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SYSTEM IDENTIFICATION MODELLING AND IMC BASED
PID CONTROL OF IMPRESSED CURRENT CATHODIC
PROTECTION SYSTEMS
EzzEldin Balla1 and MohdFua’ad Rahmat
2
1Engineering Department, Petrolinesfor Pipes and Engineering Works Holding Co.
St. 29 -Amarat, Khartoum, P.O. Box 1704, Sudan
2Department of Control and Mechatronics Engineering, Faculty of Electrical Engineering
Universiti Teknologi Malaysia, 81310 Skudai, Malaysia
Emails: [email protected], [email protected]
Correspondent author: M.F. Rahmat, [email protected]
Submitted: July 17, 2013 Accepted: Nov. 4, 2013 Published: Dec. 16, 2013
Abstract- Impressed Current Cathodic Protection (ICCP) system is the most practical method of
cathodic protection systems. This system is widely used to prevent the external corrosion of carbon steel
structures; especially those are used in underground oil and gas pipelines. In this paper, the theoretical
background, principles and concepts of ICCP systems have been discussed. An effective laboratory
scale for ICCP systems was built according to specific concepts has been clarified. Consequently,the
parametric model of this system was obtained using System Identification (SI)
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approach.Furthermore,an Internal Model Control based Proportional Integral Derivative (IMC-PID)
controller has been designed for enhancingthe performance of ICCP systems.Additionally, simulation
and onlineimplementation works have been carried out to control ICCP systems at different operating
conditions. Nevertheless, the IMC-PID controller leads todecrease both the Integral of the Absolute
Error (IAE) and the Steady State Error (SSE) which are lower values compared to the open loop
system.
Index terms:Impressed Current Cathodic Protection (ICCP) system; System Identification (SI);Internal
Model Control (IMC);Proportional Integral Derivative (PID) Control.
I. INTRODUCTION
Pipeline infrastructure has become a very popular tool for transferring and distributing oil, gas
and raw materials. Many of these pipelines extend along hundreds of miles and pass through
remote, harsh and corrosive areas which raise the prospect of cracks in their walls and cause
leaks. In case of pipelines fail due to corrosion resulting in leakage, they will often lead to loss of
products followed by environmental and financial damages on a national scale. Therefore,
protecting materials and structures against corrosion is a significant issue especially in tropical
countries such as Malaysia which has a high humid climate (corrosiveness factor). This latest,
promotes the need for specialized research to be done for preventing corrosion.
Basically, the materials corrosion phenomenon is an extremely significant problem as corrosion
weakens strength and cause failure on material. The general definition of corrosion is dissolution
or destruction of a material as a result of electrochemical reactions with its environment. Most of
the materials which undergo corrosion are metals; hence most of the corrosion definitions have
been specified to metals [1]. However, the definitions of corrosion encompass all materials;this
paper isfocused on metal-corrosion which is linked to the carbon steel that is used in underground
pipelines. In fact, soil corrosiveness varies over a wide rangedue to differences in its
compositions and solutions. Moreover, there are many factors affect the corrosiveness of the soil
such as resistivity, humidity, chlorides, sulfates, temperature and pH [2].
Several approaches have been used to protect materials against corrosion, for an instant, coating
system, cathodic and anodic protection systems. However, cathodic protection has a great history
back to around two centuries. Sir Humphry Davy reported in 1824 that “copper could be
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successfully protected against corrosion by coupling it to iron or zinc” [3].In general, cathodic
protection (CP) is a technique has been used to prevent metal corrosion by making it a cathode of
an electrochemical cell. This technique is universally used in protecting the external surface of
underground pipelines, underground storage tanks, ship hulls and sub-sea structures, etc. CP
systems weremainly used to avoid further corrosion after repairing damaged structures. However,
recently cathodic protection has been developed to prevent corrosion from being started or once it
occurs by applying one of its two methods; galvanic anode (GA) and impressed current cathodic
protection (ICCP)and more details in [4, 5].
Subsequently, the development of ICCP system control has become an interesting area of
research as a result of extremely needs of highly efficient corrosion protection
systems.Basically,the potential required for cathodic protection depends upon the steel being
protected from the environment. The output voltage of CP stationsmust be controlledon a desired
reference voltage(set point) to handle one of the protection criteria;potential shift, on potential
and off potential [6].In actual fact, TR units with high output voltage require high control
performance to maintain the correct output voltage. Moreover, applying the classical control
based on trial and error have shown significant overshoot and oscillation in the output potential.
For these reasons, more works regarding the tuning of the output of TR units are needed to
achieve better accuracy and performance[7].
Recently, Internal Model Control design forProportional Integral Derivative (IMC-PID)
controller tuning has become an active research area as an extension or application of model
based control techniques. The IMC-PID control is very simple to implement as only one
parameter need to be tuned to achieve an adequate performance[8].Accordingly, this paper
proposes online implementation of IMC-PID controller for SISO ICCP lab-scale system.
The paper is organized as follows: In section II, the concepts for lab-scale design to model ICCP
Systems has been clarified. Experimental setup for data acquisition and control designis
presented in section III. In section IV, the modelling of ICCP systems has been discussed.
Section V and section VI about the IMC based PID control and Simulation & experimental
results, respectively. The study has been concluded in section VII.
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II. THE CONCEPTS FOR LAB-SCALE DESIGN TO MODEL ICCP SYSTEMS
Pipelines are mainly made of carbon steel and coated with materials that protect them from the
chemical reactions with thecomponents of their surrounding environment. Fundamentally,the
corrosion rate of these coating materials is linked with corrosiveness factors. Example of this, the
soil variations causes potential differences (electrochemical force) on the metal surface and
resulting in corrosion cells. Accordingly,there are many types of electrochemical corrosion cells
which becomemore risky when their anodes are relatively small and the soil resistivity is very
low [9]. Mainly, ICCP systems work as a backup to the coating systems in oil and gas industries,
because of the fact that in these industries they can not fully guaranteethat pipelines are well
coated especially after the construction stages often coating defects may be produced. In addition,
well coated pipelines may develop areas of failure after a period of time and become desponded
[10]. Unfortunately, these pipelines run for thousands of miles, hence their coating defects are
difficult to find and very costly to repair.Figure 1 shows the schematic diagram of coating defects
when the coating became disbonded and there is a holiday.
Figure 1. The schematic diagram of coating defects
Accordingly, an ICCP system is introduced to solve coating defect problems and to provide an
adequate corrosion protection. ICCP systems send out direct current which is searching for a
return path to complete an electrochemical circuit. This current will keep searching out any
coating defects through which it can reach the externalsurface of the steelpipeline as it shown in
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figure2.The impressed current changes the pH of the water to higher or more alkaline level as a
result of an electrochemical reaction. At higher pH level (9 or above) steel corrosion will be
reduced to a very small amount [10, 11].In other words, the corrosion protection will be achieved
by using the ICCP system, if its electron source is sufficient to raise the potential of the protect
metal to a level at which corrosion is not occurring or negligible.In the case of well coated
pipeline which has no defects a very little impressed current may be used.
Figure 2. An ICCP system with coating defect
Based on these concepts,an ICCP system lab-scale has been designedandfigure 3 illustrates its
general block diagram which consists of; steel structure (Cathode), an anode which can be any
metal, reference electrode (RE) for measuring steel to electrolyte potential, data acquisition card
(DAQ) as an interfacing module between the ICCP system and personal computer (PC) that
provides the interfacing software for data acquisition and control [12]. The ICCP laboratory scale
system has been used for a black box system identification and online implementation of
IMC-PID controller as well.
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Figure 3. General block diagram of ICCP systems lab-scale
III. EXPERIMENTAL SETUPFOR DATA ACQUISITION AND CONTROL DESIGN
Experimental works have been carried out to build an effective laboratory scale for impressed
current cathodic protection system. Certainly, the lab-scale design in this paper is based on the
discussed concepts in section II. The laboratory works consist of the following tasks, but not
limited to:
1) Materials and coating selection.
2) Preparation of electrolyte and solution.
3) Data Acquisition Cards selection.
4) Measurement device selection.
5) Voltage and potential measurement.
Basically, the lab-scale has been designed to model the dynamic characteristics of ICCP systems
for underground coated steel pipelines. It is assumed that the coating system has failed or
disbonded and water enters the affected area in order to create corrosion activates. Based on these
assumptions, the ICCP system will be activated as a backup of the coating system in protecting
the steel pipelines; otherwise the ICCP system is deactivated or shielded. Consequently, the
coating defect in this experimental setup was represented by approximately 3% bare steel area
and figure 4 shows the components of the designed ICCP systems lab-scale.
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Figure 4.Components of ICCP systems lab-scale
The ICCP system lab-scale consists of the following materials and specifications:
1) Polyvinyl chloride (PVC) coated Steel pipewith specification of; 270 mm length, 19 mm
outside diameter, 17.5 mm inside diameter and Table 1 shows its chemical composition.
2) Cast iron anode with specification of; 30 mm length, 13 mm width, 3 mm thickness and
chemical compositionas it is shown in Table 2.
3) Copper/ copper sulphite reference electrode (CCSRE) for measuring pipe to soil potential,
and itis located in fixed position close to the pipe.
4) NI DAQ as a direct current source and an interfacing module between the ICCP system
and the computer for data acquisition.
5) Plastic box contains amount of soil with specification of; 30 mm length, 13 mm width, 70
mm depth and the soil resistivity is negligible.
6) Test post for potential measurement.
7) Connection cables.
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Table 1: Chemical composition of the steel pipe
Fe % C% Mn% Si% Cu% Sn% Ni Others
99.2 0.05 0.23 0.04 0.15 0.06 0.07 0.2
Table 2: Chemical composition of the cast iron anode
Fe % C% Mn% Si% Cu% Zn% P% Cr% Mo%
Balance 0.75 1.5 14.2 0.018 0.14 0.008 5 0.02
Figure 5 shows the final setup of the ICCP lab-scale after submerged both of the steel pipe and
the anode. In addition, a small amount of water has been added to the system for activating the
coating defect and providing more accurate potential measurement.
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Figure 5. The final setup of the ICCP system lab-scale
Both LabVIEW and MATLAB software were used as a means of data acquisition for system
identification process and control design. Accordingly, two different national instruments (NI)
data acquisition cards have been used (NI USB cDAQ 9172 and NI PCI-6221). Additionally,
differential measurement has been used to acquire the output potential and the measurement
cables are connected to measure the potential with a positive value.
IV. MODELLING OF ICCP SYSTEMS
A. SAMPLING TIME FOR DATA ACQUISITION
Step input signal with amplitude 2.5 volts was applied to the ICCP system laboratory scale for
analyzing its transient response to obtain sampling time for data acquisition, and figure 6 shows
its response.
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Figure 6.The step response of the ICCP lab-scale system
From figure 6, the rise time is approximately 0.5 seconds.For identifying the sampling time,
lots of published literature recommended that the sampling time( ) should be less than the rise
time as it is shown in Equation 1 and Equation 2 [13].
(1)
Or
(2)
Thus:
= 0.5 / 5 = 0.1 seconds (3)
Therefore, the sampling time for data acquisition is chosen to be 0.1 seconds as the system is
under investigation.
B. INPUT SIGNAL FOR SYSTEM IDENTIFICATION
The Pseudo Random Binary Sequence (PRBS) has been used as an excitation input signal to the
ICCP system. The PRBS is the forcing function thatis widely used in statistical system testing
and it has been designed as it follows:
(4)
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 50
0.5
1
1.5
2
2.5
3
Time (s)
DC
Vol
tage
/ P
ipe
to S
oil P
oten
tial
(Vol
t)
Step Input and Output Response of ICCP Lab-scale
Step Input
Output Response
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( (5)
Where, N is the number of shift register cells which are equal 6 and the test duration is 126
seconds[13].Totally 10 trials are carried out with 63 bits PRBS signal with bit interval equal 2
seconds and amplitude ( 1.7 – 5 ) volts to keep the output potential fluctuating within the
protection range ( 0.85 – 1.15 ).
C. MODEL STRUCTURE SELECTION
The open loop response ofthe ICCP system has shown significant overshoot and oscillation while
obtaining itsstep response. The noise in the ICCP System is the main cause of its output
oscillation. Accordingly, auto-regressive moving average with exogenous input (ARMAX)
model has been selected as the model structure of ICCP systems,sincethe characteristics of the
noise is taken into consideration. Figure 7and Equation 6 illustrate the general structure of
ARMAX models.
Figure 7.The general structure of ARMAX models
(6)
A, B and C are the system polynomials in the time-shift operator as are defined in Equation 7,
8 and 9, respectively. The polynomial A is monic and coprime in relation to B and k represents
the system delay in samples of time.Whereas, y (t) is the plant output, u (t) the excitation signal
and ζ(t) is an uncorrelated zero mean random sequence [14].
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(7)
(8)
(9)
Where, is the number of poles, is the number ofzeroes , is the number of coefficients
inthe polynomial C and is a delay component which represents thedelay from input to output.
D. MODEL ESTIMATION
The identification of a dynamic system is the process ofdetermining the transfer function or
equivalent mathematical model of its dynamic characteristicsthrough experiments onthe plant
which is considered a black box system. As a result of this process, a number ofparameters will
be generated and consequently themodel of the system can be estimated. In this
study,experiments were conducted starting with collecting theinput and output data based on an
open loop systemwitha sampling period 0.1 seconds. This data wassplitted into two parts, the first
part is usedformodel estimation and the second part for model validation[14, 15].The model
estimation has been done off-line using MATLAB system identification toolbox and figure 8
shows theICCP system input signal with the corresponding output signal.
Figure 8. Experimental input and output signals of the ICCP system
20 40 60 80 100 1200.8
0.9
1
1.1
P/S
Pote
ntial
Experimental Output of ICCP Lab-scale System
20 40 60 80 100 120
2
3
4
5
Time (s)
DC
Voltage
63 Bit PRBS Signals
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The main objective of the system identification approach is to obtain a parsimonious model
‘model with a few parameters as possible’ that adequately representing the system. Accordingly,
a second order ARMAX model has been selected over the estimated models (polynomial models)
using prediction-error identification method (PEM) asa means of parameter estimation
method.Consequently, the monic polynomials which are obtained from this identification process
where , , and aredefined as follows:
(10)
(11)
(12)
Basically, the ARMAX model structure consists of two transfer functions (TF); deterministic TF
between the input and the output, and stochastic TF between the noise and the output.
However,the obtained ICCP modelcan be represented bythe deterministic transfer
function .Thus, the continuous transfer function can be obtainedby using zero order hold
(ZOH) conversion method with sampling time, .
E. MODEL VALIDATION
Figure 9indicates that the estimated model output is tracking theexperimental output data with
best of 91.66 %andfinal prediction error (FPE)0.00003.
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Figure 9. Experimental and simulated output
The model is stable, minimum phase system andthe autocorrelation of the residuals for the output
(whiteness test)indicated that the residuals are uncorrelatedas it is shown in figure 10.In addition,
the cross-correlation of the residuals with the input (independence test) showed no correlation
between the residuals and the inputs. These tests and resultsdemonstratedthat the obtained model
is a good model to represent ICCP systems in simulation and control design.
Figure 10. ICCP model residuals
60 70 80 90 100 110 120 130 140-0.15
-0.1
-0.05
0
0.05
0.1
0.15
0.2
Time (s)
Am
plit
ude (
Volt)
Experimental and Simulated Output
Model Output
Experimental Output
-20 -15 -10 -5 0 5 10 15 20-0.2
-0.1
0
0.1
0.2
Autocorrelation of residuals for output P/S Potential
-20 -15 -10 -5 0 5 10 15 20-0.2
-0.1
0
0.1
0.2
Samples
Cross correlation for input DC Voltage and output P/S Potential resids
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V. IMC BASED PID CONTROL
A. INTERNAL MODEL CONTROL (IMC)
In IMC control [8, 16], the model process is equal to the process transfer function
as it is shown in figure 11.
Figure 11. IMC controller structure
To obtain the controller , factorizing the model process into invertible and non-
invertible parts as it follows:
(15)
Eliminating the non-invertible part as it will lead to instability and realization issues if
inverted, and taking into consideration only the invertible part ) which is stable and
causal.The controller is set to be equal to the inverse of the invertible part as:
(16)
This controller in is not enough to ensure the stability of the closed loop system. To ensure a
stable system, a filter must be designed.
(17)
Where is the filter parameter and n is the filter order.
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Then, the stable controller will be given by:
(18)
B. IMC-PID CONTROLLER TUNING
The PID parameter tuning law based on the relationship of the IMC and the PID controller has
been proposed by Rivera et al. [16]. Consider a second-order process model is given by:
Where, , ,
Then:
(20)
Using a first order filter :
Then:
Solving for the classical feedback controllerleads to a tuning rules for an idealPID controller:
Given:
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Then, IMC-PID parameters can be defended as it follows:
Where , and are proportional gain, integral time and derivative time, respectively.
VI. SIMULATION AND EXPERIMENTAL RESULTS
The obtainedICCP system modelcan be defined asthe form of the second order system in
Equation 19as it follows:
Accordingly, IMC-PID parameters can be achievedusing the tuning parameterswhich are
discussed in section V.Table 3shows the tuned PID parameters of IMC-PID controller when the
filter parameter is selected to be equal 0.3.
Table 3:IMC-PID controllerparameters
PID Parameters IMC-PID ParametersValues
Proportional Gain 1.43
Integral Time 0.043
Derivative Time 0.0028
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Figure 12gives a comparison between simulation and experimental results of the IMC-PID
Controller. As can be seen, the experimental IMC-PID controller has overshoot of 2.9% and
steady state error around 1%. While, the simulated IMC-PID controller has no overshoot and its
steady state error is zero. Moreover, the control signal of the simulated controller has a
significantly higher value than the experimental controller due to the fact thatthe ICCP system is
non-zero initial condition system with a native potential approximately 0.61volts.However, the
experimental controller has the lowest IAEequal 0.127, compared to the simulated one which is
0.56.
Figure 12. The comparison ofsimulated and experimental IMC-PID controller
The comparison ofthe experimental ICCP open loop and closed loop system using IMC-PID
Controlleris illustrated infigure 13.It is clear to see from the graph, the closed loop system using
IMC-PID controller has smaller IAE than the open loop systemwhich are 0.127 and
12.9,respectively.Furthermore, the steady state error of the open loop system increasedfrom 4%
to 20% after the set-point change from 0.85 to 1.15. While, the closed loop system has a good
response to the operating conditionchange with approximatelyconstant steady state error of 1%.
0 1 2 3 4 5 6 7 8 9 100
0.5
1
1.5
Pip
e t
o S
oil
Pote
ntial (V
olt)
Output Responses of Simulated and Experimental IMC-PID Controller
Experimental
Simulation
Reference
0 1 2 3 4 5 6 7 8 9 100
2
4
6
8
10
12
Contr
ol S
ignal (V
olt)
Time (s)
IMC-PID Control Signals
Experimental
Simulation
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Figure 13. The comparison of ICCP open loop and closed loop using IMC-PID Controller
VII. CONCLUSIONS
To summarize, laboratory scale for ICCP systems was designedin this paper based on specific
principles and concepts. This lab-scale has been used for system identification experiment to
obtain a parametric model of ICCP systems. Simulation and online implementation works have
been carried out and the results demonstrated that the obtained model is a good representation of
ICCP systems. The experimental results also confirmed that the performance of the system with
IMC-PID controller was significantly enhanced due to its capability to perform a good response
to the set-point change. Compared to open loop system where it failed to perform it with a huge
steady state error. Finally, the IMC-PID controller leads to decrease the integral of the absolute
error which is lower value compared to the open loop system.
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0 1 2 3 4 5 6 7 8 9 10
0.6
0.7
0.8
0.9
1
1.1
1.2
Time (s)
Pip
e t
o S
oil
Pote
ntial (V
olt)
Experimental Responses of ICCP Open loop and Closed loop Systems
Reference
Closed Loop
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