2.2 Singleloopcontrol

Process Control Strategy
Prof. Dr. Arshad Ahmad Process Control and Safety Group, Universiti Teknologi Malaysia
Process Control System

Planning and Scheduling Plantwide Computer
Real-Time Optimisation Advanced Process Control DCS Regulatory Control Process

Page (2)
Process Computer
Plant Operation by Dr. AA, 2008
Page 2.2 - #
Regulatory Control
Regulatory Control
! ! !
Most of the time, process variables are fixed at some desired set point The task is therefore to reject disturbances, etc Majority of the controllers are standard three-term controllers i.e., PID
Page (4)
Page 2.2 - #
Feedback Control
! ! ! !
Corrective Action Measure, Decide, Correct Robust Process Variables

! ! !
Controlled Variables Manipulated Variables SISO Configuration
Solution to Most Control Problem

Page (5)
Feedback Control Example

! !
Controlled variable
!
Temperature
v1
Manipulated Variable
!
TC
Steam Flowrate
V2 being adjusted to provide corrective action
v2
Page (6)
Page 2.2 - #
Feedback Control Block Diagram

D(s) SP(s) + E(s) GC(s) MV(s) CVm(s) Gv(s) Gd(s) GP(s) GS(s) Variables CV(s) = controlled variable CVm(s) = measured value of CV(s) D(s) = disturbance E(s) = error MV(s) = manipulated variable SP(s) = set point
Page (7)
+ +
CV(s)
Transfer functions GC(s) = controller Gv(s) = valve + GP(s) = feedback process GS(s) = sensor Gd(s) = disturbance process
PID Controller
! ! ! !
Developed in the 1940s, remains workhorse of practice Not optimal, based on good properties of each mode Preprogrammed in all digital control equipment ONE controlled variable (CV) and ONE manipulated variable (MV). Many PIDs used in a plant.
GC = K C (1 +
1 +) DS) )IS
& 1 'u = K C $ e + $ ) I %
( e +)
'e # ! 't ! "

Page (8)
Page 2.2 - #
Limitation of Feedback and The way forward

Disturbances
Feedforward Control
Dead time
Cascade Control Ratio Control
Measurement
Constraints Nonlinearity Interactions

MPC RTO Split-range Control Select Control
Inferential Control
Profitability
Page (9)
OVERCOMING DISTURBANCES
Page 2.2 - #
Improving Disturbance Rejection

! !
Single loop feedback controllers can reject disturbances to certain extent. Cascade control
!
Feedforward control
!
Cascade reduces the effect of specific types of disturbances.
Ratio Control
!
Feedforward control is a general methodology for compensating for measured disturbances Ratio reduces the effect of feed flow rates changes
Page (11)
Cascade Control
!
Benefits
! !
Useful in overcoming high frequency noise and disturbances Also reduces the impact of time delay
Page (12)
Page 2.2 - #
Level Controller on a Tank With and Without Cascade Control

Lsp Fin Fout
LC LT
Lsp
Fin Fout
LC
LT FT
RSP
FC
Page (13)
Analysis of Cascade Example

!
Without a cascade level controller, changes in downstream pressure will disturb the tank level. With cascade level controller, changes in downstream pressure will be absorbed by the flow controller before they can significantly affect tank level because the flow controller responds faster to this disturbance than the tank level process.
Page (14)
Page 2.2 - #
With and without cascade control
Page (15)
Cascade Control: Hot Oil System
Oil in F, T
Oil in
F, Tin
TT TC TSP
F, Tin
FC FT FSP
F, T
TT TC TSP
Fuel Gas (variable pressure)
fuel gas (variable pressure)
a) Ordinary feedback control
b) Cascade control structure
Page (16)
Page 2.2 - #
Analysis of Cascade Example

!
Without a cascade level controller, changes in upstream fuel pressure affects outlet hot oil temperature. With cascade level controller, changes in upstream pressure will be absorbed by the flow controller before they can significantly affect hot oil temperature because the flow controller responds faster to this disturbance than the oil temperature process.
Page (17)
Cascade Reactor Temperature Control
Feed
TC
Cooling water
TT
Product
Feed
Cooling water
TT
TC
RSP
TT
TC
Product
Page (18)
Page 2.2 - #
Analysis of Example
!
Without cascade, changes in the cooling water temperature will create a significant upset for the reactor temperature. With cascade, changes in the cooling water temperature will be absorbed by the slave loop before they can significantly affect the reactor temperature.
Page (19)
Multiple Cascade Example

TT TC RSP AC
RSP FC FT AT
This approach works because the flow control loop is much faster than the temperature control loop which is much faster than the composition control loop.
Page (20)
Page 2.2 - #
Key Features for Cascade Control to be Successful

! ! !
Secondary loop should reduce the effect of one or more disturbances. Secondary loop must be at least 3 times faster than master loop. The secondary loop should be tuned tightly.
Page (21)
Feedforward Control
Taking action before disturbances affecting the process, thus a Preventive Mechanism
Page (22)
Page 2.2 - #
Feedforward and Feedback Level Control

To Steam Users
LC LT
LT
To Steam Users
FT FF
Make-up Water
FT LC
LT
Make-up Water
FF +
To Steam Users
Make-up Water
Page (23)
Analysis of Feedforward and Feedback Level Control

! !
Feedback-only must absorb the variations in steam usage by feedback action only. Feedforward-only handle variation in steam usage but small errors in metering will eventually empty or fill the tank. Combined feedforward and feedback has best features of both controllers.
Page (24)
Page 2.2 - #
Derivation of FF Controller
D(s)
Gff(s)
Gds(s) Gd(s)
Cff (s)
Ga(s)
Gp (s)
++
Y(s)
Y(s) = D(s) Gds (s) Gff (s) Ga (s) Gp (s) + D(s) Gd (s) = 0 Solving for Gff (s) Gff (s) = ! Gd (s) Gds (s) Ga (s) Gp (s)
Page (25)
Feedback Control
! ! !
Can effectively eliminate disturbances for fast responding processes. But it waits until the disturbance upsets the process before taking corrective action. Can become unstable due to nonlinearity and disturbance upsets.
Page (26)
Page 2.2 - #
Feedforward Control
! ! !
Compensates for ds before process is affected Most effective for slow processes and for processes with significant deadtime. Can improve reliability of the feedback controller by reducing the deviation from setpoint. Since it is a linear controller, its performance will deteriorate with nonlinearity.
Page (27)
Combined FF and FB Control

D(s) Gff(s) Gd(s) Ysp(s) Cfb(s)
Cff(s)
+-
Gc(s)
++
Gp(s)
++
Y(s)
Page (28)
Page 2.2 - #
Example of Combined FF and FB

RSP + TC TT PC PT Steam
FF TT
Feed
Condensate
Page (29)
Combined FF and FB for the CSTR

TC
FF TT
RSP Feed
FC FT
Steam
TT
Product
Page (30)
Page 2.2 - #
Results for CSTR

6 3
FB-only
T' (K)
0 -3 -6
FF+FB
FF-only
-10
10 30 Time (seconds)
50
Page (31)
Analysis of Results for CSTR

FB-only returns to setpoint quickly but has large deviation from setpoint. FF-only reduces the deviation from setpoint but is slow to return to setpoint. FF+FB reduces deviation from setpoint and provides fast return to setpoint.
! !
Page (32)
Page 2.2 - #
Ratio Control
!
Useful when the manipulated variable scales directly with the feed rate to the process. Dynamic compensation is required when the controlled variable responds dynamically different to feed rate changes than it does to a changes in the manipulated variable.
Page (33)
Ratio Control for Wastewater Neutralization

RSP
FC FT FT
Acid Wastewater
pHC pHT
NaOH Solution
Effluent
Page (34)
Page 2.2 - #
Analysis of Ratio Control Example

! !
The flow rate of base scales directly with the flow rate of the acidic wastewater. The output of the pH controller is the ratio of NaOH flow rate to acid wastewater flow rate; therefore, the product of the controller output and the measured acid wastewater flow rate become the setpoint for the flow controller on the NaOH addition.
Page (35)
Example
FT TT Flue Gas
FT Fuel
Process Fluid
Draw schematic: For a control system that adjusts the ratio of fuel flow to the flow rate of the process fluid to control the outlet temperature of the process fluid. Use a flow controller on the fuel.
Page (36)
Page 2.2 - #
Solution: ratio
_
Ratio TC TT Flue Gas
FT RSP FC FT Fuel
Process Fluid
Page (37)
Dealing with Constraints
Page 2.2 - #
Split Range Control

!
Uses more than one manipulated variables or actuators for one control loop
Page (39)
Split-Range Control: Simple Concept

setpoint PC
F1
F2
Desired Pressure Flow F1 Flow F2
Low Close Open
Medium Open Open
High Open Close

Page (40)
Page 2.2 - #
Split Range Control: Another Example

FC FT
FT FC
Smaller Valve Total Flowrate

! !
Larger Valve
Sometimes a single flow control loop cannot provide accurate flow metering over the full range of operation. Split range flow control uses two flow controllers
! ! !
One with a small control valve and one with a large control valve At low flow rates, the large valve is closed and the small valve provides accurate flow control. At large flow rates, both valve are open.
Page (41)
Application of Split Range Control: pH Control

!
RSP
FC FT FT
Acid Wastewater
pHC
NaOH Solution
Split range for this valve
pHT
Effluent
Strategy: control of pH using ratio of NaOH to acid waste water Due to dynamic behaviour, Split range is also required
Page (42)
Page 2.2 - #
Titration Curve for a Strong Acid-Strong Base System

14 12 10 8 6 4 2 0 0
!
pH
0.002
0.004 0.006 0.008 Base to Acid Ratio
0.01
Therefore, for accurate pH control for a wide range of flow rates for acid wastewater, a split range flow controller for the NaOH is required.
Page (43)
Application of Split Range Control: Temperature Control
Cooling Water
Split-Range Temperature Controller
Steam
RSP
TT
TT
TC
Page (44)
Page 2.2 - #
Split Range Temperature Control

Signal to Control Valve (%)
100 80 60 40 20 0
Error from Setpoint for Jacket Temperature
Page (45)
Cooling Water
Steam
Override Control
!
Process are many times operated at the safety or equipment limits in order to maximize process throughput. During upset periods, it is essential that safety limits are enforced.
Page (46)
Page 2.2 - #
Override/Select Control
!
Override/Select control uses LS and HS action to change which controller is applied to the manipulated variable. Override/Select control uses select action to switch between manipulated variables using the same control objective.
Page (47)
Furnace Tube Temperature Constraint Control

TC TT RSP FC FT Fuel Flue Gas Process Fluid LS TC TT
Page (48)
Page 2.2 - #
Analysis of Tube Temperature Constraint Controller

!
Under normal operation, the controller adjusts the furnace firing rate to maintain process stream at the setpoint temperature. At higher feed rates, excessive tube temperatures can result greatly reducing the useful life of the furnace tubes. The LS controller reduces the firing rate to ensure that the furnace tubes are not damaged.
Page (49)
Column Flooding Constraint Control
DPC
LS RSP FC FT
AC
AT
Page (50)
Page 2.2 - #
Override control to protect boiler

Discharge Line Steam Loop 1 PT
Feedwater
Loop 2
LT LC
LSS
PC
Boiler Drum
Hot Gas
Page (51)
Hot-Spot Temperature Control
TT
TT
TT
TT
TT
Autioneering System
TC
FT
Example Temperature control in catalytic reactor detect temperature in various places in catalyst bed. Action based on highest temperature
Page (52)
Page 2.2 - #

2.2 Singleloopcontrol

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Process Control Strategy

Process Control System

Real-Time Optimisation Advanced Process Control DCS Regulatory Control Process

Plant Operation by Dr. AA, 2008

Plant Operation by Dr. AA, 2008

Corrective Action Measure, Decide, Correct Robust Process Variables

Controlled Variables Manipulated Variables SISO Configuration

Solution to Most Control Problem

Feedback Control Example

V2 being adjusted to provide corrective action

Plant Operation by Dr. AA, 2008

Feedback Control Block Diagram

'e # ! 't ! "

Plant Operation by Dr. AA, 2008

Limitation of Feedback and The way forward

Constraints Nonlinearity Interactions

Plant Operation by Dr. AA, 2008

Improving Disturbance Rejection

Cascade reduces the effect of specific types of disturbances.

Plant Operation by Dr. AA, 2008

Level Controller on a Tank With and Without Cascade Control

Analysis of Cascade Example

Plant Operation by Dr. AA, 2008

With and without cascade control

Cascade Control: Hot Oil System

Fuel Gas (variable pressure)

fuel gas (variable pressure)

a) Ordinary feedback control

b) Cascade control structure

Plant Operation by Dr. AA, 2008

Analysis of Cascade Example

Cascade Reactor Temperature Control

Plant Operation by Dr. AA, 2008

Multiple Cascade Example

Plant Operation by Dr. AA, 2008

Key Features for Cascade Control to be Successful

Plant Operation by Dr. AA, 2008

Feedforward and Feedback Level Control

Analysis of Feedforward and Feedback Level Control

Plant Operation by Dr. AA, 2008

Plant Operation by Dr. AA, 2008

Combined FF and FB Control

Plant Operation by Dr. AA, 2008

Example of Combined FF and FB

Combined FF and FB for the CSTR

Plant Operation by Dr. AA, 2008

Results for CSTR

Analysis of Results for CSTR

Plant Operation by Dr. AA, 2008

Ratio Control for Wastewater Neutralization

Plant Operation by Dr. AA, 2008

Analysis of Ratio Control Example

Plant Operation by Dr. AA, 2008

Dealing with Constraints

Plant Operation by Dr. AA, 2008

Split Range Control

Split-Range Control: Simple Concept

Desired Pressure Flow F1 Flow F2

Low Close Open

Medium Open Open

High Open Close

Plant Operation by Dr. AA, 2008