Process Control CL 302

Prof. Bharat Suthar

Department of Chemical Engineering

IIT Bombay, Mumbai, India, 400076

Lecture 36
Chapter#16
Enhanced Single-Loop Control Strategies
bharat.k.suthar[at]iitb.ac.in
Landline: +91 (22) 2576 7243

CL 302 | Bharat Suthar | Process Control | IIT Bombay, Mumbai, India 1

Admin:

❑ Total 5 contact hours becore DX grade

❑ Including one quiz
❑ Histogram of attendance

CL 302 | Bharat Suthar | Process Control | IIT Bombay, Mumbai, India 2

 Chapter 16

Enhanced Single-Loop
Control Strategies

CL 302 | Bharat Suthar | Process Control | IIT Bombay, Mumbai, India 3

Outline

❑ Cascade Control
❑ Time-Delay Compensation
❑ Inferential Control
❑ Nonlinear Control Systems
❑ Adaptive Control Systems

CL 302 | Bharat Suthar | Process Control | IIT Bombay, Mumbai, India 4

Cascade Control

❑ Drawback of FB Control for the 100th times:

❖ Corrective action only after CV is disturbed.

❑ What are the options here?

❖ FF Control
➢ Requires measurement of disturbances
➢ Requires process model to get to the control law.
❖ Alternative:
➢ Use secondary FB controller using secondary measurement point
➢ What is secondary measurement point?
➢ It can recognize the upset sooner than CV, disturbance is not necessary measured.
➢ Example?
➢ This approach is called cascade control.
❑ Cascade Control:
❖ Useful when the disturbances are in the MV itself
❖ Final control element exhibits nonlinear behavior

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Example: Exothermic Chemical Reactor

❖ DV#1: Reactor feed temp and composition

❖ DV#2: Cooling water temperature

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Example:

❑ Natural Draft Furnace

❖ Case 1: disturbance in the oil flow rate.
❖ Case 2: Disturbance in the fuel gas pressure (disturbance is associated with
MV)
➢ Corrective action only occurs after the temp of the oil changes (sluggish response)

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Example:

❑ Conventional FB Cascade Controller

❖ Primary (master) Control loop (TT and TC)

❖ Secondary (slave) Control loop (PT and PC)

❖ Provide improved response because the

pressure can be adjusted back quickly.

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Cascade Control

❑ Features:
❖ Two FB controllers
➢ Single control valve
❖ Output signal of the "master"
controller is the set-point for “slave"
controller.
❖ Two FB control loops are "nested"
with the "slave" (or "secondary")
control loop inside the "master" (or
"primary") control loop.

❑ Terminology:
❖ Slave vs. master
❖ Secondary vs. primary
❖ Inner vs. outer

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Cascade Control: Block Diagram

❑ Onenote: Block Diagram:

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Draw Block Diagram

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Block diagram

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Onenote:

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Block Diagram Algebra

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Stability of Cascade Control

❑ Same Char. Polynomial:

❑ If inner loop is removed (𝐺𝑐2 = 1, 𝐺𝑚2 = 0):

❖ Same as that for conventional feedback control (1 + 𝐺𝑂𝐿 = 0)

❖ If inner loop is faster in response and takes care of disturbance quicker:

➢ The stability of the system will improve (i.e. one can use larger value of 𝐾𝑐1 in the
outer loop)

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Example: Comparison

❑ Conventional FB: Char. Eq. ❑ Cascade Control (char Eq)

➢ 𝐺𝑐2 = 1, 𝐺𝑚2 = 0 ❖
5 5 4
➢ 1 + 𝐺𝑐1 𝐺𝑣 𝐺𝑝2 𝐺𝑝1 𝐺𝑚1 = 0 ❖ 1 + 𝐾𝑐2 𝑠+1 0.2 + 𝐾𝑐1 𝐾𝑐2 𝑠+1 ∙ 1 ∙ (4𝑠+1)(2𝑠+1) ∙ 0.05 = 0

➢
5 4
1 + 𝐾𝑐1 𝑠+1 × 1 × (4𝑠+1)(2𝑠+1) × 0.05 = 0 ➢ If 𝐾𝑐2 = 4

❑ Routh table: ❑ Routh table:

❑ Stability range for Kc1 ❑ Stability range for Kc1

➢ −1 < 𝐾𝑐1 < 11.25 ❖ −1.25 < 𝐾𝑐1 < 43.3
➢ Larger range of 𝐾𝑐1 possible.

CL 302 | Bharat Suthar | Process Control | IIT Bombay, Mumbai, India 16

Quickness of response:

𝑌2 𝑌2
❑ Lets take ❑ Lets take in cascade control
𝑌෨𝑠𝑝2 𝑌෨𝑠𝑝2
❖ Without inner loop: ❖ With Inner Loop
➢ Same as 𝐺𝑣 𝐺𝑝2 𝑌2 4∙
5
∙1
➢ Since 𝐺𝑐2 = 1, 𝐺𝑚2 = 0 ❖ = 𝑠+1
5
𝑌෨𝑠𝑝2 1+4∙𝑠+1∙1∙0.2
5
➢ 𝐺𝑣 𝐺𝑝2 = 𝑌 4
𝑠+1 ❖ 𝑌෨ 2 = 0.2𝑠+1
➢ Time constant 1 min 𝑠𝑝2
➢ Time constant 0.2 min

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Simulink Exercise:

Cascade Control

Conventional PI Control

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Simulink Results: D1 vs D2 effect

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Outline

❑ Cascade Control
❑ Time-Delay Compensation
❑ Inferential Control
❑ Nonlinear Control Systems
❑ Adaptive Control Systems

CL 302 | Bharat Suthar | Process Control | IIT Bombay, Mumbai, India 20

 Process Control CL 302
Prof. Bharat Suthar

Department of Chemical Engineering

IIT Bombay, Mumbai, India, 400076

Lecture 36
Chapter#16
Enhanced Single-Loop Control Strategies
bharat.k.suthar[at]iitb.ac.in
Landline: +91 (22) 2576 7243

CL 302 | Bharat Suthar | Process Control | IIT Bombay, Mumbai, India 21

Outline

❑ Cascade Control
❑ Time-Delay Compensation
❑ Inferential Control
❑ Nonlinear Control Systems
❑ Adaptive Control Systems

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Time Delay Compensation

❑ Example: 16.2
❑ Compare the set-point responses for
a second-order process with a time
delay (min) and without the delay.
𝑒 −𝜃𝑠
❑ 𝐺𝑝 = , 𝐺𝑚 = 𝐺𝑣 = 1
(5𝑠+1)(3𝑠+1)

❖ PI Controller w/o time delay 𝜃 = 0

➢ 𝐾𝑐 = 3.02 and 𝜏𝐼 = 6.5 min

❖ PI Controller with time delay 𝜃 ≠ 0

➢ 𝐾𝑐 = 1.23 and 𝜏𝐼 = 7 min Time delay of 2 min give rise to significant
➢ Gain is reduced to meet stability sluggishness in the response.
criteria

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Closer look at time delay processes

Controller action calculated Controller action calculated Process with delay

but not implemented and implemented (no delay)

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Smith’s Predictor:

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Error Signal in Smith’s predictor

❑ What is 𝐸 ′
❖ 𝐸 ′ = 𝑌𝑠𝑝 − (𝑌 − 𝑌෨2 ) − 𝑌෨1

❖ If plant model mismatch is

not there
➢ 𝑌 = 𝑌෨2

❖ 𝐸 ′ = 𝑌𝑠𝑝 − 𝑌෨1

❑ For this ideal case, the

controller responds to the
error signal that would occur
if no time delay were present

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Comparison to conventional FB

❑ Conventional FB ❑ FB + Smith’s Predictor

𝑌 𝐺𝑐 (𝐺 ∗ 𝑒 −𝜃𝑠 ) 𝑌 𝐺𝑐 (𝐺 ∗ 𝑒 −𝜃𝑠 )
= =
𝑌𝑠𝑝 1 + 𝐺𝑐 ( 𝐺 ∗ 𝑒 −𝜃𝑠 ) 𝑌𝑠𝑝 1 + 𝐺𝑐 𝐺 ∗
𝐺𝑝
𝐸′ = 𝑌𝑠𝑝 − 𝑌 (Has Time delay) 𝐸′ = 𝑌𝑠𝑝 − 𝑌෨1 (No time delay)

Theoretical advantage of eliminating

the time delay from the characteristic equation,
provide process model is reasonably accurate
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Performance of Smith’s Predictor

Conventional FB Conventional FB + Smith’s Predictor

𝑒 −𝜃𝑠
𝐺𝑝 =
(5𝑠 + 1)(3𝑠 + 1)

For 𝜃 = 0, 𝐾𝑐 = 3.02, 𝜏𝐼 = 6.5

For 𝜃 = 1, 𝐾𝑐 = 1.23, 𝜏𝐼 = 7

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Simulink Exercise

❑ What happens if plant model mismatch is there?

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Performance of Smith’s Predictor:
Disturbance rejection

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Outline

❑ Cascade Control
❑ Time-Delay Compensation
❑ Inferential Control
❑ Nonlinear Control Systems
❑ Adaptive Control Systems

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Inferential Control

❑ Problem:
❖ Controlled variable cannot be measured or has large sampling period.

❑ Possible solutions:
❖ Control a related variable
➢ (e.g., temperature instead of composition).
❖ Inferential control: Control is based on an estimate of the controlled variable.
➢ The estimate is based on available measurements.
➢ Examples: empirical relation, Kalman filter

❑ Modern term: soft sensor

❖ Using the mathematical modeling

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Temp. control instead of composition control

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Inferential Control

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Outline

❑ Cascade Control
❑ Time-Delay Compensation
❑ Inferential Control
❑ Nonlinear Control Systems
❖ Self read
❑ Adaptive Control Systems

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Adaptive Control

❑ A general control strategy for control problems where the process or

operating conditions can change significantly and unpredictably.
❖ Example:
➢ Catalyst decay
➢ equipment fouling (change in equipment characteristics)
➢ Ambient variations (rain storm, daily cycles)
❖ Many different types of adaptive control strategies have been proposed.

❑ Self-Tuning Control (STC):

❖ A very well-known strategy and probably the most widely used adaptive
control strategy.
❖ Basic idea: STC is a model-based approach.
❖ As process conditions change, update the model parameters by using least
squares estimation and recent input and output (𝑢 & 𝑦) data.

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Adaptive Control: Self Tuning Method

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Outline

❑ Cascade Control
❑ Time-Delay Compensation
❑ Inferential Control
❑ Nonlinear Control Systems
❖ Self read
❑ Adaptive Control Systems

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Takeaway Points/Summary

❑ We have studied a number of control strategies that offer the potential of

enhanced performance over what can be achieved with conventional
single-loop PID controllers.
❖ How to efficiently handle disturbances in MV
➢ Cascade control
❖ How to handle time delay in the process
➢ Smith’s predictor
❖ How to handle processes where the CV measurement is not available online
➢ Iinferential control
❖ How to handle processes that undergo changes
➢ Adaptive control

❑ Overall, the idea that process models can be effectively used to improve
the control performance is instilled.

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Reference:

❑ Process Dynamics and Control (Seborg, Edgar, Mellichamp, Doyle III)

❑ Process Control Designing Processes and Control Systems for Dynamic
Performance: Thomas E. Marlin

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