Chapter 3 Multiloop Systems

Mulat Tigabu

Addis Abeba Science and Technology

University (AASTU)
Department of Electromechanical Engineering
Addis Abeba, Ethiopia

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Table of Contents

1 Cascade Control

2 Feedforward Control

3 Feedforward Plus Feedback Control

4 Ratio Control

5 Selective Control / Override Control

6 Time Delay Compensation

7 MATLAB Exercise of Multiloop System

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Cascade Control

Cascade control: set points are sent to a secondary controller from a

primary control system, each monitoring a different variable, with the
secondary controller monitoring the data with the most time-sensitive
response.
Cascade controllers: means to connect the output signal of one
controller to the setpoint of another controller, with each controller
sensing a different aspect of the same process. The first controller
(called the primary, or archaically, master) essentially “gives orders” to
the second controller (called the secondary or archaically, slave) via a
remote setpoint signal.
Cascade control is probably the most popular complex PID control
loop. It is widely used to improve control performance by reducing
the impact of nonlinearity, stiction, or hysteresis in the final
control element.

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The terms primary controlled variable (primary variable), secondary
controlled variable (secondary variable), primary process, secondary process,
primary controller (master controller), secondary controller (slave
controller), primary loop and secondary loop.
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There must be a definite cause and effect relationship from the final
control element to the secondary variable and from the secondary
controlled variable to the primary controlled variable.
Cascade control only adds value to the overall control performance if
the secondary variable responds to the disturbance sooner and quicker
than the primary variable. The secondary loop should typically be five
times faster than the primary loop.
The tuning of cascade control loops should start from the secondary
loop with the primary loop in manual mode. When tuning the primary
loop, the secondary loop should be in cascade mode.
Cascade control is like running a business between headquarter and
branch offices.The local branch office is charged with making timely
decisions on local matters without escalating to the main office. The
headquarter only sets the long-term goals and address high-level issues.

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Cascade control is of great value where high performance is needed in
the face of random disturbances, or where the secondary part of a
process contains a significant time lag or has nonlinearity.
The principal advantages of cascade control are the following:
Disturbances occurring in the secondary loop are corrected by the
secondary controller before they can affect the primary, or main,
variable.
The secondary controller can significantly reduce phase lag in the
secondary loop, thereby improving the speed or response of the primary
loop.
Gain variations due to nonlinearity in the process or actuator in the
secondary loop are corrected within that loop.
The secondary loop enables exact manipulation of the flow of mass or
energy by the primary controller.

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Example
Figure below shows an example of cascade control where the primary
controller TC is used to measure the output temperature T2, and compare
this with the SP value of the TC; and the secondary controller, FC, is used
to keep the fuel flow constant against variables like pressure changes.

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Example

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Example

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Example

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Feedforward Control
Feedforward control is a form of control based on anticipating the
correct manipulated variables necessary to deliver the required output
variable. It is seen as a form of open loop control as the PV is not
used directly in the control action. In some applications, the
feedforward control signal is added to a feedback control signal to
drive the MV closer to its final value. In other more advanced control
applications, a computer-based model of the process is used to
compute the required MV and this is applied directly to the process.
As a disturbance enters the process, the operator observes the
disturbance and, based on the nature and quantity of the entering
disturbance, adjusts the manipulated variable in such a manner as to
prevent any eventual change or variation in the controlled variable due
to the observed disturbance.
Feedback control works to eliminate errors; feedforward control
operates to prevent errors from occurring in the first place.
A controlled variable is controlled by a manipulated variable, subject
to noises and disturbances that can be measurable or unmeasurable.
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Feedforward control is a common approach to deal with measurable
disturbances.
Feedforward control is an open-loop control and must work along with a
feedback control loop in practical applications.

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Feedforward control “intercepts” the change in the disturbance variable and
adjusts the manipulated variable in anticipation to “cancel out” the effect
of the disturbance.

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Feedforward Plus Feedback Control

In the figure below it is seen that the disturbance to the flow is

“suppressed” by the flow controller before it affects the outer level
loop. However, if the disturbance is in the feed flow to the tank, it will
directly affect the level. The flow controller will react only after the
level is already disturbed.
Suppose the dynamics from the disturbance to the controlled variable
is known. In that case, the control scheme cantry to“intercept” the
disturbance by adjusting the manipulated value with the correct
magnitude and at the right time, in anticipation of “canceling out” the
effect of the disturbance before it reaches the controlled variable. This
“intercept” and “cancel” approach is the principle of feedforward
control.

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Figure below shows a boiler heater process where the fuel oil is
adjusted following the changes in feedwater flow to maintain the
desired temperature (or steam quality) in the outlet flow.
Here the feedwater flow rate FI-101 is the primary flow, and its
fluctuations directly affect the temperature TC-102. Due to the pure
feedback nature, the cascade feedback control loop TC-102 / FC-102
/ FCV-102 does not take any corrective action before the controlled
variable TC-102 is already affected.
The feed water flow FI-101 can be added as a feedforward variable to
the existing temperature feedback control loop for improved control
performance. The water flowrate is measurable, and the dynamics
from the flow FI-101 to the temperature TC-102 are easily known and
relatively stable.
Feedforward control is an open-loop control loop added to a feedback
control loop.

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The feedforward control action is calculated based on a good
understanding of the dynamics between the disturbance and controlled
variable and must meet the following conditions to function correctly:
The dynamic relationship between the feedforward and controlled
variable (mainly the gain and delay) must be known and remain
relatively constant over time.
The time to reach the controlled variable TC-102 from the feedforward
variable FI-101 must be longer than that from the manipulated
variable FC-102 for best performance (“complete cancellation”).
The feedforward compensation to feedback control can be either
dynamic or static. A static compensation only requires the gain
compensation for the dynamics, while a proper dynamic compensation
requires knowledge on the full dynamics, including gain, delay, and lag.

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Ratio Control
Ratio control is a special case of feedforward control.A ratio control
scheme has two inputs, the primary flow and the secondary flow.
The primary flow is also called the wild stream. The ratio controller
manipulates the secondary flow stream to achieve a specified ratio
with a primary flow stream.
The ratio controller’s setpoint is thus the ratio between the secondary
flow and primary flow:
Secondary Flow rate
ratio = (1)
Primary Flow rate
This output of the ratio controller is sent down to a PID flow controller
to manipulate the secondary flow. Figure below shows an example of a
mixer with a primary stream FI-101 and a secondary stream FC-102.
The control objective is to maintain the desired ratio between the
primary and secondary flows to meet the quality requirement AI-101
on the mixed flow.
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In ratio control, we measure the flow of the first stream (referred to as
wild flow) and then calculate (based on the required ratio) the value
of the second stream (referred to as the controlled flow).
A practical way to do this is to control one stream with a conventional
flow controller and control the other stream with a ratio controller
that maintains that stream flow at some preset ratio or fraction to the
primary stream flow.
Ratio control is then a form of feedforward control of the second
steam. This is also referred to as a wild feedforward loop. You
measure the disturbance of the first flow and calculate the ratio
required for the second flow. This type of control is commonly
referred to as a multiple-loop feedback control system.

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This concept is best illustrated using the example of a home heating
system. The furnace not only needs its fuel intake controlled to
provide proper heating, but it also requires a proportional amount of
air for efficient combustion, referred to as the stoichiometric air-to-fuel
ratio. Assuming the amount of fuel flow to the furnace is A and the
amount of air required is B, the ratio of air to fuel can be expressed as
R = B/A.
Ratio control is similar to cascade control, except that the ratio
control loop does not need to be five times lower than the flow control
loop. Besides,the ratio typically is not the ultimate goal of control. In
this example, the quality variable after the mixer AI-101 is the true
objective.
A special consideration for ratio control is that ratio calculation is
subject to noise and failures, explicit division calculation should be
avoided, and the DCS built-in ratio control blocks should be used
instead.

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Selective Control / Override Control
Override controls involve two control variables and one shared
manipulated variable.
When operations are normal, one control variable (CV1) is maintained
at setpoint by adjustments to the shared manipulated variable (MV1);
the other control variable (CV2) does not make changes to MV1. CV2
can either be uncontrolled, or controlled by adjustments to a second
manipulated variable (MV2).
If changing operations, process upsets, day/night variations, or
controller range ability problems cause CV2 to approach a maximum
or minimum allowable value (if CV2 is controlled, MV2 has become
limited), control of CV2 “overrides” control of CV1 and it begins to
adjust MV1 to prevent a minimum or maximum CV2 limit violation.
When operations become normal again, CV2 moves away from its
limiting value, control of CV1 “overrides” control of CV2, CV1 control
resumes with adjustments to MV1, and control of CV2 resumes with
adjustments to MV2 as it regains rangeability.
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Override control involves two control variables, each with a dedicated
feedback controller (almost always a PID),one shared manipulated
variable and a selector block.
There are two common control scenarios that are managed using
override controls. In both cases, the control strategy is a complex
cascade and logic/code must be provided to resolve and broadcast
initialization/wind-up statuses for both controllers.
During routine, normal operations (Figure below), one control variable
(CV1) is maintained at its desired value (Controller A’s SP = CV1
SP) by adjusting one MV (MV1).
The second control variable (CV2) is maintained at its desired value
(Controller C’s SP = CV2 SP) by adjusting a second manipulated
variable (MV2).

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Both Controller A and Controller C are normal, regulatory control
loops with a dedicated CV– MV pairing. Controller B, on the other
hand, is an override controller that manipulates MV1 only when
Controller C can no longer hold CV2 at its set point and CV2
approaches its max or min value (Controller B’s set point).
Custom logic/code must be provided to ensure Controller B does not
wind up, e.g., to ensure a valid Controller B output is calculated
during normal operations when the selector block chooses Controller
A’s output.
When process conditions force Controller C into wind-up or into
initialization, CV2 is uncontrolled, and if it approaches (or violates) a
limiting value (min or max allowable value), Controller B, whose
setpoint is CV2’s desired max or min value,overrides Controller A via
the selector block and adjusts MV1 SP to maintain CV2 at its min or
max value.
When the override is active (see Figure below), CV1 is uncontrolled,
and its value varies with changing process conditions. Custom logic/
code must be provided to ensure Controller A does not wind up, e.g.,
to ensure a valid Controller A output is calculated when the override is
active, and the selector
Mulat Tigabu block
Industrial chooses
Automation Controller
and Process B’s March
output.
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As operations become normal again, CV2 moves away from its limiting
value, and Controller A overrides Controller B via the selector block
and once again can maintain CV1 at its setpoint (CV1 SP). As CV2
approaches its normal operating window, Controller C again takes over
control of CV2 and maintains it at its desired value (CV2 SP) by
adjusting MV2. The control strategy has returned to the normal
control cascade structure displayed in Figure 6.1.
The Selector block is either a high or a low selector. Whether it is a
high or low selector depends upon the CV2– MV1 sensitivity, which is
determined by the process configuration. If an increase in MV1 drives
CV2 away from violation, e.g., if CV2 SP is a max (min) limit, an
increase in MV1 decreases (increases) CV2 PV, then the override
strategy’s signal selector is a high signal selector (HSS). Alternatively,
if an increase in MV1 drives CV2 toward violation, e.g., if CV2 SP is a
max (min) limit, an increase in MV1 increases (decreases) CV2 PV,
then the override strategy’s signal selector is a low signal selector
(LSS).

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The second common override control scenario is illustrated in Figure
6.3. During routine, normal operations, one control variable (CV1) is
maintained at its desired value (Controller A’s setpoint = CV1 SP) by
adjusting MV1. The second control variable (CV2) is uncontrolled,
and its value varies with process conditions, comfortably above or
below its minimum or maximum allowable value.
In this case, Controller A is a normal regulatory control loop with a
dedicated CV– MVpairing. Controller B is an override controller that
manipulates MV1 only when CV2, normally uncontrolled, approaches
(or violates) its max or min limit value (Controller B’s set point).
Custom logic/code must be provided to ensure Controller B does not
wind up, e.g., to ensure a valid Controller B output is calculated
during normal operations, when the selector block chooses Controller
A’s output.

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When process conditions force CV2 to approach a limiting value (e.g.,
min or max allowable value– Controller B’s SP), Controller B overrides
Controller A via the selector block, and Controller B maintains CV2 at
its min or max value (Controller B’s SP) by adjusting MV1 SP. CV1 is
now uncontrolled, and its value varies with changing process
conditions (see Figure 6.4). Custom logic/code must be provided to
ensure Controller A does not wind up, e.g., to ensure a valid
Controller A output is calculated when the override is active, and the
selector block chooses Controller B’s output.
As operations become normal again and CV2 moves away from its
limiting value, Controller A overrides Controller B via the selector
block and once again can maintain CV1 at its setpoint (CV1 SP) by
adjusting MV1 SP.CV2 is again uncontrolled and varies with process
conditions. The control strategy has returned to the normal control
cascade structure displayed.

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Override control

Override control is used to maintain one controlled variable on target

without violating constraints on other controlled variables. In an
override control, there are two or more controlled variables (targets)
sharing one manipulated variable (handle), typically through a high
selector(for high override) or low selector(for low override). At any
time, only one controller is active, i.e., only one output is selected by
the selector and sent down to the next level of control elements such
as a valve. The control action requested by the most demanding
controller is selected and accepted.
An example in our daily life is the so-called adaptive cruise control in
newer cars. The regular cruise control maintains a speed target by
manipulating the fuel. Adaptive cruise adds another control target to
the requirement: the distance with the car in front. When following
too close,the adaptive cruise control overrides the speed control and
automatically slows down to ensure a safe distance.

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An override control can be an overriding protective control such as the
pressure controller PC-103, where the primary controller LC-101 is the
regulatory control during normal operations, and the protective controller
PC-103 only kicks in during abnormal operating condition that cause the
pressure to go higher than its limits.

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An override control can also be an overriding selective control where
all the controllers have an equal chance to be selected by the selector.
There is no distinction between normal operating conditions and
abnormal conditions in their roles.
For example, two tanks share one pump for level control. A selector
can be used to select which level controllers should be in control.
Whether a high selector or low selector should be used depends on
whether the two tanks’ maximum or minimum level is maintained.
The principle stays the same for both protective and selective override
control: each controller in the override control scheme is an
independent PID control loop.
The output of the most demanding controller is automatically selected
as the control action, while the outputs of the other controllers are
simply ignored. There are more control targets than control handles.
How to handle the inactive controllers whose outputs are ignored is
the challenge for override control. For those controllers, which are
effectively open-loop, the integrating action of the PID controller may
drive the output to saturation.
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Selective Control

This delay is typically unacceptable for a protective control. This

saturated condition is called reset windup or integral windup.
Prevention of reset windup is crucial when implementing override
control.
When multiple handles are available to control multiple targets, and at
any given time, only one pair of target and handle needs to be
connected, then a switch, either manual or automatic, can be used.
The practical consideration for selective control is protecting those
control handles or control targets that are not currently selected. In
the case of multiple targets, it is similar to the scenario of overriding
control and requires anti-reset windup protection, while in the case of
multiple control handles, the same bumpless transfer behavior as in
fan-out control needs to be considered.

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Limitations of PID Control
While PID controllers can produce an acceptable performance for
most applications, they can perform poorly in some.
The fundamental limitation of PID control is that it is based on a
feedback mechanism with a simple structure. Besides, the tuning
parameters are not based on direct knowledge of the underlying
process.
They remain constant even when process dynamics have changed. As
a result, many industrial processes are beyond the capability of PID
controls due to the following challenges:
Multiple inputs and multiple outputs with strong interactions.
Long time delay and very slow dynamics.
Nonlinear time-varying dynamics.
Design limits and operating constraints.
Advanced process control solutions are developed to overcome the
limitations. It is built on top of base layer controls, deals with a more
extensive scope of problems, and aims at higher level performance
targets such as quality, efficiency, and even profitability.
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Time Delay Compensation

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MATLAB Exercise of Multiloop System

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