISOPDTZ systems, as
shown in Fig. 2, theoretical response is plotted/marked as ABCD
that starts from point A (tm = 0) and ends at point D (tm = Pu /2).
Time between t = t3 and time at point A is the dead time DP , that
can be easily measured. At point B, time becomes tm = tPeak , time
to reach peak.

Pu
3.2. Identification of transfer functions

2
(8)

3. Results and discussion

Different types of transfer functions of integrating plus dead
time processes have been considered for developing analytical
expressions of relay response curves using the method mentioned
in above Section 2. In this work, three different practical examples
are considered for which relay response equations are developed
separately for each system. These mathematical equations are
simulated (for time t = 0 to t = Pu /2) to validate the theoretical
responses with experimental relay output from the process.
These model equations (yn ) denote upward or ascending trend
(sometimes curves starting from lower part or midline) of relay
response for time from t = 0 to t = Pu /2. The downward trend
is obtained from yn . A closer look to these models reveals that
these contain a simple time term (t) due to the integrating term
(s) in the denominator of transfer function; and a factor, c =
2/(1 + e0.5Pu /P ), due to the presence of first order pole in the
denominator.
3.1. Model validation
Three kinds of responses have been observed basically for three
different model structures mentioned in Table 1. For IPDT types
of process the relay responses are found to be increasing straight
till t = Pu /2 and have triangular shapes. All the responses are
symmetric. The relay outputs for ISOPDT types of processes
have rounded and smoother curved peaks while responses with
ISOPDTZ have exponentially developed cycles with both smoother
curved peaks (for P1 > Pz < 0) and sharp peaks (for P1 > Pz >
0). It has already been mentioned that the model equations are

Identification algorithms for three model structures considered

here are shown in Table 2. From a particular segment of
input/output, it can be observed that the process output follows
its input and starts (t = 0) after time delay amount DP . This time
delay can be measured from very first or initial part of the relay (till
response is zero) or as described in the end of earlier subsection. D
is the time (experimental) taken by the response to reach its peak.
After synchronizing inputoutput responses by shifting one over
the other, one can easily determine D as well as uDP by measuring
the time lag between t = 0 and start of input signal.
Thus, considering any segment (say, 3rd) when the responses
stabilizes, starting point of response (t ), tPeak and apparent
dead time (D ) can be found out easily. After constructions of
model equations and validating them with relay response, the
estimation algorithms (Table 2) for individual cases are formulated
as described below.
(a) IPDT systems: The responses are observed to be monotonic in
this case. These types of processes have two parameters namely,
process gain (KP ) and time delay (DP ). The process gain can be
calculated as or
pu /2

[
KP =

pu /2

] [
ydt

udt .

(9)

The observable boundary conditions can be applied directly as

y|t =0 = a = y|t =Pu /2

(10)

y|t =Pu /2DP = 0.

(11)

Time delay (DP ) can be found (DP = Pu /4) from initial part of the
relay response. The above two equations can be solved to get DP
and then substituting this value in the response equation, KP can
be found for any arbitrary response data (y) for a time value (t ).
Thus one can have
y
KP =
(12)
h(uDp + t Pu /4)

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R.C. Panda et al. / ISA Transactions 50 (2011) 529537

Table 2
Algorithms for identification of model structures along with their parameters.
Model structure
KP eDP s
s
K eDP s

Model parameters

Algorithm

KP and DP

DP = Pu /4 and KP =

KP , P1 and DP

s(P1 s+1)
KP (Pz s+1)eDP s
s(P1 s+1)

P1 from P1 ln

KP , P1 , P3 and DP

(13)

y|t =Pu /2tPeak = a = y|t =tPeak .

(14)

The above condition (Eq. (14)) can also be written as

y|t =Pu /2D +DP = a = y|t =D DP .
The above condition (13) leads to

P1 1

1 + ePu /2P1

= uDp 2DP .

(15)

Parameters in the RHS of the above equation are known and can be
substituted to find out P1 Eq. (14) can be used to find out process
gain (KP )
KP =

h uDp D P1 1

2e(Pu /2D +DP )/P1

1+ePu /2P1

(16)

Thus Eqs. (15) and (16) can be solved to get (P1 ) and (KP ).
(c) ISOPDTZ : These types of processes exhibit two types of
responses depending on the time delay value of the transfer
function. It has four unknown parameters, namely, process gain
(KP ), process time constant (P1 ), numerator zero (Z ) and time
delay (DP ). After observing and analyzing the response (Fig. 2), the
boundary conditions can be formulated using land mark points as:
In case the responses have rounded peaks (non-monotonic
response), one can have, the slope at the optimum point (minimum
or maximum) must be zero

dym

=0

(17)

(ym )t =tPeak (ym )t =D +tPeak = a

(18)

(ym )t =D +tPeak (ym )t =0 = (ym )t =Pu /2 (ym )t =D +tPeak .

(19)

dt

t =tPeak

In case the responses have sharp cornered edges or peaks

(monotonic response) the boundary conditions become
y|t =Pu /2D = 0.

(20)

Other two conditions become similar to Eqs. (18) and (19) as

above.
Process time delay is found from initial part of relay response.
Condition (17) leads to

kP

2(P1 Pz )etPeak /P1

P1 (1 + e0.5Pu /P1 )

= 0.

(21)

Using condition (18), one can get from model equation

a1 P1 c (etpeak /p1 e(tpeak +D ) /p1 ) =

a
KP h

h(Pu /4)

2
1+ePu /2P1

a
h(Pu /4)

= tPeak and KP =

2 (e
D P1

a
tPeak /P1 e(D +tPeak )/P1 )

(1+e0.5Pu /P1 )

1
= 0 and
P1 and P3 from tPeak P1 ln (1+e2a
0.5Pu /P1 )
t

a
(tpeak +D )
peak
a1 P1 c e
/p1 e
/p1 = KP h + D D + tpeak + a1 p1 (ce(D +tpeak )/p1 1) =

y|t =Pu /2DP = 0

2e(0.5Pu D )/P1

y|t =0,Pu /2

(b) ISOPDT systems: The responses in this case have been observed
to be non-monotonic. There are three unknown parameters,
namely, process gain (KP ), process time constant (P1 ) and time
delay (DP ). The boundary conditions that can be formulated for
identification of these parameters are

+ D .

(22)

One can obtain P1 and PZ by solving Eqs. (21) and (22)

simultaneously. Condition (19) gives rise to

Pu
4

Pu

.
(23)
D + tpeak + a1 p1 (ce(D +tpeak )/p1 1) =
4
Substituting condition (20) into the model equation (6) gives
KP =

h uDp D P1 1

2a1 e(Pu /2D +DP )/P1

P
/
2P1
u
1 +e

(24)

Therefore Eqs. (21)(24) can be solved to find out all unknown

four parameters in the non-monotonic case. Similarly, conditions
(20) and (21) lead to Eqs. (20) and (24) for the case of monotonic responses. Thus following steps are followed to estimate parameters
of ISOPDTZ using lower trenches of relay curves.
Non-monotonic response
(i) Estimate relay response amplitude (a), ultimate period of
oscillations (Pu ), apparent dead time (D ) and input delay
parameter (uDp ).
(ii) Solve Eqs. (21)(24) or (9) simultaneously to find out four
unknown parameters P1 , PZ , DP and KP .
Monotonic response
(i) Find out DP from initial part of relay response.
(ii) Solve Eqs. (21) and (22) simultaneously to find time constants
P1 , PZ .
(iii) Compute KP from Eq. (24) or (9).
3.3. Application of estimation algorithms
3.3.1. Examples
Four different processes are considered and these estimation
algorithms are applied to identify the unknown process transfer
functions. These examples (Table 3) are taken from different
literature as these describe practical examples. Let Gc (s) is the
controller transfer function that is inserted in place of relay in Fig. 1
during closed-loop control.
Example-1: A non-self-regulating process [2,16] representing a
pumped tank liquid level system is considered for this. Liquid is
pumped from the storage tank to the main tank via disturbance
pumps. The flow rate leaving the pump and the level in the main
tank is measured. A gravity drained tank introduces delay into the
system. The non-self-regulating system continues to drift upward
until it reaches a physical limitation. Thus process variable (PV)
does not return to its original level when control variable (CO)
returns. The process parameters are, KP = 0.0506%/min and DP =
6 min. The amplitude ratio and phase angle for this process may be
given as

|GP GC (j)| =

1 + (2k + 1)2 (DP )2

2
2
(2k
+ 4k + 1)(DP )
1 + (DP /2)2

2
1 + (k /(2k2 + 4k + 1))2 (DP /2)2
DP
GP GC (j) = tan1 ((2k + 1)DP ) + tan1
2

2
k

tan1
DP DP
2k2 + 4k + 1
2
where k = /DP with as an user defined parameter.

(25)

(26)

R.C. Panda et al. / ISA Transactions 50 (2011) 529537

533

Table 3
Ultimate properties and estimated transfer functions for different examples.
Example

System ultimate property

Estimated transfer function

Amplitude, a

Period of oscillation, Pu

6s
Ex-1 = 0.0506e
s

0.3289

26

0.2s
Ex-2 = 1.s0e
(s+1)

0.4338

3.9986

Ex-3 =

0.5374

3.9772

0.4750

11.9994

Ex-4 =

1.0(s+1)e0.5s
s(2s+1)
0.25(s+1)
s(2s+1)

0.0506e6s
s
1.0e0.2s

s(0.9998s+1)

1.0353(1.0027s+1)e0.5s
s(2.0060s+1)
0.252(s+1)
s(2s+1)

Fig. 3. Plot of performance (IAE) vs. lambda () during (a) set point change (optimum resulted is 0.124 while corresponding IAE is 7.3) (b) load disturbance (optimum
resulted is 0.07695 while corresponding IAE is 46.17) with Ex-2 and present control scheme.

On applying relay, this process yielded a cyclic response with

amplitude, a, 0.3289 and period, Pu , 26. Using these ultimate
properties and steps as described in item 3.2 (a) above, the process
transfer function was estimated as given in first row of Table 3.
Example 2: This example [7] is of ISOPDT type with a pole at left
half plane as given in row 2 of Table 3. The relay response from
the process was analyzed from which the ultimate properties were
calculated as, Ku = 2.9366 and Pu = 3.9986 and using these values
and following steps as provided in Section 3.2(b) above, estimated
parameters of transfer function become, KP = 1.0, P = 0.9998
and DP = 0.2.
Example 3: A numerical example of ISOPDTZ type with a left plane
zero in the numerator of the transfer function is selected. After carrying out relay feedback test, the response is subjected to analysis from which ultimate properties are found to be Ku = 2.3705
and Pu = 3.9772. After proceeding through steps as prescribed
in Section 3.2(c) above, the unknown process parameters are identified as, KP = 1.0353, P = 2.006, Z = 1.0027 and DP = 0.5
where as their actual values are KP = 1.0, P = 2.0, Z = 1.0 and
DP = 0.5.
Example 4: A process, representing water level in the boiler drum,
of similar type (ISOPDTZ ) with a right half zero in the numerator
in the transfer function is considered for estimation using relay
0.252(s+1)
feedback scheme. The identified transfer function is s(2s+1) by
present method as given in row 5 of Table 3. The same transfer
0.25(0.9999s+1)
by Gu et al. [17].
function was identified as
s(2s+1)
4. Controller design
It has been observed that most of the chemical process loops
are controlled by PID controllers. There exist different types of PID
forms [18] of which the parallel PID structure is considered for
implementation as given by
GC (s) = KC

D s
1+
+
I s D s + 1
1

(27)

where is a constant and usually taken as 0.1. The process

parameters are incorporated in the controller equation (24) where
the controller parameters are tuned through IMC-PID tuning rule
as described below.
4.1. Controller tuning
Based on matching of the coefficients of similar powers of s
term on both sides, Chidambaram [19], proposed a tuning rule
for integrating systems. As an efficient method, IMC-PID tuning
rule [20] using direct synthesis approach and approximating GC (s)
with Laurent series (to avoid singularity problem) is used to tune
the processes under present study. The problem of singularity due
to the presence of s term in the denominator, is solved using
residue theorem of Laurent series. User defined tuning parameter,
, is chosen according to Luyben [3] and Rice and Cooper [5]. How
ever, keeping in mind about the trade off between stability and
speed of closed-loop response, can be chosen by the user to have
a stable closed-loop response maintaining maximum sensitivity
of 23. Optimum was found for Ex-2 and is shown in Fig. 3.
Closed-loop performance is plotted against for set point change
(Fig. 3(a)) as well as load change (Fig. 3(b)) where minimum is
found to be 0.124 and 0.0769 respectively.
5. Closed-loop application
Example-1: A water level process (CEx-1) in the boiler steam drum
[21] is considered for this study. In this process, level is controlled
by manipulating water feed rate. The drum equipped with large
number of tubes is generally located near the top of the boiler.
Water in the vapor and liquid form traverses between drum and
boiler through downcomer and riser pipes. The transfer function
0.547(0.418s+1)e0.1s

of this process was identified as

. Due to the
s(1.06s+1)
presence of numerator zero, the step response shows an inverse
response. A PID controller is designed using tuning rule [20] for
this process that gives KC = 2.2093, I = 158.93 and D = 1.43
with = 0.3 From the closed-loop response (Fig. 4, CEx-1a), the

534

R.C. Panda et al. / ISA Transactions 50 (2011) 529537

Fig. 4. Comparison of closed-loop responses of liquid level control for a boiler drum (ISOPDTZ ) process using different PID tuning rules.

Table 4
Comparison of performances of present PID tuning scheme with similar available schemes.
Process

PID tuning method

0.547(0.418s+1)e0.1s
s(1.06s+1)
0.25(s+1)e1.0s
s(2.0s+1)

= CEx-1

= CEx-2

Controller parameters

Performance

KC

MSER

MSEL

Present
Gu et al. [17]

0.3
0.3

2.2093
1.3821

158.93
4.6308

1.43
1.42

18.372
29.391

13.198
14.185

Present
Gu et al. [17]

0.3
0.3

1.3957
1.5243

158.04
14.742

2.786
3.448

24.803
32.642

17.95
17.76

closed-loop performance (mean square error) for the servo

response case is found to be 18.372. More aggressive makes the
controller action to be constrained within limits of 0%100%. The
same system was studied by Gu et al. [17]. The results are shown
in Table 4. With same values of = 0.3, controller parameters
obtained was KC = 1.3821, I = 4.6308 and D = 1.42 and after
simulating for servo response, MSE was found to be 29.391, which
is higher than that in the present case (18.37). It is to be noted
that for each example, mean square error (MSE) has been found
for servo response (MSER ) and regulatory/disturbance rejection
(MSEL ). The regulatory responses (Fig. 4, CEx-1b) with present
tuning and Gu et al. [17] were observed to give MSE of 13.198 and
14.185 respectively (almost close values).
Example-2: This example is for an integrating system with a time
delay with numerator zero. By employing PID tuning rule (present),
controller parameters calculated was, KC = 1.3957, I = 158.04
and D = 2.786 with = 0.3. With these settings, a set point
change case was studied that yielded MSE of 24.803. Using tuning
rule proposed by Gu et al. [17] the respective controller parameters
were calculated to be KC = 1.5243, I = 14.742 and D = 3.448
with = 0.3. The servo response gave an MSE of 32.642. The
regulatory (load change) case was simulated with present tuning
rule and with Gu et al. [17] separately that yielded MSE = 17.95
and 17.76 respectively. The comparison of closed-loop responses
for set point as well as load changes is provided in Fig. 4, CEx-2.

5.1. Robustness analysis

The IMC-PID control law is designed based on the identified
process model. But, due to the change in environmental & other
factors, process parameters in real time plant changes that causes
mismatch between true plant and identified model. Hence,
a robustness study is necessary to find out the performance
of the designed controllers. A process model (CEx-2) has been
considered for this study. Parametric variation on process gain,
time delay, process time constant (denominator pole, P1 ) and
on zero (numerator zero, Pz ) are given both separately and
altogether basis to formulate new processes and the closed-loop
performance in each case is tested with the existing (already
designed) controller. It has been found that the controller is
capable of giving maximum sensitivity (Ms) of 23 with the
following ranges from their nominal values: KP = 80%, DP =
35%, Pz = 70% and P1 = 40%. Fig. 5 shows robustness of
the present controller for a model mismatch in DP = 35% with
process CEx-2.
5.2. Process with load disturbance
In order to show the applicability of present technique to
process with load disturbance, the process Ex-1 is considered
where a unit load was applied before the process block in Fig. 1.
It is assumed that the process (Ex-1) was undergoing autotuning

R.C. Panda et al. / ISA Transactions 50 (2011) 529537

535

Fig. 7. Relay feedback responses for an IPDT process [Gp (s) = 0.2 exp(7.4s)/s]
with measurement noise, NSR = 0.01.
Fig. 5. Sensitivity of present controller for a perturbation in dead time (+35%
solid line, nominal valuedash dot line, 35% dashed line) of the process model
CEx-2.

identification study. As an example, the process (Chien, 1990)

7.4s

with transfer function GP = 0.2es

was selected. The process
when subjected to relay without any measurement noise, yields,
amplitude a = 1.6 and Pu = 32. On introducing a noise of NSR =
0.005, the system output got corrupted (Fig. 7) with noise and the
same was subjected for analysis, that gave a = 1.6 and Pu = 31.8.
After using estimation algorithm, one obtains, DP = Pu /4 = 7.95,
KP = a/7.95 = 0.2013. On increasing the value of NSR slowly,
it was observed that the present procedure can be used, for
estimating parameters of this IPDT system, up to a NSR value of
5% or a noise variance (band limited white) of 0.0003.
5.4. Comparison
The parameter estimation and controller tuning methods developed here are compared with similar available techniques [11].
A higher order system GP =

Fig. 6. Use of output biased relay to restore the correct shape under load
disturbance for an IPDT system (transfer function: 0.2 exp(7.4s)/s).

(s+1)e5s
s(s+1)5

from [11] is considered

for parameter identification using present method. Table 5 shows

the results of system identification. Pu = 28; a = 6.6137; D =
6.387; tp = 1.388; Calculation of model mismatch
evalu through

by relay feedback (with relay height, h) method and was producing

limit cycles (ultimate gain, Ku and time period Pu ). At that time, a
unit step change in load entered suddenly in the process. Due to the
application of load variable, the amplitude of relay output (limit
cycles) will distort resulting ultimate gain, Ku1 and time period
Pu1 . This distortion can be rectified by adjusting relay height by
h 1h amount so that limit cycles come back to their original state
producing approximately same amplitude and period of oscillation
as before (before application of load). In order to show this, an
example Chien and Fruehauf [1] with transfer function GP =
0.2e7.4s
s

was considered. On applying relay, original amplitude of

oscillating limit cycles was measured as, a = 1.6. The results are
shown in Fig. 6. After applying load disturbance of L = 0.5, the
amplitude was observed to be, a1 = 1.42. By adjusting relay height
aa1
(in three iterations) to 1h0 =
h = 0.1125 the amplitude of
a
oscillating process response became 1.589 which is very close to
original amplitude value.
5.3. Presence of measurement noise
In practice, the process measurement is affected by noise.
Introduction of hysteresis (to prevent transient fluctuation of
relay at zero crossing) in the relay may reduce the influence of
noise in measurement to some extent. Accuracy of the presently
proposed method was rationalized by collecting input/output
data by employing a random noise with a noise to signal ratio
(NSR) of 0.005. The measured process output was subjected for

10

ation of multiplicative error (j) = = u/10 mG P d shows

P
u
that ISOPDTZ model matches the process with least error (). MSE
values are also calculated.

5.5. Real time results

Two liquid level tanks are connected in series and level of tank
2 was controlled by manipulating feed flow rate of 1st tank. The
transfer function for the combined system was identified as ISOPDT
model structure whose transfer function was estimated using relay
4.2s

feedback (Pu = 524 and Ku = 3.84) as to be YE = 1.s4431e

. With
(470s+1)
= 120, IMC-PID (Laurent) controller parameters are found to be
Kc = 1.7464 and I = 436.6. The results are shown in Fig. 8. It can
be seen that real time results are faster with no overshoot.
5.6. Stability analysis
For an openloop integrating process, the output (y) keeps on
increasing/decreasing for a change in the input variable (u). An
IMC controller can make the closed-loop stable if the following
conditions are satisfied: (1) GP has to be stable, (2) GP GIMC
must
C
be stable and (3) (1 + GP GIMC
)
G
should
be
stable.
P
C
Thus according to condition (2) above, the integrating poles of
GP must be canceled by zeros of GIMC
and according to condition
C
(3), the integrating poles of GP must be canceled by zeros of
(1 + GP GIMC
C ). As the proposed controller is of PID type, the closedloop characteristic equation,
1 + GP (s)GC (s) = 0

(28)

536

R.C. Panda et al. / ISA Transactions 50 (2011) 529537

Table 5
Comparison of identification schemes (present and available methods).
Example
GP =

(s+1)e5s
s(s+1)5

Method

Identified as FIPDT (Gm )

Identified as ISOPDT (Gm )

Identified as ISOPDTZ (Gm )

Present

0.945e7s
s

0.7319e5s
3.1953s(2.0051s+1)

1.0027(2.006s+1)e5s
s(1.0353s+1)

= 320
MSE = 3.9 103
Tao and Gao [11]

0.9664e10.97s
s

MSE = 3.3 104

= 955
MSE = 1.09 102

= 294
MSE = 0.003

1.018e8.5278s
s(2.5293s+1)

MSE = 1.7 104

6. Conclusions

Fig. 8. Comparison of closed-loop control of liquid level (real time and simulated
level).

will hold good for analyzing the stability of the closed-loop system
(while the openloop process is unstable). Let,
GP (s) =
GC (s) =

KP (z s + 1)eDP s
s(P s + 1)
KC [I D s2 + I s + 1]

I s

and

(29)

(30)

Assuming Pades approx for eDs and substituting these Eqs.

(29) and (30) into characteristic equation (28), and expanding
exponential delay term up to first five terms (neglecting remaining
higher order terms), we get
p4 s4 + p3 s3 + p2 s2 + p1 s + p0 = 0

Many chemical processes can be modeled as IPDT systems.

An ideal relay input to these types of processes produces output
with limit cycles which can be analyzed to find out ultimate
properties of the system and the process output thus obtained can
be modeled in time domain as function of these ultimate system
values. Three different types (model structures) of integrating
processes (IPDT , ISOPDT and ISOPDTZ ) have been analyzed for
modeling, identification and control in this work. Novelty of this
work lies with the treatment of integrating process with a zero in
the numerator (ISOPDTZ ) type of model. Practical examples have
been considered in rationalizing the developed model equations.
When the relay input and outputs are synchronized, the response
curves help us to find out sufficient land mark points that provide
us sufficient information for model parameter identification. Using
model equations and land mark points, parameter estimation
algorithms have been formulated separately for each model
structures. Several practical processes are selected to identify
their model parameters using these identification algorithms. A
PI controller for the level control problem of boiler water drum is
designed and the performance of the closed-loop system is studied.
The controller is found to be robust. The identification algorithm
based on relay feedback approach that has been developed here
can even be used under the presence of measurement noise. Thus
the present method of modeling, estimation and control can be
implemented on integrator plus dead time systems.

(31)

where

References

p 0 = KC KP

(32)

p1 = KC KP (z + I DP )

(33)

p2 = KC KP ((I z )DP + I (D z )) + I

p 3 = KC KP

DP I (z D ) I z D +

I P

(34)

KP KC

p4 = KP KC DP I z D ,

(35)
(36)

which are defined in interval pLi pi pUi with pLi as lower

bound and pUi as upper bound of parameters pi where i = 0,
1, 2 . . . 6. According to the Kharitonov theorem, every polynomial
(characteristic equation) in the interval family will be stable (Hurwitz) if the following four Kharitonov polynomials are Hurwitz.
K11 (s) = pL0 + pL1 s + pU2 s2 + pU3 s3 + pL4 s4 +

(37)

K12 (s) =

pL0

K21 (s) =

pU0

K22 (s) =

pU0

pU1 s

pL1 s

pU2 s2

pL2 s2

pL3 s3

pU3 s3

pL4 s4

(38)

pU4 s4

(39)

+
+ .
(40)
As the process parameters (KP , P , DP and z ) are perturbed,
+

pU1 s

pL2 s2

pL3 s3

pU4 s4

closed-loop stability changes. It is found (using Eqs. (37)(40))

that about 30% perturbation on all parameters simultaneously is
possible by this controller. With the present method, using a PID
controller, calculated gain margin for process Ex-4 we get gain
margin is 9.7 and phase margin is 58.

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