Introduction

Complex Processes

In practice, control engineers may encounter:

A process has significant disturbances.
A process with multiple outputs controlled by a single input
A process has multiple inputs to control a single output.
The output of a process is not available.
Controllers discussed before may not perform well, more
complex
control structures has to be used.
 Processes with Significant Disturbances
Distillation column
Bottom temperature controlled by
adjusting reboiler steam flowrate

Problem:
For a given valve opening, change steam
supply pressure affect steam delivered to
the reboiler, varying column temperature

Solution:
A more effective control scheme is
required for improved performance
Stirred heating tank example
Objective:
Regulate T, temperature inside tank, by
adjusting the rate of steam flow through
the coil.

Problem:
By conventional scheme, T cause in Ti
and controller take corrective action. If
fluctuations in Ti are frequent and
substantial, the scheme fails

Solution:
A scheme detect changes in disturbance
Ti and implement preventive control
action before upset T.
Air Handling Unit (AHU)
Variable to be
controlled
OA% and RA%,
Supply Air temperature,
Supply Airflow rate,
Duct pressure, etc.

Manipulating variables
Chilled Water pump
Chilled Water valve
Fan speed, etc.
Cascade Control Systems
Example
Flow controller (FC) in between
temperature controller (TC) and
control valve
Purpose:
Steam supply pressure fluctuation
compensation to deliver desired
steam flowrate.

Configuration:
TC output is the set-point of FC

Characteristics:
the output of one is the set-point of
the other.
Example: AHU
Purpose:
To improve the response to
changes in chilled water
supply pressure

Method:
Measure pressure drop across
control valve to adjust the
valve position. With a cascade
control technique, the flow
rate controller will correct any
change in the chilled water
flow rate.
 Principles of Cascade Control
Primary control loop: The main process g(s) with output y to be controlled by
manipulating a single input u using controller gc1.
Secondary control loop: this controller is set up to regulate u by adjusting final
control element with transfer function gv(s).

Requirements:

•The disturbance d2 must be in

inner loop, it is controllable by
the secondary controller

•The inner loop must respond

much more quickly that outer
loop to regulate u before it
disturbs the entire process
 Closed-Loop Characteristics
Inner loop

When h1 = 1:
As gc2 increases,
g * → 1 g2* → 0
1

And, as a result u → ud
 Closed-Loop Characteristics
Overall closed-loop

with a fast-acting inner loop

(high gc2, the overall system
becomes much less vulnerable to
the effects of the fluctuations in
d2 than the system under
conventional feedback control.
Cascade Controller Tuning
Inner loop: high proportional gain value for fast inner-loop response
Outer loop: tuned with the inner loop in operation for overall performance.

Inner loop: eliminate the

input disturbance, P or PI is
sufficient

Outer loop: PID controller

Tuning Example

The inner loop PI control

Open loop transfer function

Outer loop PID controller

The desired closed loop transfer function

From Gcl(jωi), Gop(jωi) is

A’X=B’
 Anti-reset Windup
If both loops use PI or PID control, both need anti-reset windup devices. Primary
controller may use output of secondary loop as feedback signal.

If secondary loop has reset windup,

y2(s)≠r2(s), r2 is proportional to E1 and
In normal operation, y2(s)=r2(s) y2 is the deviation.
Feedback/ Feedforward
Control Systems
 Example
Frequent disturbances in feed temperature
Conventional control: must wait that upset
process to take action
Cascade control: not solution: disturbance is not
associated with the manipulated variable.
Feedforward control: Measure feed temperature
Ti,,makes adjustments in the steam flowrate to the
heating coil for changes in Ti.

Feedforward control: compensate measured

disturbance before process is affected

Process output: never measured in feedforward

control
 Design

The disturbance d is measured

The effect of d on the output y is available
Always associated with disturbance rejection

For set-point tracking

For disturbance rejection

Example

Set-point tracking, yd(s) = A/s,

Disturbance rejection:
 Practical Considerations
Drawbacks:
•d must be measurable
•requires a perfect process model
•gst and gff involve the reciprocal of the process transfer function

May be too complicated to be realizable in time.

time delay e-αs in g, reciprocal contain the term eαs, require a prediction.

both g and gd with time-delay, and the time delay in gd smaller than g, then gff. will
contain a term in eγs where γ > 0; prediction required

Feedforward control is usful as many process disturbances are measurable.

Lead/lag unit provides reasonably good performance as a feedforward controller.
Lead/Lag Units in Feedforward Control

Estimate lead/lag unit parameters

Gain term: Kff=Kd/K

Lead time constant: τ
Lag time constant: τd
Associated delay: γ=β−α
Compare Feedback with Feedforward Control
Feedback Feedforward

Advantages

Not require identification and Acts before a disturbance has been felt
measurement of disturbance by the system.
Insensitive to modeling errors. Good for slow systems or significant
dead time.
Insensitive to parameter changes. Not introduce instability in the
closed-loop response.
Disadvantages

Control action is taken after Requires all disturbances and their

disturbances have been felt. direct measurement.
Unsatisfactory for slow and Cannot cope with unmeasured
significant dead time process. disturbances.
It may create instability in the Sensitive to process parameter
closed-loop response. variations.
Feedback/Feedforward Control
Purpose: complement the disturbance rejection properties of the feedforward
controller with the "ruggedness" of the feedback controller

characteristic equation

**If the disturbances are (partially or

completely) unmeasurable, feedback loop
picks up the residual error and eliminates it
with time
Ratio Control
 Applications
Special form of feedforward control maintain constant ratio between two
variable. If one changes, the other also changes to maintain the desired ratio.

Both flowrates are measurable, one stream can be controlled while the other
flowrate cannot be controlled (wild stream).

Salt solution mixer:

•salt concentrate flowrate can be regulated
•water flowrate cannot (wild stream)

Objective:
To maintain uniform salt concentration
within the mixing tank, necessary to
maintain constant ratio of water and salt
concentrate flowrates.
Ratio divider
Measuring both flow rates and obtaining
current ratio by electronic divider.
In ratio controller, the observed ratio is
compared to the desired ratio set-point.
The error is used to set the flow rate required
for the salt concentrate stream.

Property:
The actual ratio of the flow streams is obtained
from process and passed on to the controller; the
controller use this information to calculate change
needed in the salt concentrate flow rate for the
desired ratio.
 Ratio station
Measuring "wild stream" flowrate
Multiplying it at "ratio station" by the desired
ratio to produce the flowrate of the other
stream for desired ratio.
The output of ratio station is the set-point of
flow controller; compares with the actual
flowrate of the salt concentrate stream.

Property:
Flow controller direct regulates flowrate of the
salt concentrate stream; the information it
receives from the ratio station is its set-point
 Design Strategy

Two Loops Ratio Control

No wild stream, both loops are controlled.
This scheme is more robust as it can reject disturbance
of main control loop so that the response of secondary
loop becomes smoother.

Variable Ratio Control

The ratios are different at different set

points.
Single Input Control
Multiple Outputs
Override Control
The manipulated variable regulate one output under normal operation, and to
control another in abnormal operation (when the process is unsafe under
abnormal operation without the "override" to the second output variable).

Metal surface temperature of tubes containing crude oil

must below the metallurgical limit.

Surface temperature at several locations along the tube

are measured.

If exceeds a preset value, HS switches from "normal"

to "abnormal" loop by adjusting fuel flowrate.

When "normal" loop calls for less fuel than required to

maintain maximum tube temperature, it switch back.

During "abnormal" operation, crude oil exit

temperature below its set-point, but as close as possible
while ensuring safe operation of the furnace.
Protection of a boiler system
Steam pressure in boiler is controlled through pressure control loop on discharge.
Water level in boiler above lower limit to keep the heating coil immersed in water

When the liquid level falls below the allowable limit, LSS switches the
control action from pressure control to level control (loop 2) and closes the
valve on the discharge line
 Auctioneering Control
Control loop is fixed, the output variable to be used may change

Temperature profile along the tubular reactor.

Hot spot: The point of highest temperature along

the length of the tubular reactor

Variation Factors:
1. Feed conditions (temperature, flow rate,
concentration)
2. Catalyst activity
3. Temperature and flow rate of the coolant.
Multiple Inputs Control
Single Output
Split-Range Control
Multiple manipulated variables to span the range of possible set-point

A batch reactor requires temperature

program to produce a product
•150C at beginning of the batch
•1000C at the end.
•The cooling water is at 50C
•The low-pressure steam is at 1800C

Certain amount of cooling water and

steam used for controller output of
required reactor jacket inlet temperature.
Uses overlap in the range of each valve
for more precise control.
Used broad span temperature control,
year-round heating/cooling of buildings.
Multiple Inputs improving Dynamics
Co-operative Control
Several temperature set-points for heating tank for downstream reactor.
Normal operation for set-points are process steam going to the tank heating coil.
Auxiliary heater helps speed up move to set-point up change.
Auxiliary cooler helps the tank quickly achieve the new set-point down change.

CONTROLLER SCHEDULE
Deviation from set-point Controller active
ΔT < - 100C TC3+TC1
- 100C < ΔT < + 100CTC1
ΔT > + 100C TC2+TC1

Drawback:
require expensive electrical energy while the
steam to the coil is very cheap as a byproduct
from another process unit.
Inferential control
 Inferential control
Measurement of true controlled variable is not available in a timely manner
1. An on-stream sensor is not possible
2. An on-stream sensor is too costly
3. Unfavorable sensor dynamics (long dead time) or is located far downstream
4. A inferential variable is available