Enhancement of single-loop PID controller and hybrid control techniques

Advance Topics in Process Control 1
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CHAPTER 5:
Enhancement of single-loop
PID controller
3. Feed-Forward plus Feedback Control
To combine the advantages of both Feed-forward and feedback

controllers, one can consider the hybrid control system with Gm = Gv =1,
d
ysp _
Gsp
+
Gc2 Gd
+
ysp + u
y
Gc1 Gp +
+ _ +
Figure 20: Feedback + Feed-Forward Control system
From the Block diagram:
y = G p u + Gd d
u = Gc1 ( y sp − y ) + Gc 2 (Gsp y sp − d )
Substituting for u and rearranging gives:
G p (Gc1 + Gc 2Gsp ) Gd − G p Gc 2
y= y sp + d
1 + G p Gc1 1 + G p Gc1
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We notice:
1. The stability of the overall system is still given by the same characteristic
equation.
The stability characteristic of a feedback system is not affected by

the addition of a feed-forward loop.
2. The feed-forward controller is still given by the same law as before.
Applying the hybrid FF and Feedback control system for the heated tank is shown in
the figure:
Ti, Fi
_ Ti
Tsp
Gsp = τs + 1
+
+ +
FiρCp λ
1
G c 1 = K c (1 + )
τ1 s
T, F
e
_
Tsp
+
Figure 21: Hybrid Feed-Forward and Feedback control of Heated
Tank
Feedforward control
Feedforward-Feedback
control
Deviation remaining from
feedforward control only
time
0
Figure 22: Comparison between FF and FF+FB control systems
We notice:
Offset may occur when FF alone is used with some modeling error occurs in the
steady state gain of the FF controller.

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Remark:
If the dynamic of the disturbance is faster than that of the manipulated variable, i.e.
τd<τp, then using Hybrid FF and FB leads to double correction, which may cause large
overshoot and poor performance.
4. Ratio Control
In some aspects ratio control can be considered as a special type of feed-

forward control where two loads are measured and held in a constant ratio
to each other.
A Wild stream
FA
Desired Ratio
FT
+
_ Ratio
Divider GR controller
Measured Error
Ratio
FT
FB
B
Controlable stream
Valve
A Wild stream
FA
FT
Desired
Ratio
+
Ratio
FT _ GR controller
Error
FB
B
Controlable stream
Valve
Figure 23: Ratio Control Example

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4.1 Applications of Ratio Control

Ratio control is used for a variety of applications including:
• Keep constant the ratio between the feed flow rate and the steam
in the reboiler of a distillation column,
• Hold constant the reflux ratio in a distillation column.
• Control the ratio of two reactants entering a reactor at a desired
value.
• Hold the ratio of two blended streams constant in order to maintain
the composition of the blend at the desired value.
• Hold the ratio of a purge stream to the recycle stream constant.
• Keep the ratio of fuel/air in a burner at its optimum value
• Maintain the ratio of the liquid flow rate to vapor flow rate in an
absorption column constant.
Stack gas
FR
FC FT
A stream B stream
FT FR
Air
R Purge
Fuel
FT FR
Recycle
FR
FT
Distillate
Reflux

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5. Split Range Control (MV > CV)
This control configuration has one controlled variable and more than one
manipulated variable.
A single process output is controlled by coordinating the actions of

several manipulated variables.
Remarks:
• This type of control configuration is not very common in chemical
industry.
• The error signal is split into several parts, either equally or at
specified ratio, to regulate several manipulated variables.
TC TT
Cold water
Steam
Figure 24: Example of Split Range Control

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6. Selective (override) control (MV<CV)
If a process has fewer manipulated variables than controlled variables, a

strategy is needed for sharing the manipulated variables among the
controlled variables. A common strategy is to use selectors to choose the
appropriate process variables among a number of available
measurements.
6.1 Maintaining Safety of the Equipment

Examples of these situations include:
• Safeguard the operation of variable speed pumps.

• Safeguard the operation of high temperature or pressure reactors.
• Avoid flooding in distillation columns
• Safeguard the operation of furnace.
The selector compares signals P1 and P2 and chooses the highest one. This type of
control is also called override control.
If q < qmin Î switch from level control to Flow control
Slurry in
LT LC
p2
h
p1
HS FC
Holding Tank
FT
q
Slurry out
Figure 25: A selective control for sand-water slurry system
6.2 Improving Control Performance

Plug flow reactor with moving hot spot. A control strategy that
accomplishes this goal is shown in Fig 21. The high selector selects the
transmitter with the highest output and the control is based on this
temperature.

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Reactants
Products
SP
TT TT TT TT TC
HS Cooling meduim
Figure 26: A plug flow reactor with selective control
6.3 Optimization of the process (See Corripio)

Consider the furnace of Figure 26, where fuel oil is used to provide heat to a
number of process units. Each individual unit manipulates the flow of oil required
to maintain its controlled variable at set point. A bypass control loop is also provided.
A bad or inefficient operation of the process is the one for which the oil temperature is
heated above the value that would satisfy the need of the users. In this case most of
the valves would not be wide open and large quantity of fuel would be burned to
reach the unnecessary high oil temperature.
Stack gas
Hot oil
T
sp
Fuel sp
T
sp
T
sp
sp
Figure 27: Hot oil system

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The effective operation that would save energy is the one that would maintain the oil
leaving the furnace at a temperature just enough to provide the necessary energy to
the users with hardly any flow through the bypass valve. In this case most of the
temperature control valves would be open most of the time. To achieve this goal, the
selective control strategy, shown in Figure 26, first selects the most open valve using
a high selector. The valve position controller controls the selected valve position at
large value i.e. 90 % open by manipulating the set point of the furnace temperature.
This saves energy because it will maintain the temperature just hot enough to provide
needed heat to the users.
6.4 Protecting against sensor/transmitters failures

Selectors are also used to protect against transmitter failures by selecting a
valid transmitter signal among several. Redundant transmitters monitor the process
variable and the median selector chooses the right one for control. Redundant sensors
are commonly used in a hostile environment of high temperature or corrosive where
failures rate are high thus avoiding the shutdown of the process.
6.5 Other Override Control examples

• Protection of Boiler system
• Protecting a compressor system
Boiler PT
LT LC HS PC
Water
Hot gas
HS FC
PC
SC
Gas in PT FT
Gas out
Motor Compressor

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7. Inferential Control
In some case, the controlled variable can not be measured directly or

continuously such as
• Reid Vapor pressure

• Density
• Melt Index
• Molecular weight
• Gas composition
Therefore, inferential control makes use of a secondary measurement to

estimate (infer) the unmeasured variable.
Inferring the unmeasured output can be achieved through:
• Using physical laws, (Relating T to C through thermodynamic)

• Using a model equation
• Using Empirical modeling
7.1 Inferential control through modeling

Consider the block diagram of the process shown in Fig 28, with one
unmeasured controlled output y and one secondary measured output z.
Unmeasured
Process disturbance
d
Gd1 Gd2
Manipulated + Controlled
u variable output
GP1 (unmeasured)
+ y
+
+ Secondary
GP2 measurement
z
Figure 28: Process with need for inferential control
The open loop transfer function:
y(s) = Gp1(s) u(s) + Gd1(s) d(s) (1)

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z(s) = Gp2(s) u(s) + Gd2(s) d(s) (2)
We can solve for d(s) in the second equation to find the following
estimate of the unmeasured disturbance
1 G p2 (s) (3)
d (s) = z( s ) − u( s )
Gd ( s ) Gd 2 ( s )
Substituting back in equation (1) yields,
⎡ G (s) ⎤ G (s) (4)

y( s ) = ⎢G p1 ( s ) − d 1 G p 2 ⎥u ( s ) + d 1 z( s )
⎣ G d2 ( s ) ⎦ G d2 ( s )
This equation provides the estimator needed which relates the

unmeasured controlled output to measured variables u(s) and z(s). Figure
29 shows the resulting block diagram for the inferential control.
Controller y
ysp + u
Gc Process z
Set point _
Gd 1
G p1 = Gp2
Gd 2
+
Gd 1
+ Gd 2
Estimates of unmeasured
output y
Estimator
Figure 29: Process under inferential control system
Remarks:
• Generally inferential control is used when composition is the
desired controlled variable. Temperature is the most common
secondary measurement.
• From Equation (4), the accuracy of the inferential control scheme

depends on the good estimation, e.g. depends on the good
knowledge of the process Gp1(s), Gp2(s), Gd1(s) and Gd2(s).
Generally these process elements are not known perfectly and

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therefore the inferential control would provide control with varying

quality.
7.2.1 Example: Inferential control of a distillation column

Consider a distillation column, which separates a mixture of propane-butane in
two products. The reflux ratio is the manipulated variable. The feed and overhead
compositions are unmeasured so there is need for inferential control. The secondary
measurement to infer the overhead composition is the temperature at the top tray. The
process inputs are the feed composition (disturbance) and reflux ratio (manipulated
variable) while the outputs are the overhead propane composition (unmeasured
controlled variable) and temperature of top tray (secondary measurement).
0.9e −2 s 1.2e − s (5)

y( s ) = d (s) + u( s )
70s + 1 30 s + 1
0.2e −0.2 s 1 (6)

z( s ) = d (s) + u( s )
60 s + 1 20 s + 1
Unmeasured
Process disturbance
d
0.9 se −2s 0.2 se −2s
G d1 = Gd 2 =
70s + 1 60s + 1
Manipulated +
u variable 1.2 se −1s
G p1 =
30s + 1 + y Overhead
composition
+
1 + Temperature
G p2 =
20s + 1 z of top tray
(a)

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Controller y
ysp + u
Gc Process
Set point _ z
1.2e − s 4.5(60s + 1)
−
30s + 1 (70 s + 1)( 20s + 1)
+
60s + 1
4 .5
70s + 1
Estimates of unmeasured +
output y
Estimator
(b)
Figure 30: (a) Block diagram of distillation column; (b)
corresponding inferential
7.2 Nonlinear (Empirical) Inferential systems

Recently, online estimation techniques such neural networks have been
used to estimate unmeasured variables from available plant data. The
output estimator is called soft sensor.
Empirical inferential system is not limited to the use of NN. Any linear
regression methods can be used to correlate the unmeasured variable to
the measurements of secondary variable or other measured process
variables.
7.3 Implementation issues
Inferential control is appropriate when:

• Measurement of the true controlled variable is not available
because:
o An on-stream sensor is not possible
o An on-stream sensor is too costly
o Sensor has unfavorable dynamics (long time delay, lab
analysis)
• A measured inferential variable is available.


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Advance Topics in Process Control 1

To combine the advantages of both Feed-forward and feedback

Figure 20: Feedback + Feed-Forward Control system

From the Block diagram:

Substituting for u and rearranging gives:

Chemical Engineering Department

The stability characteristic of a feedback system is not affected by

2. The feed-forward controller is still given by the same law as before.

Chemical Engineering Department

In some aspects ratio control can be considered as a special type of feed-

Chemical Engineering Department

4.1 Applications of Ratio Control

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5. Split Range Control (MV > CV)

A single process output is controlled by coordinating the actions of

Figure 24: Example of Split Range Control

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6. Selective (override) control (MV<CV)

If a process has fewer manipulated variables than controlled variables, a

6.1 Maintaining Safety of the Equipment

• Safeguard the operation of variable speed pumps.

If q < qmin Î switch from level control to Flow control

Figure 25: A selective control for sand-water slurry system

6.2 Improving Control Performance

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Figure 26: A plug flow reactor with selective control

6.3 Optimization of the process (See Corripio)

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6.4 Protecting against sensor/transmitters failures

6.5 Other Override Control examples

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In some case, the controlled variable can not be measured directly or

• Reid Vapor pressure

Therefore, inferential control makes use of a secondary measurement to

Inferring the unmeasured output can be achieved through:

• Using physical laws, (Relating T to C through thermodynamic)

7.1 Inferential control through modeling

Figure 28: Process with need for inferential control

The open loop transfer function:

y(s) = Gp1(s) u(s) + Gd1(s) d(s) (1)

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z(s) = Gp2(s) u(s) + Gd2(s) d(s) (2)

Substituting back in equation (1) yields,

⎡ G (s) ⎤ G (s) (4)

This equation provides the estimator needed which relates the

• From Equation (4), the accuracy of the inferential control scheme

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therefore the inferential control would provide control with varying

7.2.1 Example: Inferential control of a distillation column

0.9e −2 s 1.2e − s (5)

0.2e −0.2 s 1 (6)

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7.2 Nonlinear (Empirical) Inferential systems

7.3 Implementation issues

Inferential control is appropriate when:

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