Chapter 2

Traditional Advanced Control

Approaches Feedforward, Cascade
and Selected Control
2-1 Feed Forward Control (FFC)
Block Diagram
Design of FFC controllers
Examples
Applications


Why Feedforward ?
Advantages of Feedback Control
Corrective action is independent of sources of
disturbances
No knowledge of process (process model) is required
Versatile and robust
Disadvantages
No corrective action until disturbance has affected the
output. Perfect control is impossible.
Nothing can be done about known process disturbance
If disturbances occur at a frequency comparable to the
settling time of the process. Then process may never
settle down.
Feedforward Control

Feedforward
Controller

Disturbance
Process
Output
Manipulated
Variable

Feedforward Control
Advantages
Corrective action is taken as soon as disturbances
arrives.
Controlled variable need not be measured.
Does not affect the stability of the processes
Disadvantages
Load variable must be measured
A process model is required
Errors in modeling can result in poor control
LI
FFC
steam
FI
LI
steam
FI
FFC FB

Feedback control
Feedforward control
Combined feedforward-feedback control
LI
FB
Boiler
Feed control
steam
FI
EXAMPLES
Design Procedures (Block diagram
Method)

G
L
(s)

Load transfer function

G
F
(s)


Load

Manipulated
Variable
G
p
(s)
Process
X
2
C

Outp
ut
L
M





FF
Controller
Derivation
( ) ( ) | |
( ) ( )
( )
( )
( )
( ) function transfer process , (2)
function transfer load ), ( ) 1 ( : need
or
0 ) (
Hence ). ( all for 0 ) ( want We
) ( ) (
) ( ) ( ) ( ) ( ) (
) ( ) ( ) ( ) ( ) (
s G
s G
s G
s G
s G
s G s G s G
s L s C
s L s G s G s G
s L s G s G s L s G
s M s G s L s G s C
P
L
P
L
F
F P L
F P L
F P L
P L
=
= +
=
+ =
+ =
+ =
Examples
Example 1
Let G
p
(s)=K
p
/
p
s+1, G
L
(s)=K
L
/
L
s+1
Then, G
F
(s)=-(K
L
/K
p
)(
p
s+1)/(
L
s+1)
Therefore, feedforward controller is a lead-lag unit.
Example 2
Let G
p
(s)=K
p
e
-Dps
/
p
s+1, G
L
(s)=K
L
e
-DLs
/
L
s+1
Then, G
F
(s)=-(K
L
/K
p
)(
p
s+1)/(
L
s+1)e
(-DL+DP)s

If -DL+DP is positive, then this controller is unrealizable.
However, an approximation would be to neglect the
delay terms, and readjusting the time constants. In this
case, perfect FF compensation is impossible.
Tuning feedforward controllers
Let
This has three adjustable constants, K,
1
,
2
Tuning K, K is selected so that for a persistent
disturbance, there is no steady state error in
output.
Adjusting
1
,
2
can be obtained from transfer
functions. Fine tune
1
,
2
such that for a step
disturbance, the response is somewhat
symmetrical about the set point.


1
1
) (
2
1
+
+
=
s
s
K s G
F
t
t
Example: A simulated disturbed plant
Waste water
treatment
Disturbed
flow rate
BOD
Chemicals
(CV)
DV
MV
Simulated Block Disgram
( ) ( ) ( )
1
1 2 3 s s s + + +
Disturbed flow
rate
+
( )
3
1
1 s +
Chemicals
Feedforward v.s. Feedback Control
0 5 10 15 20 25 30
-0.2
-0.15
-0.1
-0.05
0
0.05
0.1
0.15
FB
FF
Example: Distillation Column
Example: Distillation Column
Mass Balance: F=D+B
Fz=Dy+Bx
D=F(z-x)/(y-x)
In practice



For example: If light key increase in feed, increase
distillate rate.

set set
set
x y
x z F
D

=
) (
Design of Feedforward Control Using
Material and Energy Balances
Consider the hear exchanger




Energy Balance yields Q=WC(T
2
-T
1
)=W
s

Where =hear of vaporization W
s
=WC(T
2
-T
1
)/

This equation tells us the current stream demand based on (1)
current flow rate, W, (2) current inlet temperature, T
1
, (3) desired
value of outlet temperature T
2
.
Steam
T
2

w, T
1

Condensate
W
s

Control Law and Design
Implementation:






Note no dynamics are incorporated

K
X
measured
Tset
Gain
measured
Ws
w
T1
-
+
When to use Feedforward ?
Feedback control is unsatisfactory
Disturbance can be measured and
compensated for
Frequency of disturbance variations are
comparable to frequency of oscillation of the
system
Output variable cannot be measured.
There are large time delays in the system

2-2 Cascade Control
Block Diagram
Design Considerations
Applications
Illustrative Example : Steam Jacket

PC PT
TC
Illustrative Example: Steam Jacket -
Continued
Energy Balance of the Tank:


Energy Balance of Jacket:


Material Balance of the Jacket

( ) Loss Heat = T T hA
dt
dT
V
J

( )
dt
n P d
R
V
R n
V P
dt
d
dt
dT
s J J
s
J J J
/
=
|
|
.
|

\
|
=
condensate n
dt
dn
in
s
=
Illustrative Example: Steam Jacket -
Continued
Assume:






Where X=valve position

( )
( )( )
( )
( )
( )( )
2
1 1 10
1
1 3 1 30
1
) (
+ +
~
+ +
~
s s
s X
s P
s s s P
s T
J
J
Block Diagram

Feed back
Controller
Steam
Valve
Stirred
Tank
T
set

Steam
supply
pressure
Valve
position
Jacket
steam
pressure
primary
Tank
Temp.
secondary
Primary
Controller
Jacket
Pressure
Controller
Steam
Valve
Stirred
Tank
T
set
secondary
Jacket
pressure
supply
pressure
Tank
Temp.
Secondary loop
Primary loop
Principal Advantages and Disadvantages
Advantages
Disturbances in the secondary loop are corrected by
secondary controllers
Response of the secondary loop is improved, thus
increasing the speed of response of the primary loop
Gain variations in secondary loop are compensated by
secondary loop
Disadvantages
Increased cost of instrumentation
Need to tune two loops instead of one
Secondary variable must be measured
Design Considerations
Secondary loop must be fast responding otherwise
system will not settle
Time constant in the secondary loop must be smaller than primary
loop
Since secondary loop is fast, proportional action
alone is sufficient, offset is not a problem in
secondary loop
Only disturbances within the secondary loop are
compensated by the secondary loop. Hence,
cascading improves the response to these
disturbances

Applications: 1. Valve Position Control





Valve motion is affected by friction and pressure
drop in the line. Friction causes dead band. High
pressure drop also causes hysteresis in the valve
response
Useful in most loops except flow and pressure
Control
Valve
Motor
Desired
position
Secondary
loop
Valve
position
Air Pressure to
Valve Motor

Application 2. Cascade Flow Loop

Output From
Primary Controller
no cascade
Output From
Primary Controller
FC
FT
F
set

DP
cascade
G
C2
G
C1
G
P1
G
P2

Primary
controller
Secondary
controller
Secondary
process
primary
process
c
m
2
e
2
m
set
Secondary loop
Primary loop
c
set
2
1 1
1 1 2
1
C
P C
P C
set
G
G G
G G
m
m
=
+
=
G
C2
G
CL
G
P2

m
set
m
2
c
c
set
2 2
2 2
1
P CL C
P CL C
set
G G G
G G G
c
c
+
=
Gc 12
) 1 10 ( ) 1 (
1
2
+ + S S ) 1 3 )( 1 30 (
1
+ + S S
+
-
Primary
+
-
G
C2
Secondary
G
2
(S)

G
3
(S)

2
3 2
12 1
12
G
G G
c
+
=
u
u
For a cascade system
(open-loop)
Without cascade control
3 2
G G
c
=
u
u

Illustrative Example: Steam Jacket
Continued Cascade Case
W
u
= 0.53

Mag = 20*log
10
(AR) = -30 (dB)
AR = 0.0316


6228 . 31
1
= =
AR
K
u
Illustrative Example: Steam Jacket
Continued No Cascade Case
W
u
= 0.25

Mag = 20*log
10
(AR) = 0 (dB)
AR = 1


1
1
= =
AR
K
u
Illustrative Example: Steam Jacket
Continued No Cascade Case
K
u
= 1;w
u
= 0.25;P
u
= 2*Pi / w
u
= 25.1327
K
c
= K
u
/1.7 = 0.5882
Tau
i
= P
u
/ 2 = 12.5664
Tau
d
= P
u
/8 = 3.1416
Illustrative Example: Steam Jacket
Continued Cascade Case
K
u
= 20;w
u
= 0.53;P
u
= 2*Pi / w
u
= 12
K
c
= K
u
/1.7 = 11.8
Tau
i
= P
u
/ 2 = 6
2-3 Selective Control Systems
Override Control
Auctioneering Control
Ratio Control


Change from one controlled (CV) or manipulated variables
(MV) to another
LT
LC LSS
PC
Normal
loop
water
steam
1. Override Control Example Boiler Control
LSS: Low Selective Switch Output a lower of two inputs
Prevents: 1. Level from going too low, 2. Pressure from
exceeding limit (lower)
motor
SC
HSS
PC FC
Gas out
Gas in
Normal loop
Example: Compressor Surge Control
High Pressure Line
Low Pressure Line
PC
PC
HSS
Example: Steam Distribution System
Length of reactor
T
e
m
p
e
r
a
t
e

T
1
T
2
Hot spot
2. Auctioneering Control Systems
Temperature profiles in a tubular reactor
TT TT TT TT
HSS
Cooling flow
Auctioneering Control Systems
TC
Temperature Control
Steam
T
2

Bypass

Exchanger
TC
Split Range Control: More than one manipulated variable is
adjusted by the controller
Boiler 2
Steam Header
Boiler 2
Boiler 2
PC
Example: Steam Header: Pressure Control
FT
Driver
FT
A
Wild stream
Controlled Stream
B
F
B

G
c
Desired
Ratio
F
A
3. Ratio Control Type of feedforward control
However, one stream in proportion to another. Use if the ratio
must be measured and displayed
Disadvantage:
Ratio may go
To erratic
A
Wild stream
FT
Desired Ratio
Multiplier

FC
FT
Controlled stream
F
B
F
A
Another implementation of Ratio Control
+
-