Feedforward Control

2
 Feedback control loops can never achieve perfect control of a chemical
process, that is, keep the output of the process continuously at the
desired set point value in the presence of load or set point changes.
 The reason is simple: A feedback controller reacts only after it has
detected a deviation in the value of the output from the desired set
point.
 Unlike the feedback systems, a feedforward control configuration
measures the disturbance (load) directly and takes control action to
eliminate its impact on the process output.
 Therefore, feedforward controllers have the theoretical potential for
perfect control.

Process Dynamics & Control

 Feedforward Control
3
 In Figure 21.1a we can see the general
form of a feedforward control system. It
measures the disturbance directly and
then it anticipates the effect that it will
have on the process output.
Subsequently, it changes the
manipulated variable by such an amount
as to eliminate completely
the impact of the disturbance on the
process output (controlled variable).
Control action starts immediately after a
change in the disturbance(s) has been
detected.
 In Figure 21.1b the schematic of a
typical feedback loop is shown. It is
clear that feedback acts after the fact in
a compensatory manner, whereas
feedforward acts beforehand in an
anticipatory manner.
Process Dynamics & Control
 Logic of Feedforward Control
4
 Consider the stirred tank heater shown in Figure 1.1. The control
objective is to keep the temperature of the liquid in the tank at a desired
value (set point) despite any changes in the temperature of the inlet
stream.

Process Dynamics & Control

 Feedforward Control of Various Processing Units
5
 Let us now look at some
common feedforward control
systems used in chemical
processes.
1. Feedforward control of a heat
exchanger:
The objective is to keep the exit
temperature of the liquid constant
by manipulating the steam
pressure. There are two principal
disturbances (loads) that are
measured for feedforward control:
liquid flow rate and liquid inlet
temperature.

Process Dynamics & Control

 Feedforward Control of Various Processing Units
6
2. Feedforward control of a drum boiler:
Here the objective is to keep the liquid level in the drum constant. The two
disturbances are the steam flow from the boiler, which is dictated by varying
demand elsewhere in the plant, and the flow of the feedwater. The last is also
the principal manipulated variable.

Process Dynamics & Control

 Feedforward Control of Various Processing Units
7

3. Feedforward control of a
distillation column:
The two disturbances here are the feed
flow rate F and the composition c. The
available manipulated variables are the
steam pressure in the reboiler and the
reflux ratio. The composition of
overhead or bottom product is the
control objective. Feedforward control
is particularly useful for a distillation
column, because its response time can
be measured in hours leading to large
amounts of off-specification products.

Process Dynamics & Control

 Feedforward Control of Various Processing Units
8

4. Feedforward
control of a CSTR:
Inlet concentration and
temperature are the two
disturbances, and the
product withdrawal flow
rate and the coolant flow
rate are the two
manipulations. There are
two objectives: to maintain
constant temperature and
composition within the
CSTR.

Process Dynamics & Control

 Relative Advantages and Disadvantages of Feedback
9
Controllers

Advantages Disadvantages
1. It does not require 1. It waits until the effect Of the
identification and disturbances has been felt by the
measurement of any system. before control action is
disturbance. taken.
2. It insensitive to modeling 2. It is unsatisfactory for slow
errors. processes or with significant dead
time.
3. It is Insensitive to parameter
changes. 3. It may create instability in the
closed-loop response.

Process Dynamics & Control

 Relative Advantages and Disadvantages of Feedforward
10
Controllers

Advantages
1. Acts before the effect of a
disturbance
has been felt by the system.
2. Is good for slow systems
or with significant dead
time.
3. It does not introduce
instability in the
closed-loop response.
Disadvantages
1. Requires identification of all
possible disturbances and their
direct measurement.
2. Cannot cope with unmeasured
disturbances.
3. Sensitive to process parameter
variations.
4. Requires good knowledge of the
process model.

Process Dynamics & Control