Advanced Control systems

Feedforward Control Cascade control Override Control Features, performance & Examples

Principle and comparison with feedback control

Feedback control is an important technique that is widely used in the process industries. Its main characteristics are as follows. 1. Corrective action occurs as soon as the controlled variable deviates from the set point, regardless of the source and type of disturbance. 2. Feedback control requires minimal knowledge about the process to be controlled; in particular, a mathematical model of the process is not required, although it can be very useful for control system design. 3. The ubiquitous PID controller is both versatile and robust. If process conditions change, retuning the controller usually produces satisfactory control.

However, feedback control also has certain inherent disadvantages: 1. No corrective action is taken until after a deviation in the controlled variable occurs. Thus, perfect control, where the controlled variable does not deviate from the set point during disturbance or set-point changes, is theoretically impossible. 2. Feedback control does not provide predictive control action to compensate for the effects of known or measurable disturbances. 3. It may not be satisfactory for processes with large time constants and/or long time delays. If large and frequent disturbances occur, the process may operate continuously in a transient state and never attain the desired steady state. 4. In some situations, the controlled variable cannot be measured online, and, consequently, feedback control is not feasible.

Introduction to Feedforward Control

The basic concept of feedforward control is to measure important disturbance variables and take corrective action before they upset the process. Feedforward control has several disadvantages: 1. The disturbance variables must be measured on-line. In many applications, this is not feasible. 2. To make effective use of feedforward control, at least a crude process model should be available. In particular, we need to know how the controlled variable responds to changes in both the disturbance and manipulated variables. The quality of feedforward control depends on the accuracy of the process model. 3. Ideal feedforward controllers that are theoretically capable of achieving perfect control may not be physically realizable. Fortunately, practical approximations of these ideal controllers often provide very effective control.

Boiler Level Control

The feedback control of the liquid level in a boiler drum:

 A boiler drum with a conventional feedback control system is shown in the previous slide. The level of the boiling liquid is measured and used to adjust the feedwater flow rate. This control system tends to be quite sensitive to rapid changes in the disturbance variable, steam flow rate, as a result of the small liquid capacity of the boiler drum. Rapid disturbance changes can occur as a result of steam demands made by downstream processing units. The feedforward control scheme, shown in the next slide, can provide better control of the liquid level. Here the steam flow rate is measured, and the feedforward controller adjusts the feedwater flow rate.

The feedforward control of the liquid level in a boiler drum.

 In practical applications, feedforward control is normally used in combination with feedback control. Feedforward control is used to reduce the effects of measurable disturbances, while feedback trim compensates for inaccuracies in the process model, measurement error, and unmeasured disturbances.

The feedfoward-feedback control of the boiler drum level.

Tank Heater Control

Tank level control (feedback) Outlet temp. control (feedforward-feedback) If cold water temp. changes, feedforward controller will adjust the steam flow rate as soon as the temperature change is detected. If the feedforward action is not enough due to model error, measurement error and etc., feedback controller will compensate the difference.

Feedforward Controller Design Based on Steady-State Models

A useful interpretation of feedforward control is that it continually attempts to balance the material or energy that must be delivered to the process against the demands of the load. For example, the level control system, shown in the previous slides, adjusts the feed water flow so that it balances the steam demand. Thus, it is natural to base the feedforward control calculations on material and energy balances.

 To illustrate the design procedure, consider the distillation column shown in the drawing which is used to separate a binary mixture. The symbols B, D, and F denote molar flow rates, whereas x, y, and z are the mole fractions of the more volatile component. The objective is to control the distillation composition, y, despite measurable disturbances in feed flow rate F and feed composition z, by adjusting distillate flow rate, D. It is assumed that measurements of x and y are not available.

The steady-state mass balances for the distillation column can be written as
F ! DB Fz ! Dy  Bx

Solving for D gives F z  x D! yx Because x and y are not measured, we replace these variables by their set points to feedforward yield the control law: !
F z y sp xsp xsp

Feedforward Controller Design Based on Dynamic Models

In this section, we consider the design of feedforward control systems based on dynamic, rather than steady-state, process models. As a starting point for our discussion, consider the block diagram shown in the drawing Additional signal path through Gt and Gf has been added.

The closed-loop transfer function for disturbance changes is:

Y s Gd  Gt G f Gv G p ! D s 1  GcGvG pG
Ideally, we would like the control system to produce perfect control where the controlled variable remains exactly at the set point despite arbitrary changes in the disturbance variable, D. Thus, if the set point is constant (Ysp(s) = 0), we want Y(s) = 0, even though D(s)

Gd Gf !  Gt Gv G p
The block-diagram, in the previous slide, indicates that a disturbance has two effects. It upsets the process via the disturbance transfer function, Gd; however, a corrective action is generated via the path through GtGfGvGp. Ideally, the corrective action compensates exactly for the upset so that signals Yd and Yu cancel each other and Y(s) = 0.

Example
Suppose that Kd Gd ! , d s 1 Gp ! Kp
p

s 1

Then, the ideal feedforward controller is Kd Gf ! Kt Kv K p s 1 s 1 d

p

This controller is a lead-lag unit with a gain given by Kf = -Kd/KtKvKp.

Cascade Control: Motivation

- The FB controller can respond only after some changes appear in measurement of CV. The FF controller can act faster, but requires accurate model. If a secondary measurement can recognize the disturbance, then the disturbance can be handled more efficiently. The jacket temp. can be controlled by adjusting cooling water flow rate. If the CW inlet temp changes, the jacket temp. will change with same flow rate. The changes in CW temp. in the jacket is an indication of the disturbance.

Cascade control of exothermic chemical reactor

Example: Furnace temperature control

A furnace temperature control that uses conventional feedback control

In conventional FB control, the hot oil temperature is controlled by the fuel gas flow rate. The valve characteristics is not linear and results the detrimental effects on performance of PID controller If the pressure of fuel gas (disturbance) changes, the flow rate of fuel gas becomes different even at the same valve opening.

A furnace temperature control that uses cascade control

Cascade control Primary (master) loop: furnace outlet temperature control Adjust the fuel pressure set point (directly related to fuel flow) Secondary (slave) loop: fuel pressure control Maintain fuel pressure regardless of fuel feed pressure and valve characteristics

Distinguishing Features
Reject the disturbance in the slave loop before it affects the main process variables. Two FB controllers but only a single control valve (or other final control element). Improve the dynamics of the slave process Cascade Controller Tuning Two controllers master and slave master establishes setpoint for slave controller slave maintains process input at desired value Tuning rules inner loop: fast controller, tight tuning why is proportional control often used? Tuning rules outer loop performance controller tune with inner loop controller active

Implementation of the cascade control

The slave process is at least 3 times as faster as master loop in terms of response time. The slave loop may not need to be controlled exactly at set point. (Imode is not necessary in many cases.) It needs to be controlled to provide fast action on disturbance and set point change. (P-mode may be suffice in most cases.) Due to some reasons, the slave may not be able to follow the set point for considerable period. Reset feedback is required for output tracking as well as anti-reset windup. The slave loop should be tuned first while the master in manual. The tune the master while the slave is in automatic mode. If the slave is retuned for some reasons, the master should be retuned. The master can be transferred to autoafter the slave becomes auto.

Block diagram of cascade control

Overall transfer function for cascade control

Characteristic equation

The stability is affected by both GC1 and GC2. The slave controller GC2 usually enhance the stability characteristics of the whole system and thus larger value of master loop gain can be applied. Cascade control also makes the closed-loop process less sensitive to model errors.

 Comparisons of the performance

Change in L2

Change in L1

Principles of override control

Override Control: arrangement of control loops to prevent the violation of safety, environment, operational constrains. Normal control loop will be overridden by another loop if contingency situation occurs. Control configuration must altered when: an upper or lower limit on a manipulated variable is encountered,

an upper or lower value of a controlled or output variable from the process is reached

Example:
Objectives: regulate level and exit flow rate in a pumping system for a sandwater slurry Slurry velocity in the exit line must be kept above the lower limit. ( if slurry velocity is too slow, it causes sand sediment.) Normal: Level controller is working. Flow is too low: FC adjusts the pump to increase slurry flow rate Level controller: slow P control with normal set point (tight level control is not required) Flow controller: fast PI control with high set point and reset feedback
A selective control to handle a sand/water slurry

Example: Surge tank flow/level control

Objectives: Maintain flow at set point L > Lmin (too low level causes cavitation) Normal: flow controller is working If L is low, level controller takes over and reduce outlet flow. Flow controller: PI controller with reset feedback Level controller: tightly tuned P control with lower limit of level as set point.
By the reset feedback, the integration stops while the level controller takes over. By adjusting the gain of LC, the switching can be adjusted.

Example: Compressor flow control

Objectives: Maintain the flow at set point P < Pmax (preventing overload) Normal: flow controller is working If P is too high, the pressure controller takes over and reduce motor speed set point. Flow controller: PI controller with reset feedback Pressure controller: tightly tuned P control with high limit of press. as set point.

Example: Distillation composition control

Objectives: Maintain the temperature at set point (composition control) (P < (Pmax (preventing flooding) Normal: temperature controller is working If (P is too high, the differential pressure (DP) controller takes over and reduce the steam flow set point.
Temp. controller: PI controller with reset feedback DP controller: tightly tuned P control with flooding limit of DP as set point.

Inferential Control
In some control problems, the process variable to be controlled (CV) can not be measured on-line conveniently or infrequently. (e.g., product composition) If other measurements that can be measured rapidly have close relation with the targeted CV, the targeted CV can be inferred from these measurements.
For binary distillation column, there is a unique relation between composition and tray temperature via Gibbs phase rule. Density ? composition of binary mixture Turbidity ? particle concentration, biomass A combination of several measurement can be used. The model is required. Sometimes, it is called soft sensor. The parameters in the correlation may be updated, if necessary, as actual composition measurement become available.

Selective Control
Utilize the best suitable measurement among many measurements. High Selector (HS), low selector (LS), or median selector (MS) can be used.
Examples Hot spot temperature control The location of hot spot travels. Use many distributed sensors. Or, interpolate to find hot spot.

Enhancing sensor reliability Exclude faulty measurements. Use 3 or more same sensors.

Variable Structure Control

Example: Floating pressure of distillation column Objectives: Maintain the column pressure by adjusting cooling area through reflux flow rate control If the level is too low (below the heat transfer area), the vent must be open to relieve the column pressure.
Pressure Controller: control the P by adjusting reflux flow rate. Level controller: takes over if level is too low. (L<Lmin) If LC takes over, there is a discrepancy, and it opens the vent valve. The K in summing station decides the vent speed. The two cases should be similar in response time.

Split Range Control

Depending on the process condition, different MV should be used. Use one controller Controller output will be split by range splitter. Examples Pressurize or depressurize Heating or cooling Acid feed or base feed in neutralization

Other Complex Control Schemes

Blending process control Objectives: Maintain product composition Maximize production The additive flow rates are limited. (constrained) Control scheme: Override control for max. production Ratio control for composition Valve position control for additive flow constraint

Boiler Control
Objectives: Maintain drum level Maintain furnace pressure Maintain steam flow rate Maintain the air-fuel ratio Maintain the excess oxygen

Control scheme: FF/FB control for level control FB control for furnace pressure FB control for fuel flow rate Ratio control for air-fuel ratio Cascade control for excess oxygen control