Research Journal of Applied Sciences, Engineering and Technology 13(2): 143-152, 2016

DOI:10.19026/rjaset.13.2925
ISSN: 2040-7459; e-ISSN: 2040-7467
© 2016 Maxwell Scientific Publication Corp.
Submitted: June 8, 2015 Accepted: September 3, 2015 Published: July 15, 2016

Research Article
PLC-based Smith Predictor for Control of the Temperature Process with Long Dead Time
1
M. Balaji and 2K. Porkumaran
1
Department of Electronics and Instrumentation Engineering, College of Engineering and
Technology, Pollachi,
2
Institute of Technology, Coimbatore, Tamilnadu, India

Abstract: This study presents the development of dead-time compensator with Proportional Integral-Derivative
(PID) controller and their implementation in real-time using the Programmable Logic Controller (PLC) on a heater-
furnace system that constitute the temperature process. Though PID controller is effective to most of the processes,
it has draw backs when used to control the processes with significant dead time. Therefore to eliminate the effects of
long dead time, the dead-time compensator combined with PID is proposed. The control equation for the proposed
dead time compensator is developed using the mathematical model of heater-furnace system and ladder logic
program is created in GE Fanuc Versamax PLC. The PID controller is tuned using process reaction curve method
and programmed in PLC. The proposed controller has an outer loop control mechanism with dead time compensator
which feeds the inner loop PID controller. The effects of dead time on the performance of PID controller are
eliminated through the outer loop control mechanism whose output does not contain modelling errors. The results of
the proposed dead-time compensator with PID are compared with the results of the conventional PID controller
without dead time compensation for both steady state response and servo-regulatory response. The results of the
proposed controller show better improvement in the time domain specifications compared to conventional PID
controller.

Keywords: Dead-time compensator, GE Fanuc PLC, long dead time, PID controller, temperature process

INTRODUCTION significant, Astrom et al. (1994). PID controllers with

dead time compensation are reported to eliminate dead
Most control problems in the process industry are time. However, for unmeasured load disturbances at the
solved using PID controllers. The predominant reason process input, the ultimate performance is set by the
is that the PID controller can be tuned manually by total dead time from the process equipment, piping,
“trial and error” procedures, as it only has three control valves, instrumentation and digital devices. This
adjustable parameters. The possibility to make manual shows that a dead time compensator can offer some
adjustments in the controller parameters is significant improvement in load rejection by facilitating more
though automatic tuning procedures are available, aggressive tuning of the PID but with a considerable
Astrom and Hägglund (1995). The PID control risk of oscillations from an inaccurate dead time. In the
algorithm is widely used in process industries because process industries, the occurrence of “dead time” or
of its simplicity, robustness and successful practical “transportation lag” is very common. For the majority
application. When there are long dead times in the of simple control loops, the amount of dead time is
process, the control performances obtained with a PID usually not significant when compared to the time
controller are, however, limited. For these processes, constant, Astrom et al. (1994). For more complicated
Dead Time Compensating controllers (DTCs) may control loops like those for quality control, dead time
improve the performance considerably (Smith, 1959). can be very significant and may even be longer than the
These controllers require a process model to develop system time constant. The reasons for this include
model predictive control. This usually means a analysis delay and the down-stream location of the
significant increase in controller parameters and thus sampling point for the quality analyser. Another class
the complexity of the controller design, Astrom and of examples is characterized by a multitude of small
Hägglund (1995). It has been found in practice that the lags, such as a long bank of heat exchangers, or a
widely used PID controller would rapidly lose its distillation column with many trays, giving rise to what
effectiveness when the process dead time becomes is called “apparent” dead time.

Corresponding Author: M. Balaji, Department of Electronics and Instrumentation Engineering, College of Engineering and
Technology, Pollachi, Tamilnadu, India
This work is licensed under a Creative Commons Attribution 4.0 International License (URL: [Link]
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Normey-Rico and Camacho (1999) proposed a process. This model-based controller is theoretically a
dead time compensator with three adjustable good solution to the problem of controlling the time
parameters. Matausek and Micic (1996) proposed a delay systems. This approach improves the
modified Smith predictor (MSP) for controlling higher- performance and robustness of the system in the real
order processes with integral action and long dead-time. time applications. This helps in maximized utilization
Matausek and Micic (1999) proposed a MSP with of the PLC ladder logic functions. Another important
tuning formulae. Furukawa and Shimemura (1983) part is that the cost spent on purchasing PLC software
proposed a prdeictive control mechanism to stabilize an with the non-conventional PID toolboxes can be greatly
unstable plant with time delay. Gawthrop (1977) reduced. The GE Fanuc Versamax PLC that supports
proposed a predictive controller based on adaptive least arithmetic operation and floating-point data types is
square method. Guzmán et al. (2008) presented an used to develop the control program for dead-time
interactive tool for studying and understanding the compensator. The heater-furnace system available in
different alternatives available for controlling systems the process control lab is considered for implementing
with large delay. Hagglund (1992) described a the control scheme. Therefore to eliminate the effects of
predictive PI (proportional-integral) controller with long dead-time in temperature of the heater-furnace
dead-time compensation. Hamamchi et al. (2001) system, DTC with PID controller is proposed and
considered the Coefficient Diagram Method to achieve implemented using the GE Fanuc Versamax PLC. The
a good step response to a set point change. steady-state and servo-regulatory responses of DTC-
Ingimundarson and Hägglund (2001) described tuning PID controller is validated with conventional PID
procedures for dead-time compensating controller by controller.
considering both stable and integrating processes.
Ingimundarson and Hägglund (2002) validated the MATERIALS AND METHODS
dead-time compensator (DTC) using the performance
criterion integrated absolute error when a step load Heater-furnace system: The heater-furnace (known as
disturbance is applied at the plant input. Kristiansson temperature system) system that is available in the
and Lennartson (2006) presented tuning methods for PI process control lab of the institution is used as the test
and PID controller. Kaya (2003) extended the modified system. The furnace takes considerable time to respond
PI-PD Smith predictor which leads to significant to the heat supplied by the heater. This creates a dead
improvements in the control of processes with large time in the process and is significantly high. The front
time constants. Liu et al. (2005), proposed a panel of the heater-furnace system is shown in the
proportional controller is subtly employed to stabilise Fig. 1. The system contains an electrically heated
the setpoint response and then an optimal controller is furnace, a k-type thermocouple, temperature
analytically designed for setpoint tracking. Normey- transmitter, Silicon Control Rectifier unit (SCR) and a
Rico and Camacho (2002) proposed a unified 2 degrees blower. The output range of thermocouple is 0 mV to
of freedom robust dead-time compensator, for both 49.988 mV with a temperature range of about 0 to
stable and integrative plants. Normey-Rico and 1000°C. An electrical heater is used to heat the furnace
Camacho (2008) reviewed the main dead-time and a blower is used to maintain a uniform temperature
compensators (DTC) described in literature. Palmor and around the furnace. The thermocouple senses the
Blau (1994) developed an automatic tuning algorithm temperature and the transmitter converts the mV signal
for DTC common to industrial process controllers. The
into 4 to 20 mA current standard. The transmitter output
auto-tuner is capable of setting eight tuning parameters.
is connected to the PLC analog input module. The 4 to
Pagano et al. (2001), analysed the methods of stability
20 mA output from the PLC is wired to the SCR circuit
for MSP with integrative plant. García and Albertos
which actuates the heater.
(2013) proposed a general structure to control long
time-delay plants is proposed without approximating
the delay. Rao and Chidambaram (2005) suggested a GE Fanuc Versamax PLC: The GE (General Electric)
modified form of Smith predictor for unstable processes Fanuc Versamax PLC available in the process control
with time delay. Vrečko et al. (2001) presented a new lab is chosen as controller to develop smith predictor.
MSP for processes with a long time delay as an The PLC has 16 numbers of digital inputs and 16
extension of the double controller-scheme. Watanabe numbers of digital outputs. It also has 4 analog inputs
and Ito (1981) proposed a new process-model control and 4 analog outputs. The analog Input-output module
system which can yield zero steady-state error and supports both (0-10) V range and (4-20) mA standard.
desired transient responses. The PLC supports arithmetic instructions and floating-
In the proposed approach Smith Predictor based point data types other than integer-type data. The
dead-time compensator is added to the PID control loop IC200CPU001 is used as the processor for the PLC
to eliminate effects caused by the long delay time in the module (VersaMax® PLC User's Manual, 2001).
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Fig. 1: The front panel of the heater-furnace system

The processor, input and the output modules are The following is the control equation of PID
powered by a 24 VDC power supply module. The PLC Controller which has several variants in discrete form:
has a RS 232 communication interface to communicate
with the Personal Computer (PC). The control  

 =  + 
  +   (1)
algorithm is programmed in the PC and downloaded 

into the PLC’s CPU using the RS 232 communication

interface.  =   −  (2)

PID Controller: The Proportional Integral Derivative where,

(PID) control is widely used in process industries u = The control signal
because of its simplicity, robustness and successful e = The error signal
practical application. Although advanced control yr(t) = The reference signal
techniques can show significantly improved y(t) = The process variable
performance, a PID control system can suffice for many K = The gain
industrial control loops. Although, a PID controller has Ti = The integration time
only three adjustable parameters, finding appropriate Td = The derivative time
settings is not simple, resulting in many controllers
being poorly tuned and time consuming plant tests often Thus, the PID controller can be understood as a
being necessary to obtain process parameters for controller that takes the present, the past and the future
improved controller settings. of the error into consideration. The transfer function
There are several approaches for controller tuning, GC(s) of the PID controller is:
with that based on an open-loop model being most
popular. This model is typically given in terms of the   =  1 + +   (3)

plant’s gain (K), time constant (τ) and time delay (θ).
For a given a plant model, controller settings are often 
  =  + +   (4)
obtained by direct synthesis. 

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It is difficult to obtain satisfactory performances of Effects of dead time on the system: Time delay occurs
control systems with time delay, which is a well- in the control system when there is a delay between
recognized problem in many control processes. Time command response and the start of output response.
delay, also called dead time, is mostly aroused by The delay cause a decrease phase margin which implies
transportation lags, measurement lags, analysis times, a lower damping ratio and a more
ore oscillatory response
computation and communication lags and Sensor lags. for the close-loop
loop system. Further it decreases the gain
It exists in a lot of systems such as industrial process margin thus moving the system to instability. First-
First
control systems, engineering systems, economical and order process model with dead time which is
biological systems. represented as:
These dead times can stem from process dynamics,  !
actuatorss or sampling. The delays are often either   =  (7)
"
assumed negligible or constant, but in some cases the
variance in delay times (jitter) plays a significant role. where,
There exists a variety of methods for control of time time- K : Process gain
delay systems with constant delays, but the to toolset for T : Process time constant
dealing with varying time-delays
delays is much more limited
limited. θ : Dead time constant
The general first-order order transfer function in
continuous domain is described by equation: Figure 2 depict the occurrence of oscillation with
delay which will affect the system. This will
 automatically produce more delay. Therefore
  = (5)
 eliminating the effects of dead time from the system
becomes more significant.
Dead time (θ) is the time delay between the process
and the sensor.
or. The transfer function for dead time is: time compensator with PID: A new control
Dead-time
strategy for the Dead Time Compensator (DTC) that
!
  =  (6) replaces the conventional controller by a PID structure
is proposed. The Smith Predictor is one of the most
Causes of dead time: popular dead-time compensating controller and most
widely used algorithm for dead-timetime compensation in
industry. The proposed controller uses the Smith
• Transportation lag: The Transportation Lag is the Predictor dead time compensator with PID thus
delay between the time an input signal is applied to eliminating the effect of dead time from the control
a system and the time the system reacts that input performance, meanwhile with holding the effectiveness
signal. It is common in Industrial process. of PID. This is a model-based
based controller effective for
• Sensor lag: Sensors and analyzer can take precious processes with long dead time. It has an inner loop with
time to yield their measurement
rement results a main controller that is designed without the dead time.

Fig. 2: Simulink diagram of PID controller

troller with dead time

Fig. 3: The structure of Dead time compensator (Hamamchi et al., 2001)

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Fig. 4: Equivalent form of DTC with PID

Start

Read the Controller output (CO) values for Temperature process y (n)

Initialize the Set point, Kp, Ki, Kd and Sampling Period

Read PV and CO

Feed PV to the PID Controller

PID output for without delay Process is calculated at each sampling instant

The PID output values are stored in the Register at each nth instant

Calculate the Process output without delay

An up counter which counts till 11 is energized (dead time x Samp)

PID output for with delay Process is taken from process station at each sampling time

th
The PID output values are stored in the Register at each n instant

Calculate the output for process with delay

Error obtained by the subtraction of Plant output and process output with delay

PV obtained by the addition of process without delay and model Error

PV value is given to the PID Controller Block as input

Fig. 5: Flowchart for control program

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The effects of load disturbance and modelling error 0.0497
; − 2 + 0.0449
; − 3 +
are corrected through an outer loop. Gc (s) is the transfer 0.0406
; − 4 + 0.0367
; − 5 (14)
function of the controller in continuous domain. Gp (s)
is transfer function of the plant,  ! is Dead time of where, m1(n) represents the Plant model output without
the plant. Gpm(s) represent the transfer function for the delay. The control action at the nth and (n-1)th sampling
model of the plant,  !$ is the dead time of the plant instants represented as u(n) and u(n-1) as in Eq. (14).
model. The closed loop transfer function without DTC The output from the temperature process station (4-20
would be (Hamamchi et al., 2001): mA) is given as input to the PID controller. The DTC is
designed based on the discrete transfer function as in
C (s ) G C (S )G P (S )e − θ ds (8) Eq. (14) and the control program is written in PLC
=
R (S ) 1 + G C (S )G P (S )e − θ ds using the ladder logic functions. The output of the
heater-furnace system is read through the analog input
And the closed loop characteristic equation is: module of the PLC. In each sampling time (5 Sec), the
output of the DTC is compared with the output of the
1 + G C (S )G P (S )e −θds = 0 (9) heater-furnace system. The error generated from the
comparison is summed up with the model output from
The time delay item e θ&' in characteristic the inner loop. The error output is taken as the
equation could produce phase lag and make the system measured value or process variable and given to the
unstable. Then the closed loop transfer function with PID controller. The velocity-form of PID (VFPID)
DTC is: controller is developed in PLC. In this form, instead of
the actual value of the controller output signal, its
C(S ) GC (S )GP (S )e −θds (10) change from the preceding sampling instant is
= computed.
R(S ) 1 + GC (S )GP (S ) + GC (S )GP (S )e −θds − GC (S )GPm (S )e −θdms
The tuning of VFPID for the heater-furnace system
In the case of Gp = Gpm and θd = θdm, the transfer is done using process reaction curve method (Balaji and
function can be written as: Vijayakumar, 2009). The PV (Process Variable) is
given as input to the PID controller and the above steps
( *+ *, - ./01 are repeated up to the process station reached the given
= (11) set point. Figure 5 the step-by-step procedure
) *+ *, 
implemented in developing the control program for the
The corresponding characteristic equation is: proposed DTC with PID controller is shown.

1 +    = 0 (12) RESULTS AND DISCUSSION

It can be observed that the time delay is eliminated The results obtained and the performance measures
in the characteristic Eq. (12) which will improve the of the proposed DTC with PID controller is presented
control performance significantly. From the Eq. (12), and compared with the results of the conventional
the Fig. 3 is equivalently transformed to Fig. 4 as VFPID controller. The proposed DTC with PID
follows: controller is implemented in real time for reducing the
effects of dead time in heater-furnace system.
Design and development of DTC Using PLC: The
open loop transfer function obtained from the Simulation results: The heater-furnace system is a
temperature process station is given as in Eq. (13); K= slow responding process as compared with that of a
0.61234, τ = 10.06, td = 56 sec, Where K is the process flow or level process. Therefore VFPID controller is
gain, τ is the time constant and td is the delay time. The preferred over the position-form PID (PFPID)
controller. The open-loop tuning method called process
transfer function obtained from this process parameters
reaction curve method is used to tune the gain values of
are, (Balaji and Vijayakumar, 2009):
the PID controller, (Balaji and Vijayakumar, 2009). The
.4 567 - .891
Simulink diagram of VFPID and DTC with PID
 = (13) controllers are shown in Fig. 6. The simulation result of
.4
the tuned VFPID controller is compared with the
Transfer function in Eq. (13) can be converted into simulation result of the proposed DTC with PID
discrete form using Z-transformation. The control controller.
equation for DTC for temperature process in discrete- Figure 7 shows the simulation results for
time domain from Eq. (10) is: conventional PID (VFPID) and DTC with PID which
are taken to ensure the correctness of the controller
: ; = 0.06086
; + 0.0550
; − 1 + design for the heater-furnace system with mathematical
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 Res. J. Appl. Sci. Eng. Technol., 13(2): 143-152, 2016

model. It is evident from the response shown in Fig. 7, Real-time results for VFPID: Figure 9 shows the
that the DTC with PID has performed better in steady- response of the VFPID controller with Dead time and
state conditions. The overshoot posed by VFPID is overshoot. It is seen that VFPID controller takes
completely eliminated in the simulated response of long time to reach set point and has a high
proposed DTC with PID controller. Figure 8 shows the overshoot.
error between the process model and actual heater- The Peak overshoot is about 6.25°C and the rise
furnace system. time is 9 min. The Output of the VFPID controller takes

Fig. 6: Simulink diagram for PID and proposed DTC with PID for heater-furnace system

Fig. 7: Response of VFPID and DTC with PID for temperature process
10 Error

0
Error ( °C)

90
105
120

150
165

210

300

330

360

390
405
420
30

60

135

180
195

225
240

285

315

345

375
15

45

75

255
270
0

-5

-10

-15

-20 Time (sec)

Fig. 8: Error between the actual system and system model

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Fig. 9: Response of VFPID controller

Fig. 10: Response of DTC with PID

Fig. 11: Servo-regulatory response for VFPID

Table 1: Performance comparison of time domain specifications of DTC with PID and VFPID
Type of controller Rise time (Min) Peak (°C) Over shoot (%) Settling time (Min)
DTC with PID 4 256.0 2.68 6
VFPID 9 256.0 2.40 20

20 min to reach the set point. The parameters of PID observed that there is a significant reduction in
controllers are Kp = 4; Ki = 0.001; Kd = 0.1; Sampling overshoot and settling time.
time, Ts = 5 sec. Though a peak overshoot of about 6.0°C has
occurred the rise time is just 4 min which indicate that
Real-time results for DTC with PID: The online the response of DTC with PID is faster than VFPID.
results obtained on implementing the DTC with PID for This is because of the fact that the DTC with PID has
the heater-furnace system is shown in Fig. 10. It is eliminated the effects of dead time. The settling time of
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