2 nd Mercosur Congress on Chemical Engineering 4 th Mercosur Congress on Process Systems En

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CONFIGURATION OF PID/FEEDBACK ANDPID/FEEDBACK/FEEDFORWARD CONTROLLERS IN TEMPERATURE CONTROL OF A HTST HEAT EXCHANGERMaria Isabel BERTO*1, Vivaldo SILVEIRA JR.21 Instituto de Tecnologia de Alimentos (ITAL), Grupo Especial de Engenharia (GEE)Av. Brasil, 2880 - CP 139, Campinas, SP, Brazil, 13.073-001. *Corresponding Author.- Phone Number: +55 19 3743-1828.Fax Number +55 19 3743-1834 e-mail address: miberto@.br2.Depto. Engenharia de Alimentos – UNICAMP – Rua Monteiro Lobato, 80 - CP 6121 –Barão Geraldo - Campinas – SãoPaulo – Brazil, 13.081-970. e-mail address: vivaldo@fea.unicamp.br $EVWUDFW The goal of this work was the building, instrumentation and implementation of conventional controllers in a HTST (High Temperature Short Time) continuous processing prototype of fruit juice. A plate heat exchange with three stages of heat exchange (regeneration, heating and cooling) and a holding tube were used to achieve a holding time of 40 s at 91o C, used in the processing of orange juice. Water at high temperature and propylene-glycol solution were used to heat and cool the product, respectively. The three fluid lines were instrumented and controlled according to the strategies and logics used. The control strategies and logics implemented were the conventional controllers PID/feedback and PID/feedback/feedforward. PID/feedback was tuned by the methodology of Aström et al. (1984), while PID/feedback/feedforward controller was tuned by the process reaction curve methodology with dynamic compensation. The controlled variables were the pasteurization temperature located after the holding tube, and the cooling temperature at the outlet of the pasteurizer; while the manipulated variables were the flow rates of the secondary fluids. The controls were evaluated and compared through the performance indices IAE, ITAE e ISE and through the behaviors of the manipulated variables, after step changes in the product inlet temperature. The results showed that the error of both configured controllers, kept on the process temperatures within ±0,5 o C range after the imposed step changes. The performance indices of the tested controllers presented similar values, indicating efficiency of the controllers in the maintenance of the pasteurization and cooling temperatures.Keywords: HTST, PID, feedback, feedforward, pasteurization, plate heat exchange.1. IntroductionHigher processing temperatures for a shorter time are possible if the product is sterilized before it is filled into pre-sterilized containers in a sterile atmosphere. This forms the basis of UHT processing (also termed aseptic processing). It is used to sterilize a wide range of liquid foods, including milk, fruit juices and concentrates, cream, yogurt, wine, salad dressing, egg and ice cream mix (Fellows, 2000). In orange juice pasteurization studies demonstrate that lower temperatures are sufficient to inactivate microorganism activities, although, in order to prevent the loss of cloudiness, higher temperatures are required. This loss of cloudiness has been directly related to the activity of the enzyme pectin methyl esterase (PME). Therefore, PME inactivation is generally used as an indicator of the adequacy of pasteurization because it is known to be more heat resistant than the commonmicroorganisms (Basak et al., 1996). The time temperature combination used in this study was 91o C/40s, temperature/time combination indicated in Eargman et al. (1976), Kimball (1991) and Correa Neto (1998) researches. Another factor that is also important to maintain the juice cloud stability is to make an efficient cooling process and to keep a low temperature during storage, transport and in the local market. A low and constant temperature minimizes any further change of the enzyme activity in the juice (Arbaisah et al., 1997). More than a few works about controller in pasteurization process have been made, although they are mostly focused in milk pasteurization, the use of conventional controllers and feedback strategy (Negiz et al., 1996; Negiz et al., 1998; Schlesser et al., 1997; Ibarrola et al., 1998; Shief et al., 1992).The main goal of this work is to implement and compare the efficiency of the strategies PID/feedback and PID/feedback/feedforward in controlling the pasteurization and the cooling temperatures in a plate heat exchanger. The main objective of the controllers was to keep those temperatures within the range of ±0.5o C after disturbances in the product inlet temperature. Since the juice process does not have a standard safety range, ±0.5o C was assumed, based on the maximum oscillation permitted in milk pasteurization process, according to HACCP (Hard Analysis and Critical Control Point), prescribed by FDA (Food and Drug Administration).2. Materials and Method0DWHULDOVExperimental assays were carried out in the pilot plant test in the Laboratory of Control and Automation of Food Process, in the Food Engineering Department of the State University of Campinas (UNICAMP), in Campinas, São Paulo, Brazil. The pilot plant consists of a pasteurization system, with a three - stage pasteurizer (regeneration, heating, cooling) and a holding tube (GEA Tuchennhagen do Brasil Ltda, Campinas, SP, Brazil), linked with the secondary fluid systems. The three fluid systems (product, heating water and refrigerant solution) were equipped with temperature, pressure and flow sensors and with variable speed pumps. The instrumentation, automation and control system used were hybrid, equipped with both analogical and Fieldbus Foundation technologies. Aimax for Windows®was the supervising MMI (Man-Machine Interface) used for the remote supervision of the process. Figure 1 shows the flow configuration of the pasteurizer used.'HVFULSWLR n RI WKH SODQWThe HTST pilot plant was dimensioned to work with 150L/h of product flow rate, and with the time/temperature combination of 91o C/40 s, applied to the pasteurization process of orange juice at 12o Brix. A diagram of the plant is shown in Figure 1. The raw product was stored in tanks TQ-401 and TQ-402, from where it was pumped to the pasteurizer. The first stage is the regenerator where the raw product was heated to an intermediate temperature using otherwise wasted energy from the pasteurized product. In the second stage, the preheated product was heated to the pasteurization temperature using a hot water flow coming from a closed circuit composed of a tank with electrical resistances. In the holding tube, thermically insulated, the product was kept in the pasteurization temperature during the required time (40 s). If the product temperature verified by the sensor installed in the end of this holding tube (TE408) was bellow the set point, a divert valve (V3V) wouldreturn the product to the raw tank. The pasteurized product, whose temperature is above the set point, was sent back to the other side of the regeneration section to be pre-cooled. The last stage was the cooling section, where propylene glycol at 25%m/m was responsible to cool the product to the storage temperature. The final product was stored in a tank TQ-403.Fig. 1. PHE flow configurationTwo controllers were configured to keep the set point of the hot water temperature in the heat system. The first one was an on-off type, installed in the resistance (RET601) located in the water tank. It maintains the water temperature (TE601) within ±2o C range of its set point. The second one is a PID controller that kept the water temperature (TE602) on its set point adjusting the potency of a 2500 W resistance (REM-601) located at 20 cm from the inlet of the heat stage.Fig. 2. Process diagramTable 1 shows the temperatures and fluid flow rates used to satisfy the time/temperature combination of the HTST pasteurization proposed in this process. In those experimental assays where the controllers were configured and tuned, water was used to substitute the product because of the extensive number of experiments.This substitution was adopted since the orange juice drink has low soluble solid contents, making its thermo physical and rheological properties similar to the water properties.7DEOH Operational conditions at steady state of the proposed HTST processRegeneration stage Heat stageCooling stageProductRaw product PasteurizedproductPre-heated product Heating water Propylene glycol solution Cooled productFlow rate (L/h) 150 150 150 483 1920 150 Inlet temperature (o C) 26.2 (TE405) 91.0(TE408) 61.8 (TE406) 96.2 (TE602) -1.7 (TE304) 54.3 (TE409) Outlet temperature (oC) 61.8 (TE406) 54.3(TE409)91.5 (TE407) 87.2 (TE603)2.5 (TE305) 8.9 (TE410)0HWKRGRORJ\Controller tuningHeat and cooling sections were analyzed separately during the configuration and tuning essays to prevent the influence of the regeneration stage. In the case of the heating section, the divert valve was kept permanently closed to conduct the pasteurized product to the tank TQ-403 preventing it from returning to the regeneration stage after passing through the holding tube. In the case of the cooling section, the hot water was turned off to allow the product passage through the regeneration and heat section with the same temperature.In order to have the product coming into the sections with the same temperature of the steady state, the product stored in tank TQ401 was pre-heated to the same inlet temperature as described in Table 1: 61.8 oC for the assays made in the heating stage and 54.3 oC for the assays made in the cooling stage.PID/feedback tuningIn both stages, the PID/feedback strategy was tuned according to Aström et al. (1984) methodology. This methodology consists of imposing oscillations to the manipulated variable (secondary fluid flow rate) and registering the process variable behavior (pasteurization or cooling temperature), in order to obtain critical gain (K cr ) and critical period (P cr ). These parameters are used to calculate the suggested PID parameters (K c , τi e τd ). In the heat section, an oscillation of ±95 L/h was provoked toward the set point of the hot water flow rate (483 L/h) in the period of 30 s. During those tests, the PID controller tuned by Berto, (2004) kept the changes in the inlet hot water temperature within the range of ±0.5 oC. In the case of the cooling temperature, the flow rate of propylene glycol solution was the manipulated variable. An oscillation of ±550 L/h was provoked toward the set point of these flow rate (1920 L/h) at the period of time of 30 s. The temperature of the inlet propylene glycol solution (TE 304) was also kept within the range of ±0.5 o C, by the PID controller tuned by Silva (2003).PID/feedback/feedforward tuningPID/feedback/feedforward controller was tuned according the dynamic method of lead/lag time unit (LLAG), detailed in Ogunnaike et al. (1994). This methodology consists in the configuration of the PID feedforward parameters by imposing step changes in the external variable of the system (inlet product raw temperature) and in the manipulated variable (secondary fluid flow rate) in order to obtain the process reaction curves. The magnitude of these step changes must be chosen based in the assumption that they must be as small as possible to make a measurable change in the controlled variable. Therefore, the graphic parameters of these two curves are used to calculate the PID/feedforward constants (K df , τdf e t df ).The design of the PID/feedback/feedforward in the fieldbus system consists of specifying in the configuration software the parameters K c , τi e τd of feedback strategy, and the term K df of the feedforward strategy. The tuning of the feedforward controller in the heat section was made using the process reaction curves obtained after step changes of 96.7 L/h in the hot water flow rate and +10.1oC in the inlet product temperature. In order to tune the controller of cooling temperature, a step change of 461 L/h at propylene glycol flow rate and +8.3 at inlet product temperature were imposed to obtain the process reaction curves used in parameters estimation.Step changes assaysThe efficiency of the implemented controllers was evaluated after step changes in the inlet product temperature (TE405). Although these disturbances were not a perfect step change, they were considered as so, to allow the analyses results. They were imposed through changing the tank of raw product through the pneumatic valves (VP401 e VP402). This step changes were done after the temperatures and fluid flow rates of steady state showed in Table 1 were obtained. The controllers were tested and the parameters were modified in case the controlled temperatures diverged more than ±0.5oC. Table 2 shows the magnitude of the step changes made in the system after the controllers tuned.The controllers were evaluated and compared through the behaviors of the manipulated variables, after disturbances in the product inlet temperature and through performance indices IAE (Integral Absolute Error), ITAE (Integral Time Absolute Error) e ISE (Integral Square Error) calculated according to Coughanowr & Koppel (1978). As shown in Table 2, the step changes made were not the same. This fact is due to the experimental difficulties to control the temperature in the jacket of the raw product tank. Therefore, the performance indices (IE) were calculated in reference to the step change made (A IE IE R =), where A is the magnitude of the step change imposed in the system.Table 2. Step changes imposed in the inlet product temperature to evaluate the PID/feedback and PID/feedback/feedforwardcontrollersStep change magnitude (ºC) PID/feedbackPID/feedback/feedforwardPositive step change 8.1 6.8 Negative step change-7.9 -6.53. Results and Discussion3.1. Controller tuningFeedback controllerAn oscillation of ±95 L/h was provoked toward the set point of the hot water flow rate (483 L/h) in a period of 30 s. Table 3 shows critical gain (K cr ), critical period (P cr ) and the PID parameters (K c , τi e τd ) calculated by Aström et al. (1984) methodology (calculated values) and the re-tuned values. According to assays done in pilot plant, the calculated proportional gain of PID/feedback controller had to be decreased from 17.4 to 9.0 to minimize oscillations in pasteurization temperature. In the cooling stage, the oscillation of ±550 L/h provoked toward the set point of the flow rate of propylene glycol solution generated the parameters shown in the same table. Since the controller worked satisfactorily, in this case the PID parameters were not modified.These results showed that the tuning methodology of Aström et al. (1984) used to configure PID/feedback parameters is quite efficient, since it was necessary to modify only the proportional gain to have oscillations in pasteurization temperature within the range of ±0.5oC. More than that, parameters calculated in cooling temperature controller were not modified in order to work satisfactorily. These results confirmed the effectiveness of this methodology, already analyzed by Berto et al. (2004).Table 3. Parameters of the tuning of PID/feedback controller in the heat section.Heat sectionCooling section ParametersCalculated values Re-tuned values Calculated values used without re-tuning Critical period - P cr (s) 60.0 60.0 Critical gain K cr , (ºC/Hz)28.94 20.5 Proportional gain, K c , (ºC/Hz) 17.4 9.0 12.3 τi (s) 30.0 30.0 30.0 τd (s)7.57.5 7.5PID/feedback/feedforward controllerTable 4 shows the parameter K df of the feedforward strategy calculated according to LLAG method and used together with PID/Feedback ones, K c , τi e τd (Table 3) to configure the controllers of heat and cooling sections.Table 4. Parameters K df of PID/ feedforward controller.Heat section.Cooling section.Calculated values Re-tuned values Calculated values Re-tuned values K c-ff 2.9 0.5 10.0 0.9According to these results it was realized that the calculated proportional gain of feedforward strategy (K cff ) through the methodology used had to be reduced 6 times in the case of pasteurization temperature controller and 11 times in the cooling temperature controller. Experiments done showed that the higher the term K cff , the greater the oscillations on temperature after imposing step changes in the process. The small values of the re-tunedparameters, 0.5 and 0.9 for heat and cooling section respectively, indicated that the feedback strategy is mostly sufficient to maintain the controlled temperatures within the desired security range.Step changes assaysNext figures shows the step changes imposed in the system, and the behavior of the difference of secondary fluid flow rate (∆V = V-Vsp) actuated by controllers, to maintain the process temperature. The difference of inlet secondary fluid temperatures (∆T = T-T sp ) were also plotted to show that they kept within the range of 0.5ºC. Figures 3 and 4 show the PID/feedback tuned in the heat stage, to control the pasteurization temperature after step changes made in the inlet temperature (∆Tp) of +8,1 e –7,9 oC toward the set point of steady state.∆V (L /h )E r r o r =T -T s p (oC )Time(min)∆T (oC )∆T (oC )Fig. 3. PID/feedback controller of heat stage: step change of +8.1 ºC in the inlet product temperature (∆T p ), difference of hotwater flow rate (∆V wh ) and difference of inlet hot water temperature (∆T Wh).-0,4-0,20,00,20,4∆V (L /h )E r r o r =T -T s p (oC )Time(min)20406080∆T (oC )∆T (oC )-0,8-0,40,00,40,8Fig. 4. PID/feedback controller of heat stage: step change of -7.9 ºC in the inlet product temperature (∆Tp), difference ofhot water flow rate (∆Vwh) and difference of inlet hot water temperature (∆TWh).Figures 5 and 6 show the same parameters of PID/feedback/feedforward controller, after step changes madein the inlet temperature (∆T p ) of +7,1 e –6,6 oC toward the set point of steady state.∆V (L /h )E r r o r =T -T s p (oC )Time(min)∆T (oC )∆T (oC )Fig. 5. PID/feedback/feedforward controller of heat stage: s tep change of +6.8 ºC in the inlet product temperature (∆Tp),difference of hot water flow rate (∆Vwh) and difference of inlet hot water temperature (∆TWh).∆V (L /h )E r r o r =T -T s p (oC )Time(min)∆T (oC )∆T (oC )Fig. 6. PID/feedback/feedforward controller of heat stage: step change of -6.5 ºC in the inlet product temperature (∆Tp),difference of hot water flow rate (∆Vwh) and difference of inlet hot water temperature (∆TWh).Figure 7 show the behavior of PID/feedback controller tuned in the cooling stage after a step change of+8.1ºC made in the product inlet temperature (∆T p ). The others related behaviors of PID/feedback and PID/feedback/feedforward controllers tuned in cooling stage can be seen in Berto (2004).∆V (L /h )E r r o r =T -T s p (oC )Time(min)∆T (oC )∆T (oC )Fig. 7. PID/feedback controller of cooling stage: step change of +8.1 ºC in the inlet product temperature (∆Tp), differenceof propylene glycol flow rate (∆Vpg) and difference of inlet propylene glycol temperature (∆Tpg).Table 5 show the relative performance indices (ISE R , IAE R e ITAE R ) for each step change made in the system,for each configured controller. The parameters maximum overshoot (Mp), peak time (t p ) and setting time at 0.1 oC (t s ) were also identified and showed in the same Table.Table 5. Relative performance indices of PID/feedback and PID/feedback/feedforward controllersPID/feedback PID/feedback/feedforwardHeating stage Cooling stage Heating stage Cooling stage Step change (+) (-) (+) (-) (+) (-) (+) (-) Intensity (ºC) 8.1 -7.9 8.1 -7.9 6.8 -6.5 6.8 -6.5 ISE R (ºC 2s/ºC) 0.004 0.05 0.280.10 0.08 0.06 0.07 0.14 IAE R (ºCs /ºC) 6.05 9.11 18.77 8.577.63 6.00 9.35 11.45 ITAE R (ºCs 2/ºC) 32.94 35.65 88.21 27.43 31.68 23.44 49.51 67.23 t p (min) 2.25 2.15 2.25 1.602.25 2.85 2.25 1.65 Mp (ºC)0.2 -0.2 0.4 -0.3 0.2 -0.3 0.2 -0.3 t s(min) 4.2 4.4 7.7 5.1 5.85 6.15 6.2 4.8By analyzing Figures 3 to 7 and Tables 5 it is possible to conclude that both strategies were adequate to keep the process temperatures within the range of 0.5ºC. It is possible to observe that the PID/feedback controller configured in the heat section presented lower values of relative performance indices, setting time and maximum overshoot than the PID/feedback/feedforward values. On the other hand, in the case of the cooling temperature the inverse was noticed: lower values for these parameters were calculated for this strategy. Although, the proximity of the relative performance indices demonstrate that it is not possible to confirm the superiority of one out of the two strategies.4. ConclusionThe PID/feedback and PID/feedback/feedforward controllers were implemented in a HTST (High Temperature Short Time) continuous processing prototype of fruit juice. PID/feedback was tuned by the methodology of Aström et al. (1984), while PID/feedback/feedforward controller was tuned by the process reaction curve methodology with dynamic compensation. The efficiency of both controllers were evaluated and compared in order to maintain the pasteurization and cooling temperatures after step changes imposed in the inletraw product temperature. Relative performance indices, IAER , ITAERe ISERcalculated were similar for bothcontroller, however lower values were noticed in the PID/feedback configured for the pasteurization temperature controller while PID/feedback/feedforward presented lower values of these indices for the cooling temperature controller. Nevertheless, the proximity of the relative performance indices demonstrates that it is not possible to confirm the superiority of one out of the two strategies.ReferencesArbaisah, S. M.; Asbi, B. A.; Junainah, A. H.; Jamilah, B.; Kennedy, J. F. (1997) Soursop pectinesterases: Thermostability and effect on cloud stability of soursop juice. Carboydrates Polymers, 34, 177-182Aström, K. J.; Hägglund, T. (1984) Automatic tunning of simple regulators with specifications on phase and amplitude margins. Automatica, 20 (5), 645-651Basak, S.; Ramaswamy, H. S. (1996) Ultra high pressure treatment of orange juice: A kinetic study on inactivation of pectin methyl esterase. Food Research International, 29 (7), 601-607Berto, M. I. (2004) Avaliação experimental do controle da pasteurização contínua de um fluido modelo de suco de laranja.Tese (Doutor em Engenharia de Alimentos) - Departamento de Engenharia de Alimentos, Universidade Estadual de Campinas, 271p.Berto, M. I.; Sá, F. R.; Silveira Junior, V. (2004) Avaliação de controles pid adaptativos para um sistema de aquecimento resistivo de água. Ciência e Tecnologia de Alimentos, 24 (3), 478-485Correa Neto, R. D. S. (1998) Processamento de suco de laranja pasteurizado em garrafas depolietileno tereftalato (pet).Dissertação (Mestre em Tecnologia de Alimentos) - Tecnologia de Alimentos, UNICAMP, 88p.Eargman, B. A.; Rouse, A. H. (1976) Heat inactivation temperature-time relationships for pectinesterase inactivation in citrus juice. Journal of Food Science, 41 (6), 1396-1397Fellows, P. (2000) Food processing technology. 2 ed. Boca Raton: CRC PressIbarrola, J. J.; Guillén, J. C.; Sandoval, J. 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C.; Ferng, L. H. (1992) Application of a fuzzy logic controller in temperature control of a pilot high-temperature short-time heat exchanger. Food Control, 2, 91-96Silva, F. V. D. (2003) Comparação do desempenho de um sistema de refrigeração para resfriamento de líquido controlado a diferentes modos de controle. Tese (Doutor em Engenharia de Alimentos) - Departamento de Engenharia de Alimentos, Universidade Estadual de Campinas, 327p.AcknowledgmentThe authors would like to thank The State of São Paulo Research Foundation, FAPESP (00/00437-0) for financial support.。