Process Control
in Chemical Engineering
Agung Nugroho, Ph.D.
8-Jan-24 1
Topics
Week Title
Week 01 Introduction to Process Control
Week 02 Mathematical modeling, Dynamic Modeling
Week 03 Laplace Transformation, Transfer Function and Block Diagram
Week 04-05 Dynamic Behavior of Typical process systems (1st , 2nd order)
Week 06 MATLAB simulink
Week 07 Development of Empirical models from process data
Week 08 Midterm Exam
Week 09-10 Feedback Controllers and Instrumentation
Week 11 PID controllers
Week 12-13 Dynamics behavior and Stability of closed-loop control systems
Week 14 Tunning PID Controller
Week 15 FF, ratio, cascade controller
Week 16
8-Jan-24 Final Exam 2
W10: Feedforward, Ratio, and Cascade
Control
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Syllabus
• Course Syllabus:
– Feedforward Control System
– Ratio Control
– Cascade Control
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Topic 1:
Feedforward Control
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Feedback Control
A boiler drum with a conventional feedback control system
• The level of the boiling liquid (CV) is
measured and used to adjust the feedwater
flow rate (MV).
• This control system tends to be quite
sensitive to rapid changes in the disturbance
variable, steam flow rate, as a result of the
small liquid capacity of the boiler drum.
• Rapid disturbance changes can occur as a
result of steam demands made by
downstream processing units.
Figure 15.2 The feedback control of the liquid level in a boiler drum.
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Feedback Control
Final Control
Element
Controller
Sensor
Transmitter
Controller Sensor
Final Manipulated variable Controlled
element variable
Process
Disturbances Other outputs
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Advantages Feedback control
• Very simple technique
• Effective for all disturbances
• Provides zero ss offset
• Works with minimum knowledge of the process
Disadvantages Feedback control
• Does not take control action until the process
output has deviated from set point
• Affects the closed-loop stability
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Feedforward Control
• The feedforward control scheme can
provide better control of the liquid
level.
• Here the steam flow rate (DV) is
measured, and the feedforward
controller adjusts the feedwater flow
rate (MV).
Figure 15.3 The feedforward control of the liquid level in a boiler drum.
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Feedforward Control
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Feedforward Control
Advantages Feedforward control Disadvantages Feedforward control
• Compensates for a ■ The disturbance variables must be
disturbance before the measured on-line. In many
process output is affected applications, this is not feasible.
• Does not affect the stability ■ Can not eliminate steady-state offset
of the control system ■ Requires a sensor and model for
each disturbance
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Date: 8-Jan-24 Sustainable Transportation 12
Comparison FB and FF controller
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Feedback-Feedforward Control
Flow steam
(DV)
Flow
feedwater Level (CV)
(MV)
Figure 15.4 The feedfoward-feedback control of the boiler drum level.
• In practical applications, feedforward control is normally used in combination with feedback control.
• Feedforward control is used to reduce the effects of measurable disturbances, while feedback trim compensates for
inaccuracies in the process model, measurement error, and unmeasured disturbances.
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Feedback-Feedforward Control
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Block Diagram of FB-FF Controller
Figure 15.11 A block diagram of a feedforward-feedback control system.
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The closed-loop transfer function for disturbance changes is:
𝑌 𝑠 𝐺𝑑 + 𝐺𝑡 𝐺𝑓 𝐺𝑣 𝐺𝑝
=
𝐷 𝑠 1 + 𝐺𝑐 𝐺𝑣 𝐺𝑝 𝐺𝑚
To produce perfect control where the controlled variable remains exactly at the set
point despite arbitrary changes in the disturbance variable, D. 𝐺𝑑
𝐺𝑓 = −
𝐺𝑡 𝐺𝑣 𝐺𝑝
Thus, if the set point is constant (Ysp(s) = 0),
we want Y(s) = 0, even though D(s) ≠0 Equation for the ideal feedforward controller.
Diagram block indicates that a disturbance has two effects.
• It upsets the process via the disturbance transfer function, Gd; however, a corrective action is
generated via the path through GtGfGvGp.
• Ideally, the corrective action compensates exactly for the upset so that signals Yd and Yu cancel
each other and Y(s) = 0.
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Example 1
Suppose that we have FF-FB controller with transfer function:
𝐾𝑑 𝐾𝑝
𝐺𝑑 = ,𝐺 = , 𝐺𝑡 = 𝐾𝑡 𝑎𝑛𝑑, 𝐺𝑣 = 𝐾𝑣
τ𝑑 𝑠 + 1 𝑝 τ 𝑝 𝑠 + 1
Derive the equation for the transfer function of ideal feedforward
controller
𝐺𝑑
Solution 𝐺𝑓 = −
𝐺𝑡 𝐺𝑣 𝐺𝑝
𝐾𝑑 τ𝑝 𝑠 + 1
𝐺𝑓 = −
𝐾𝑡 𝐾𝑣 𝐾𝑝 τ𝑑 𝑠 + 1
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Example 2
Suppose that we have FF-FB controller with transfer function:
𝐾𝑑 𝐾𝑝 𝑒 −𝜃𝑠
𝐺𝑑 = , 𝐺𝑝 = , 𝐺𝑡 = 𝐾𝑡 𝑎𝑛𝑑, 𝐺𝑣 = 𝐾𝑣
τ𝑑 𝑠 + 1 τ𝑝 𝑠 + 1
Derive the equation for the transfer function of ideal feedforward
controller
𝐺𝑑
Solution 𝐺𝑓 = −
𝐺𝑡 𝐺𝑣 𝐺𝑝
𝐾𝑑 τ𝑝 𝑠 + 1
𝐺𝑓 = − 𝑒 𝜃𝑠
𝐾𝑡 𝐾𝑣 𝐾𝑝 τ𝑑 𝑠 + 1
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Stability consideration of FF controller
𝑌 𝑠 𝐺𝑑 + 𝐺𝑡 𝐺𝑓 𝐺𝑣 𝐺𝑝
=
𝐷 𝑠 1 + 𝐺𝑐 𝐺𝑣 𝐺𝑝 𝐺𝑚
The characteristic equation is 1 + 𝐺𝑐 𝐺𝑣 𝐺𝑝 𝐺𝑚
Stability of the system is when 1 + 𝐺𝑐 𝐺𝑣 𝐺𝑝 𝐺𝑚 = 0
No Gf in the characteristic equation → The feedforward controller has no effect on the
stability of the feedback control system
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Topic 2:
Ratio Control
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Ratio Control system
• A ratio controller is a special type of feedforward
controller where disturbances are measured and
their ratio is held at a desired set point by
controlling one of the streams.
• The flow rates are measured through flow
transmitters (FTs).
• Ratio controls are used where we have to control
one physical quantity with the ratio of two
different physical quantity as shown in figure.
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Date: 8-Jan-24 Sustainable Transportation 23
Method of Ratio Control
u and d are measured
d are measured
Rm= um/dm, is calculated. RS multiply dm with Kr → usp
Compared Rm with Rd
Compared um with usp
Adjust the valve on u
Adjust the valve on u
Application of Ratio Control
1.Setting the relative amounts of components in blending
operations
2.Maintaining a stoichiometric ratio of reactants to a
reactor
3.Keeping a specified reflux ratio for a distillation column
4.Holding the fuel-air ratio to a furnace at the optimum
value.
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Performance Improvements
Typical Performance Improvements using Ratio Control
Impurity Concentration
w/o ratio control
w/ ratio control
Time
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Ratio Control for Top Distillation:
Method 1
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Ratio Control for Top Distillation:
Method 2
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Ratio Control for Wastewater Neutralization
RSP
FC
FT FT
NaOH
Acid Solution
Wastewater
pHC pHT
Effluent
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Example 3
FT TT
Draw schematic for a control system
that adjusts the ratio of fuel flow to Flue
the flow rate of the process fluid to Gas
control the outlet temperature of the
process fluid. Use a flow controller on
FT
the fuel. Process
Fluid
Fuel
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Solution
× TC
FT TT
Flue
RSP Gas
FC
FT
Process
Fluid
Fuel
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Advantages of Ratio Control Disadvantages of Ratio Control
• Allows user to link two streams to ■ Often one of the flow rates is not
produce and maintain a defined ratio measured directly and the controller
between the streams. assumes that the flows have the
correct ratio through the control of
• Simple to use.
only the measured flow rate.
• Does not require a complex model.
■ Requires a ratio relationship between
variables that needs to be maintained.
■ Not as useful for variables other than
flow rates.
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Topic 3: Cascade Control
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Cascade Control
• In cascade control, a process is controlled by two controllers in such way that
both are acting for each other.
• Cascade control is technique which contain two closed loop control cascaded to
each other in such way that first loop controller output will be set point for
second loop controller. It is called remote set point (RSP) for second controller.
• In cascade control first loop called master and second loop called slave
controller.
– Master controller generate the set point for the slave controller.
– Slave controller control the process depends upon the remote set point
provided by master controller.
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Level Controller
Fin
Lsp ■ Without a cascade level controller,
Fout changes in downstream pressure will
LC LT disturb the tank level.
Fin ■ With cascade level controller, changes
Lsp in downstream pressure will be absorbed
Fout by the flow controller before they can
LC LT significantly affect tank level because
FT the flow controller responds faster to
this disturbance than the tank level
FC process.
RSP
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Reactor Temperature Control
Feed
■ Without cascade, changes in the cooling water
TC
temperature will create a significant upset for
Cooling the reactor temperature.
water
TT
Product
■ With cascade, changes in the cooling water
Feed
temperature will be absorbed by the slave
loop before they can significantly affect the
RSP
TT TC reactor temperature.
Cooling
water
TT TC
Product
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Performance Improvements
Typical Performance Improvements using Cascade Control
6
FB-only
3 Compensating for
Disturbances Reduces
T' (K)
0 Deviations from Setpoint
and Settling Time
-3
Cascade
-6
-10 10 30 50
Time (seconds)
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Performance Improvements
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Example 4
PT
Solution
Steam RSP
TC PC PT
TT Steam
TT
Feed
Feed
Condensate Condensate
• Draw schematic:
• A temperature controller on the outlet stream is cascaded to a
pressure controller on the steam which is cascaded to a control
valve on the condensate.
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Cascade Control
Distinguishing features:
1. Two FB controllers but only a single control valve (or other final control
element).
2. Output signal of the "master" controller is the set-point 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
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Block Diagram of Cascade Control
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Cascade block diagram Using Simulink
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Example 5
Consider the block diagram in Fig. 16.4 with the following transfer functions:
5 4
Gv = G p1 = G p2 = 1
s +1 ( 4s +1)( 2s +1)
1
Gd 2 = 1 Gm1 = 0.05 Gm2 = 0.2 Gd1 =
3s + 1
Response Dynamic
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Using Simulink
Response of
unit step on D2
Response of
unit step on D1
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Drawbacks of Cascade Control
Drawbacks of Cascade Control Advantages of Cascade Control
• Cascade control makes the system more
complex. • Reduce the dead time in the control system.
• Cascade control required more instruments • Can be combined with feed forward and other
and equipment which leads the cost of type of controllers.
process. • Improved dynamic response and performance
• Tuning of cascade controllers are more difficult and provide limit on secondary variable.
than close loop control. • Cascade control should always be used if you
• It requires an additional measurement (usually have a process with relatively slow dynamics
flow rate) to work. (like level, temperature, composition,
• Cascade control should generally not be used if humidity) and a liquid or gas flow, or some
the inner loop is not at least three times faster other relatively-fast process, has to be
than the outer loop, because the improved manipulated to control the slow process.
performance may not justify the added
complexity.
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Practice Question
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Question 1
Identify and
analyze the
each control
system in the
figure
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Question 2
Identify and
analyze the
each control
system in the
figure
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Question 3
Identify and analyze
the each control
system in the figure
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See you on next lecture
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