Controller Design and Stability Analysis of Intensification Process using Analytical Exact Gain-Phase Margin approach

Abstract

The controllable intensified process has received immense attention from researchers in order to deliver the benefit of process intensification to be operated in a desired way to provide a more sustainable process toward reduction of environmental impact and improvement of intrinsic safety and process efficiency. Despite numerous studies on gain and phase margin approach on conventional process systems, it is yet to be tested on intensified systems as evidenced by the lack of available literature, to improve the controller performance and robustness. Thus, this paper proposed the exact gain and phase margin (EGPM) through analytical method to develop suitable controller design for intensified system using Proportional-Integral-Derivative (PID) controller formulation, and it was compared to conventional Direct Synthesis methods (DS), Internal Model Control (IMC), and Industrial IMC method in terms of the performance and stability analysis. Simulation results showed that EGPM method provides good setpoint tracking and disturbance rejection as compared to DS, IMC, and Industrial IMC while retaining overall performance stability as time delay increases. The Bode Stability Criterion was used to determine the stability of the open-loop transfer function of each method and the result demonstrated decrease in stability as time delay increases for controllers designed using DS, IMC, and Industrial IMC, and hence control performance degrades. However, the proposed EGPM controller maintains the overall robustness and control performance throughout the increase of time delay and outperform other controller design methods at higher time delay with $\pm 20\ \%$ uncertainty test. Additionally, the proposed EGPM controller design method provides overall superior control performance with lower overshoot and shorter rise time compared to other controllers when process time constant is smaller in magnitude (${{\varvec{\tau}}}_{\mathbf{p}}=0.01\ \mathrm{ and }\ 0.1$) than the instrumentation element, which is one of the major concerns during the design of intensified controllers, resulting overall system with a higher order. The desired selection of gain margin and phase margin were suggested at 2.5 to 4 and 60 °–70 ${}^\circ$, respectively, for a wide range of control conditions for intensified processes where higher instrumentation dynamic would be possible to achieve robust control as well. The proposed EGPM method controller is thought to be a more reliable design strategy for maintaining the overall robustness and performance of higher order and complex systems that are highly affected by time delay and high dynamic response of intensified processes.