Tuning Generalized Predictive PI controllers for process control applications

Predictive PI (PPI) controllers have demonstrated to exceed traditional PID controllers when they are applied to systems with long delays. This work proposes a new controller structure and tuning that we call Generalized Predictive PI (GPPI) controller which provides greater design flexibility than PI and PPI strategies. To realize a fair comparison, the design and tuning rules for discrete PI and PPI controllers were developed using optimal arguments based on the root-locus, for critically damped response before a step change in the reference. Experimental results, using industrial equipment, have illustrated the tuning methodology and the performance of the proposed controller under real conditions. Flow and water level process in a laboratory flume were considered. For these processes, First Order Plus Time Delay (FOPTD) models are used. The GPPI control results are encouraging, reducing the settling time plus a very small overshoot before step change in the reference regarding the PI and PPI strategies, up to 41.03% for the flow control loop and up to 54.21% for the level control loop. The discrete analysis of the strategies in the Z plane was performed, allowing for a direct translation to recursive equations that can then be programmed into a Programmable Logic Controller (PLC), other industrial controllers such as Distributed Control Systems (DSC), or microcontrollers, such as Arduino, Raspberry or FPGA. This is an important result, since it demonstrates that the increased complexity of the proposed controller does not hamper its implementation in industrial controller systems. In this work, we used a Rockwell ControlLogix \protect \relax \special {t4ht=®} PLC with Structured Text programming language. •Systems with long time delays are particularly challenging for a PID controller.•The Predictive PI controller has been previously proposed as a PID alternative.•The Generalized PPI controller proposed here extends on the PPI controller..•The Generalized PPI controller offers more performance design freedom.•The Generalized PPI controller introduces a limited increase in complexity.•Experimental verification shows superior performance of the GPPI controller.