PROCESS CONTROL

APPLICATION

CBE495, Spring 2020

Professor Dae Ryook Yang

Dept. of Chemical & Biological Engineering

Korea University

CBE495 Process Control Application Korea University 1-1

Objectives of the Class

• Application of process control techniques
• Advanced process control
– Feedforward control, ratio control, override control
– Selective control, optimizing control, valve position control
– Etc.
• Multivariable process
– Interaction analysis
– Multiloop PID control
• Model Predictive Control
• Supervisory and statistical control

• Java applets will be used to understand the concepts

better
• Matlab
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 SYLLABUS
• Based on the basic process control concepts, advanced
control techniques such as feedforward control, ratio
control, cascade control, multiloop control, model
predictive control, statistical control and etc. will be
taught and practiced.

• Lecture hour
– 15:30-16:45 Tuesday, (Changeui Bldg. 106)
– 15:30-16:45 Thursday, (Changeui. Bldg. 106)

• Textbook
– Seborg D.E., T.F. Edgar, and D.A. Mellichamp, Process Dynamics
and Control, 3rd Ed., John Wiley & Sons Inc., New York, NY (2011)
– Lecture note
(http://www.cheric.org/eduction/lecture/process/CHBE495)
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• Lecture aids
– Java Applets
– Matlab

• Course Grading
– Attendance(10%)
– Participation (10%)
– Project(30%)
– Final exam(30%)
– Homework(20%)

• Office hour
– Basically, anytime when I am available. If you need
appointment, call 3298
– Also, you can get some assistance from graduate students of
the process systems laboratory (New Eng. Bldg #710)

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 PROLOGUE

• How to use Matlab

– Use Korea University license.

– Basics of Matlab language

– Simulink
– Toolboxes (Control, optimization)

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CBE495 LECTURE I
FEEDFORWARD CONTROL
AND RATIO CONTROL

Professor Dae Ryook Yang

Spring 2020
Dept. of Chemical and Biological Engineering
Korea University

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 FEEDFORWARD CONTROL
• Feedback control
– Corrective action based on process output (CV)
– If PID is used, no a priori knowledge is required
– However, it can respond only after some changes occurs in CV

• Feedforward control
– Based on the measurement of disturbance, feedforward
controller can respond even before any changes occurs in CV
– It requires process model which can predict the effect of
disturbance on CV
– If there are some modeling error, feedforward control action
will be erroneous (No corrective action)

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• Typical example
– Boiler level control

• In order to overcome the shortcomings of the

feedback or feedforward controls, combine them!
 Feedforward-feedback control

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 • Tank heater control
– Tank level control (feedback)
– Outlet temp. control (feedforward-feedback)

If cold water flow changes,

feedforward controller
will adjust the steam flow
rate as soon as the cold
water flow change is
detected.

If the feedforward action

is not enough due to the
model error, measurement
error and etc., feedback
controller will compensate
the difference.

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Steady-State Feedforward (FF) Control

• Dynamic model for CSTH (Energy balance)

Where

• Steady-state model for CSTH

Based on the steady-state relation between

variables, a control law can be derived.

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 • Static FF controller
– The feed temperature must be measured.
– The desired exit temperature (Tsp) should be entered manually
instead of the exit temperature.
– The feed flow rate should be measured or at least known.

– This FF controller is bilinear.

– If the model is accurate, a change in disturbance variables such
as feed temperature, feed flow rate will be compensated
eventually.
– The transient cannot be compensated with static FF control.

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• Field applicable FF Controller

– Transmitters

– IP transducer and control valve

– FF control law

where

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 Dynamic Feedforward Controller Design
• Closed-Loop Transfer Function for Load Change

– Ideal FF control: C(s)=0

– Dynamic feedforward controller

• Theoretically, perfect disturbance rejection is possible.

• FF controller can be quite complex
• The stability is not affected by FF controller

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• Examples
1)
(Lead-lag type)

2)

(Time lead: physically unrealizable)

3)

(Not proper: physically unrealizable)

 Remedy: Use a lead-lag type FF controller and tune it.

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 • Example

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• Comparison of static and dynamic FF Controller

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 Tuning Feedforward Controllers
• Feedforward controller gain (Kf)
– Calculate from the model and adjust so that the offset can be
eliminated for some change in load
• Lead and lag time constants
– Lead: add all the time constants in the numerator plus time
lead of the ideal FF controller
– Lag: add all the time constants in the denominator of the ideal
FF controller
– Fine tuning:
• From initial guesses of the time constants,
• Adjust lead so that the areas of above and below the set points in
the response of step change in disturbance are about same.
• Then adjust the lag until satisfaction while the difference between
lead and lag is maintained constant.

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• Example
– Increase lead: speed up to the steady state
– Decrease lead: slow down to the steady state

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 Configurations for Feedforward-Feedback
Control

• Feedback trim • FB controller output is the

• FF does not affect the set point of the FF controller
stability • FF does affect the stability
• Another way is that the FB controller output adjust
the FF controller gain
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• A Typical Block diagram for FF-FB control

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 Ratio Control
• A special type of FF control
• Objective: maintain the ratio of two variables

M: Manipulated variable
L: Load variable
– The calculation of ratio is performed in terms of the original
variables, rather than deviation variables
– Typical applications
• Blending operations
• Maintaining a stoichiometric ratio of reactants to a reactor
• Keeping a specified reflux ratio for a distillation column
• Holding the fuel-air ratio to a furnace at the optimum value

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Ratio Control Schemes

Method I Method II

– Actual ratio is calculated

– Set point is desired ratio – Constant process gain
– Process gain varies (nonlinear) – Widely used (preferred)

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