Feedforward and Ratio

Control
ISA Mentor Program Presentation by:
Gregory K. McMillan
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Presenter

• Gregory K. McMillan is a retired Senior Fellow from Solutia/Monsanto and an ISA

Fellow. Greg was an adjunct professor in the Washington University Saint Louis
Chemical Engineering Department 2001-2004. Greg received the ISA “Kermit Fischer
Environmental” Award for pH control in 1991, the Control Magazine “Engineer of the
Year” Award for the Process Industry in 1994, was inducted into the Control “Process
Automation Hall of Fame” in 2001, was honored by InTech Magazine in 2003 as one
of the most influential innovators in automation, and received the ISA Life
Achievement Award in 2010. Greg is the author of numerous ISA books on process
control, his most recent being Advances in Reactor Measurement and Control and
Good Tuning: A Pocket Guide - 4th Edition. Greg has been the monthly “Control Talk”
columnist for Control magazine since 2002. Greg is the founder and co-leader with
Hunter Vegas of the ISA Mentor Program for users. Greg’s expertise is available on
the web sites: http://www.controlglobal.com/blogs/controltalkblog/
http://automation.isa.org/author/gregmcmillan/

2
What is the most Prevalent Upset?

 In the process industry, nearly all inputs that affect

production are process streams and utility streams
 The Process Flow Diagram (PFD) reveals the effects of
streams on plant performance but unfortunately out dated
 Changes in stream flow are usually fast and the degree of
disruption is determined by the lack of automation (e.g.,
manual actions), Safety Instrumented System (SIS) and
sequential actions, interactions, resolution, repeatability,
rangeability, response time, reliability and PID tuning
 Feedforwards most needed for abrupt flow or flow with
stream conditions used to computed a flow of energy or
a component using stream temperature and composition.

3
Feedforward Multiplier vs Summer

 When there is no secondary flow or speed controller, the feedforward summer in the
primary controller is used to directly manipulate a valve position or power input
signal. A secondary controller is too slow for pressure control.
 When there is a flow or speed controller, Ratio control is predominantly used where a
secondary flow or speed controller setpoint is manipulated to follow a leader flow or
speed that is multiplied by a desired ratio. Ratio control is used to assist primary PIDs for
composition, level, pH, temperature, & quality control.
 In Ratio control the leader and follower flow first go to a Ratio block whose output is the
input to a Bias/Gain block whose output is the cascade setpoint for a flow or speed
controller. The setpoint (SP) of each block (ratio or bias) can be set by operator (auto
mode) or automatically corrected by a primary PID (cascade mode). The manipulation of
the primary PID of the Bias SP and Ratio SP is effectively a feedforward summer and
feedforward multiplier, respectively. The use of the ratio and bias/gain blocks provide the
operator visibility and accessibility in ratio control particularly important for understanding
and procedural automation during startup, changes in products and abnormal operations.
 The Bias SP is manipulated for volumes with back mixing due to agitation,
turbulence or boiling (e.g., vessels and columns).
 The actual and desired Ratio SP are displayed. During startup until the process is at
its normal operating point, the primary controller is often in manual. In this case the
operator runs with a manually set bias and ratio without correction.
Ratios Here, There and Everywhere
 Blend composition control - additive/feed (flow/flow) ratio
 Column temperature control - distillate/feed, reflux/distillate, reflux/feed,
steam/feed, and bottoms/feed (flow/flow) ratio
 Combustion temperature control - air/fuel (flow/flow) ratio
 Drum level control - feedwater/steam (flow/flow) ratio
 Extruder quality control - extruder/mixer (power/power) ratio
 Heat exchanger temperature control - coolant/feed (flow/flow) ratio
 Neutralizer pH control - reagent/feed (flow/flow) ratio
 Reactor reaction rate control - catalyst/reactant (speed/flow) ratio
 Reactor composition control - reactant/reactant (flow/flow) ratio
 Sheet, web, and film line machine direction (MD) gage control -
roller/pump (speed/speed) ratio
 Slaker conductivity control - lime/liquor (speed/flow) ratio
 Spin line fiber diameter gage control - winder/pump (speed/speed) ratio
 Header pressure control – letdown/user (flow/flow) ratio
For level and pressure, the mass flow theoretical ratio is simply 1. For other
loops, the ratio is seen as the ratio of stream flows on a Process Flow Diagram.
Cascade Ratio or Cascade Bias
Correction by Primary PID output

Follower
Flow or Speed

Cascade Bias Original Relationship per

Correction Process Flow Diagram (PFD)

Cascade Ratio
Correction

Leader
Flow or Speed

 Automatic correction of cascade Ratio Setpoint (feedforward multiplier) creates a gain factor in the open loop gain that is proportional to flow.
 For plug flow processes this multiplier gain factor cancels out a process gain that is inversely proportional to flow.
 For back mixed processes, the process time constant being inversely proportional to flow cancels out process gain nonlinearity in the PID tuning
where the PID gain is proportional to the process time constant divided by the process gain.
In this case the correction of the cascade ratio creates a residual nonlinearity that adversely affects PID tuning
 The primary PID output scaling is more critical and prone to error when correcting a Ratio Setpoint
 The PID output scaling can be as simple as -50% to +50% of secondary PID scale when correcting a Bias Setpoint
 Finally, many corrections in Ratio Control are simply associated with offsets from bias errors in the flow measurements or unmeasured loads
 When in doubt which is best, automatically correct the Bias Setpoint
 You can slowly adapt the uncorrected Ratio or Bias Setpoint by use of a generic integral only controller to reduce the correction by primary PID
Loop and Load Disturbance Dynamics
Block Diagram
Measured
Disturbance

Feedforward correction should arrive at

this point at same time as the Load Upset
How do we improve Feedforward?

 Understand dynamic compensation

 Feedforward (FF) Lag = Load Lag (disturbance variable path lag)
 Feedforward (FF) Lead = Loop Lag (controller output path lag)
 Feedforward (FF) Delay = Load Delay – Loop Delay
 Feedforward (FF) Gain = Load Gain / Loop Gain
 Seek instruction on how to use auto tuning software to
identify dynamic compensation
 Setup disturbance variable test like manipulated variable test
 Insure feedforward does not arrive too soon or is too great
or counter to current trajectory causing an inverse response
 Use a slightly larger FF delay and lag than estimated (e.g., +10%)
 Use a considerably lower FF gain than estimated (e.g., -40%) but if
load and loop gain are well known, gain reduction can be -10%
 Intelligently suppress FF if current trajectory is in opposite direction
8
 FF Loop Deadtime = 10 sec
Off Loop Lag = 20 sec

FF Delay FF Delay
Mismatch Mismatch
FF Delay 0 sec + 10 sec
Mismatch
− 10 sec

Figure 12.1a Effect of Feedforward Delay Mismatch on

PID PV for Moderate Self-Regulating Process
 Loop Deadtime = 10 sec
Loop Lag = 100 sec

FF
Off

FF Delay FF Delay
Mismatch FF Delay Mismatch
− 10 sec Mismatch + 10 sec
0 sec

Figure 12.1c Effect of Feedforward Delay Mismatch on

PID PV for Near Integrating Process
 FF Loop Deadtime = 10 sec
Off Loop Lag = 20 sec

FF Lag
FF Lag Mismatch
Mismatch + 10 sec
0 sec
FF Lag
Mismatch
− 10 sec

Figure 12.2a Effect of Feedforward Lag Mismatch on

PID PV for Moderate Self-Regulating Process
 Loop Deadtime = 10 sec
Loop Lag = 100 sec

FF
Off

FF Lag FF Lag
Mismatch Mismatch
FF Lag
− 10 sec + 10 sec
Mismatch
0 sec

Figure 12.2c Effect of Feedforward Lag Mismatch on

PID PV for Near Integrating Process
 FF Loop Deadtime = 10 sec
Off Loop Lag = 20 sec

FF Gain FF Gain
Mismatch Mismatch
+50 % FF Gain
Mismatch − 50 %
0%

Figure 12.3a Effect of Feedforward Gain Mismatch on

PID PV for Moderate Self-Regulating Process
 Loop Deadtime = 10 sec
Loop Lag = 100 sec

FF
Off

FF Gain
Mismatch
0%
FF Gain FF Gain
Mismatch Mismatch
+ 50 % − 50 %

Figure 12.3c Effect of Feedforward Gain Mismatch on

PID PV for Near Integrating Process
 Steam Header Feedforward
and Decoupler (Linear Valves)
Definition of Loop Lag and Leader Lag:
Loop Lag is Primary Loop’s time constant in path of follower flow or speed to primary process output
(primary time constant in self-regulating process and secondary time constant in an integrating process)
Leader Lag is Leader’s time constant in path of leader flow or speed to the primary process output
(load is positive for user pulling steam from header and negative for user pushing steam into the header)

Disturbance 1 Flow Disturbance 2 Flow

Load1 (kpph) Load2 (kpph)

FF1 Delay => Load1 Delay – Loop Delay DEADTIME DEADTIME FF2 Delay => Load2 Delay – Loop Delay

FF1 Lead = Loop Lag

(block diagram Secondary Lag FF2 Lead = Loop Lag
LEAD/LAG LEAD/LAG
FF1 Lag = Load1 Lag FF2 Lag = Load2 Lag
Letdown Flow
To Lower
Header (kpph)
If Load Delay is less than Loop Delay,
FF1 FF0 FF2
often a delay can be inserted in the PID
SP that is triggering the disturbance.
The SP before the delay is used as Header
ADD PID PV
the feedforward signal so that Loop Delay is
now less than Load Delay. This is an important (psig)
often overlooked technique! FF Gain
0.8 to 1.0 Header
If Load1 nonlinear valve must be used as an inference of flow
PID SP
a signal characterizer (SG) would be needed on FF1 PID (psig)
SG would use installed flow characteristic of load valve. Header FF
SG Y outputs would be 0 – F1max (kpph) FF Scale
SG X inputs would be 0-100% position 0 – FFmax (kpph) Header
where F1max is max Load1 valve flow where FFmax is PID OUT
max letdown 0 -100%
valve flow (% of Fmax)
ANALOG Valve Signal
OUTPUT 0 -100%
If letdown valves are not linear,
(% of Fmax)
a signal characterizer (SG) would be needed on PID OUT
SG would use installed flow characteristic of letdown valve.
SG Y outputs would be 0-100% signal
SG X inputs would be 0-100% max letdown valve flow
Ratio Control Dynamic Compensation
& Adaptive Feedback Correction of Ratio
Examples of Follower to Leader flow ratio corrected by Primary Controller output:
Reboiler Steam Flow to Column Feed ratio corrected by Temperature Controller
Receiver Distillate Flow to Column Feed ratio corrected by Temperature Controller
Reagent Flow to Neutralizer Feed ratio corrected by pH Controller
Follower Reactant Flow to Leader Reactant Flow ratio corrected by Composition Controller

Follower Flow
Follower PV or Speed (e.u.)
Leader Flow Leader PV Actual Ratio PV
or Speed (e.u.) after correction
AUTO Ratio SP RATIO
CAS Ratio SP

Uncompensated
Follower Flow or Speed SP
(Leader PV x Ratio)

Follower Delay => Leader Delay – Loop Delay DEADTIME

Follower Lead = Loop Lag

Secondary
LEAD/LAG
Follower Lag = Leader Lag PID PV
Primary (e.u.)
PID PV Dynamic (Follower PV)
(e.u.) Compensated
Follower SP
Secondary AUTO SP (e.u.)
Gain
Primary Secondary CAS SP
PID SP AUTO Bias SP BIAS/GAIN PID
PID (e.u.)
(e.u.) (Corrected Follower
CAS Bias SP Flow or Speed SP)
Secondary
Primary PID OUT
PID OUT Zero Correction SP 0 -100%
-0.5xFmaxto 0.5xFmax
Bias Correction (e.u.) Gradual Adaptation
PID by PID Integral Valve Signal
Only Controller ANALOG 0 -100%
OUTPUT (% of Fmax)
0.5xRnorm to 2.0xRnorm Adaptive
Ratio Correction PID OUT
 Ratio Control Dynamic Compensation
& Adaptive Feedback Correction of Bias
Definition of Loop Lag and Leader Lag: Examples of Follower to Leader flow ratio corrected by Primary Controller output:
Loop Lag is Primary Loop’s time constant in path of follower flow to primary process output Reboiler Steam Flow to Column Feed ratio corrected by Temperature Controller
(primary time constant in self-regulating and secondary time constant in an integrating process) Receiver Distillate Flow to Column Feed ratio corrected by Temperature Controller
Leader Lag is Leader’s time constant in path of leader flow to the primary process output Reagent Flow to Neutralizer Feed ratio corrected by pH Controller
Follower Reactant Flow to Leader Reactant Flow ratio corrected by Composition Controller

Follower Flow
Follower PV or Speed (e.u.)
Leader Flow Leader PV Actual Ratio PV
or Speed (e.u.) after correction
AUTO Ratio SP RATIO
CAS Ratio SP

Uncompensated
Follower Flow or Speed SP
(Leader PV x Ratio)

Follower Delay => Leader Delay – Loop Delay DEADTIME

Follower Lead = Loop Lag

Secondary
LEAD/LAG
Follower Lag = Leader Lag PID PV
Primary
(e.u.)
PID PV Dynamic (Follower PV)
(e.u.) Compensated
Follower SP
Secondary AUTO SP (e.u.)
Gain
Primary Secondary CAS SP (e.u.)
PID SP AUTO Bias SP BIAS/GAIN PID
PID (Corrected Follower
(e.u.)
CAS Bias SP Flow or Speed SP)
Secondary
Primary PID OUT
PID OUT Zero Correction SP 0 -100%
0.5xRnorm to 2.0xRnorm Gradual Adaptation
Ratio Correction by PID Integral
PID Valve Signal
Only Controller ANALOG 0 -100%
OUTPUT (% of Fmax)
-0.5xFmaxto 0.5xFmax Adaptive
Bias Correction (e.u.) PID OUT
Steam Header System
Feedforward Control
PX 1-3, PX 1-2, PX 2-3, PX 2-2, PX 3-3, PX 3-2 are Deadtime and Lead/Lag blocks in series for dynamic compensation of feedforward signals
PY 1-1, PY 2-1, PX 3-1 are Add blocks where generator flows are negative and user flows and decoupling flows are positive signals
Decoupling flows from lower header letdown valves typically do not need dynamic compensation if valves are in same proximity of header
Feedforward signals are in same engineering flow units (kpph) with Feedforward scale in PID set to be max flow of manipulated letdown valve
All letdown valves must be precise (0.1% resolution 0.2% deadband) fast valves (4 sec T86 86% response time) with linear flow characteristics

Steam Steam − Hi SP
Generators Users
+ PY
Cogen
FC
3-1 (kpph) 3-1
FT PX FT PX FT
3-2 +
3-3 3-3 3-2 3-1

Lo SP Hi Pressure Header

Steam − Norm SP PC RY
Steam
Generators Users + FF
2-1c 2-1
Hi Signal
Boiler
PY PC
Hi SP Selection
2-1 2-1a
FT PX FT PX (kpph) FT
+
PC Vent
2-3 2-3 2-2 2-2 2-1b 2-2
PT
2-1 Med Pressure Header

Steam Steam − Norm SP

Generators Users
+ PY FF PC
1-1a Hi SP
1-1
(kpph)
FT PX FT PX PC Vent
1-3 1-3 1-2 1-2 1-1b
PT
1-1 Lo Pressure Header
Liquid Reactor Ratio Control of
Reactants with Feed Maximization
Reactant ZC1-4 SP ZC1-4 is an enhanced PID VPC
FC SP LC
Ratio Control OUT 1-1 1-8
RC Leader PT PC FC 1-1 ZC
1-5 1-5 SP 1-4
1-2
Reactant A FT FT Vent
1-1 1-5
LY
1-8 Level SP for LT TT TC
Optimum 1-8 1-3 1-3
Follower SP FC
1-2 Residence Time process recirculation

TT TC
Reactant B FT 1-4 1-4
1-2
Return
Dynamic compensation of reactant ratio control is not CTW
needed because reactants arrive at the same point
at the same time in reactor if
equal reactant flow setpoint filters are used.
AT AC
1-6 1-6
Valve Position Controller ZC1-4 pushes coolant
valve to max position to maximize reactant feed rate.
The ZC1-4 setpoint is the maximum position.
The ZC1-4 should have smart integral action to
Makeup
prevent interaction and limit cycles. The correction for
a valve position less than setpoint should be slow to CTW
provide a slow approach to optimum. The correction for SP FC
a valve position greater than setpoint must be fast to 1-7
provide a fast getaway from the point of loss of control.
Directional setpoint rate limits with dynamic reset limit in jacket recirculation
an enhanced PID that tempers integral action FT Product
can achieve these optimization objectives. 1-7
Column 1 Top Temperature
Ratio Control: Small Distillate Flow
Relative Advantages: Internal reflux control inherently
SP
compensating for changes in reflux temperature and Z
inherent decoupling of energy and material balances
Relative Disadvantages: Slower control of bottoms
FC
1-5
composition (problematic for stripping columns)
Receiver LT LC
1-6 1-6
FT
1-5 Tight Level
Reflux Control

TT TC SP FC
1-8 1-8 1-3
Steam/Feed FC Bias
Ratio Control 1-1 Correction RY
RC Leader 1-3
FT
1-2 Column 1-3
Distillate
Compensation

FT Distillate/Feed
1
Dynamic

1-1 Ratio Control

RX Feed
1-2 Follower Leader Flow RC RX
Flow Feedforward 1-3 1-3 Dynamic
Compensation
SP FC Follower Flow
1-2
Loose Level
Control SP FC
FT LT LC 1-4
1-2
Steam Z Sump 1-7 1-7

FT
1-4
Bottoms
Column 2 Top Temperature
Ratio Control: Large Distillate Flow
Relative Advantages: Faster temperature control SP
since independent of level control
Z
Relative Disadvantages: Moderate interaction FC Loose Level
between energy and material balances 1-5 Control
Receiver
LT LC
1-6 1-6
FT
1-5
Reflux SP

TT TC FC
1-8 1-8 1-3
Steam/Feed FC
Ratio Control 1-1
Bias
RC Leader Correction FT
1-2 Column RY
1-3
Distillate
Compensation

FT
1-1 2 Reflux/Feed
1-5

Compensation
RX Feed
Dynamic

Follower Ratio Control

Dynamic
1-2
Leader Flow RC RX
Flow Feedforward 1-5 1-5
SP FC
1-2 Follower Flow
Loose Level
Control SP FC
FT LT LC 1-4
1-2
Steam
Z Sump 1-7 1-7

FT
1-4
Bottoms
Column 3 Bottom Temperature
Ratio Control: Large Bottoms Flow
Relative Advantages: Fastest temperature control SP
Relative Disadvantages: Severe interaction between Z
energy and material balances and possibly less process FC Loose Level
sensitivity from manipulation of separation (vapor rate) 1-5 Control
Receiver
LT LC
1-6 1-6
FT
1-5
Reflux SP

FC
1-3
Steam/Feed Reflux/Feed
FC
Ratio Control Ratio Control
1-1
RC Leader Leader Flow RC FT
1-2 Column 1-5 Follower Flow 1-3
Distillate
Compensation

FT
RX
3
Dynamic

RX 1-1
Feed 1-5 Dynamic
1-2 Follower Compensation
Flow Feedforward
TT TC
RY SP FC 1-8 1-8
1-2 1-2
Loose Level
Control SP FC
LT LC 1-4
FT
1-2
Steam Z Sump 1-7 1-7

FT
Bias
1-4
Correction Bottoms
Column 4 Bottom Temperature
Ratio Control: Small Bottoms Flow
Relative Advantages: Fast temperature control if level
control is tight but this may not be possible due to level
SP
inverse response (good steam/feed ratio is critical) Z
Relative Disadvantages: Moderate interaction between
FC Loose Level
energy and material balances and possibly less process
1-5 Control
sensitivity from manipulation of separation (vapor rate)
Receiver LT LC
1-6 1-6
FT
1-5
Reflux SP

FC
1-3
Steam/Feed Reflux/Feed
FC
Ratio Control Ratio Control
1-1
RC Leader Leader Flow RC FT
1-2 Column 1-5 Follower Flow 1-3
Distillate
Compensation

FT
RX
4
Dynamic

RX 1-1
Feed 1-5 Dynamic Bottoms/Feed
1-2 Follower Leader Flow Compensation RC Ratio Control
Flow Feedforward 1-4 Follower Flow
TT TC RY RX
RY SP FC 1-8 Bias 1-4 1-4
1-8 Dynamic
1-2 1-2 Correction Compensation
Tight Level
Control SP FC
LT LC 1-4
FT
1-2
Steam
Z Sump 1-7 1-7

FT
Bias
1-4
Correction Bottoms
 Questions?

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