Advanced Control Techniques

Dr. U. D Dwivedi (Assistant Professor) Rajiv Gandhi Institute of Petroleum Technology, Raebareli

Instrument Abbreviations
AT Analyzer (Composition) Transmitter FT Flow Transmitter LT Level Transmitter PT Pressure Transmitter TT Temperature Transmitter FC Flow Controller LC Level Controller TC Temperature Controller PC Pressure Controller LL Liquid Level LI Level Indicator TI Temperature Indicator PV Pressure Valve PI Pressure Indicator I/P Current to Pressure transducer

Feedforward and Ratio Control

Chapter 15

Chapter 15

Chapter 15

Chapter 15

Introduction : Feedforward Control

Chapter 15

Control Objective: Maintain Y at its set point, Ysp, despite disturbances. Feedback Control: Measure Y, compare it to Ysp, adjust U so as to maintain Y at Ysp. Widely used (e.g., PID controllers) Feedback is a fundamental concept Feedforward Control: Measure D, adjust U so as to maintain Y at Ysp. Note that the controlled variable Y is not measured.

Chapter 15

Comparison of Feedback and Feedforward Control

1) Feedback (FB) Control Advantages: Corrective action occurs regardless of the source and type of disturbances. Requires little knowledge about the process (For example, a process model is not necessary). Versatile and robust (Conditions change? May have to re-tune controller). Disadvantages: FB control takes no corrective action until a deviation in the controlled variable occurs. FB control is incapable of correcting a deviation from set point at the time of its detection. Theoretically not capable of achieving perfect control. For frequent and severe disturbances, process may not settle out.

Chapter 15

2) Feedforward (FF) Control Advantages: Takes corrective action before the process is upset (cf. FB control.) Theoretically capable of "perfect control" Does not affect system stability Disadvantages: Disturbance must be measured (capital, operating costs) Requires more knowledge of the process to be controlled (process model) Ideal controllers that result in "perfect control: may be physically unrealizable. Use practical controllers such as lead-lag units 3) Feedforward Plus Feedback Control FF Control Attempts to eliminate the effects of measurable disturbances. FB Control Corrects for unmeasurable disturbances, modeling errors, etc. (FB trim)

Chapter 15

4) Historical Perspective : 1925: 3 element boiler level control 1960's: FF control applied to other processes EXAMPLE : Heat Exchanger

Chapter 15

w = Liquid flow rate w s = Steam flow rate T1 = Inlet liquid temperature T2 = Exit liquid temperature

Chapter 15

Control Objective: Maintain T2 at the desired value (or set-point), Tsp, despite variations in the inlet flow rate, w. Do this by manipulating ws. Feedback Control Scheme: Measure T2, compare T2 to Tsp, adjust ws. Feedforward Control Scheme: Measure w, adjust ws (knowing Tsp), to control exit temperature,T2.

Feedback Control

Chapter 15

Feedforward Control

Feedforward/Feedback Control of a Heat Exchanger

Chapter 15

Chapter 15

Chapter 15

Ratio Control
Objective: maintain the ratio of two process variables at a specified value

where, u and d are physical variables, Used in mixing systems where an uncontrolled flow of material (wild flow) is monitored and used to control the second material which is controlled according to the desired ratio between the two components.

Chapter 15
Method I

Chapter 15
Method II

Chapter 15

Cascade Control
A cascade control system is a multiple-loop system. Desirable when Single-loop performance unacceptable and a measured variable is available.

Cascade control systems use a second feedback loop with a separate sensor and controller.
Cascade reduces the effect of specific types of disturbances. objective in cascade control is to divide a difficult process control into two portions a secondary control loop is formed around a major disturbances thus leaving only minor disturbances to be controlled by the primary controller

Better control of the primary variable Primary variable less affected by disturbances Faster recovery from disturbances

Cascade Control (multi-loop):

Chapter 16

Cascade Control (multi-loop):

Chapter 16

Analysis of Cascade Example

Without a cascade controller, changes in the pressure of fuel gas supply will disturb the hot oil temperature. Sluggish response With cascade controller, changes in gas pressure will be corrected by the pressure controller (PC) before it can significantly affect hot oil temperature because the PC responds faster to this disturbance than TC (the primary controller).

Cascade Control (multi-loop)

Distinguishing features:

Chapter 16

1. Two FB controllers but only a single control valve (or other -final control element). 2. Output signal of the "master" controller is the setpoint for slave" controller. 3. 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

SELECTIVE CONTROL SYSTEMS (Overrides)

For every controlled variable, there must be at least one manipulated variable. In some applications

NC NM
# of manipulated variables

Chapter 16

# of controlled variables Low selector:

High selector:

Chapter 16

multiple measurements one controller one final control element

Inferential Control
Problem: Controlled variable cannot be measured or has large sampling period.

Chapter 16

Possible solutions: 1. Control a related variable (e.g., temperature instead of composition). 2. Inferential control: Control is based on an estimate of the controlled variable.
The estimate is based on available measurements.
Examples: empirical relation, Kalman filter, Artificial Intelligence (AI), Neural Network

Modern term: soft sensor

Chapter 16

Adaptive Control
A general control strategy for control problems where the process or operating conditions can change significantly and unpredictably.

Chapter 16

Example: Catalyst decay, equipment fouling

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 u & y data.

Note: For predictable or measurable changes, use gain scheduling instead of adaptive control
Reason: Gain scheduling is much easier to implement and less trouble prone.

Chapter 16

Time Delay Compensation

Model-based feedback controller that improves closed-loop performance when time delays are present Effect of added time delay on PI controller performance for a second order process (1 = 3, 2 = 5) shown below

Chapter 16

Chapter 16

Chapter 16

*e s G *e s No model error: G G = =
GC

GC GC G Y = Ysp 1 + GC G 1 + GC G* 1 e s

GC G*e s GC G Y = = Ysp 1 + GC G* 1 + GC G*

(16 22)

(sensitive to model errors > +/- 20%)

Chapter 16

Chapter 16

Chapter 16

Chapter 16

Chapter 16

Chapter 16

Chapter 16

Gain Scheduling
Objective: Make the closed-loop system as linear as possible. Basic Idea: Adjust the controller gain based on current measurements of a scheduling variable, e.g., u, y, or some other variable.

Chapter 16
Note: Requires knowledge about how the process gain changes with this measured variable.