Design and Implementation of Optimal PID Controller Using PLC for Al-Tahady ESP

The electrostatic precipitator (ESP) is an extensively used system in metallurgical industries and the generation of power to decrease the release of dust in the flue gas. In the design of the Electrostatic precipitator unit, gas emission uniform distribution is expected to fulfil its best aggregation performance. Programming Logic Controller (PLC) is a controller for industrial process automation and self-monitoring. A lot of industries utilized PLC to automatically control the entire process with less involvement from the human and to evade errors. In this paper, A mathematical model for Electrostatic precipitator from physical parameters and analysis has been developed. The controller is built depending on this model using the basic principle of a well-known A Proportional Integral Derivative (PID) controller to control the high voltage of the Electrostatic precipitator (ESP) by adjusting the opening of voltage and current by applying analogue signals (4-20 mA) from output cards of the PLC. The simulation results paved the way to build a practical system. building the mathematical model by using the Identification Toolbox of MATLAB® Version 9.6. The system was built using Allen Bradley PLC. The effect of control parameters (PID) in the case of voltage or current has been studied to demonstrate the efficiency of the model for the precipitator and observer in the case of the control system for the Al-Tahady ESP. The PID controller was built and the best values for the Electrostatic Precipitator controller are (KP=2.3904, KI=3.5382, KD=0.3). PID controller reduces steady-state errors.