Clyde - Botha 1644317453 A

THE COPPERBELT UNIVERSITY
School of mines and minerals sciences
CE 560 / MT 580
Process control
Lecture 05
Control strategies
C. Botha (Mr.)
Contacts: Chemical Engineering Department
Email: clyde.botha@cbu.ac.zm
Alt. Email: bthclyde@gmail.com
January, 2021
Control configuration selection: feedback and feedforward configurations
o Figure 3.4 (b) is an example of Fi (ft3/min), Ti (oF)
feedforward control configuration.
o In this control scheme, the

Thermocouple
T
disturbance variable (input) is T - h
Set point Q
measured prior to its effect on the Ts

+ ϵ
F (ft3/min), T (oF)
process. Controller
+
Condensate
Fst (Ib/min)
Steam
o The measurement is used to adjust
the manipulated variable.
Fig.3.4 (b) Feedforward control configurations for stirred tank heater.
Select the control configuration: feedback and feedforward configurations
o In feedforward, controller anticipates what effect the change in the disturbance will have
on the process.
o Adjustments are then made beforehand to correct the effect of the disturbance on
process.
o The objective, as with any control, is to keep values of the controlled variable at or near
the desired levels.
o As can be seen from figure 3.4 (b), the thermocouple measures the temperature of the
feed stream (disturbance).
o This measurement is then used to adjust the steam flow-rate to bring about the necessary
corrections to the system temperature.
Select the control configuration: Feedback control strategy
o In some cases, more than one option for feedback/feedforward control configuration is
possible. See figure 3.5 (a) and (b) for liquid level control.
o For the two feedback control configurations in figure 3.5, the same information
(measurement of the liquid level) is used.
o In figure 3.5 (a), the liquid level measurement is used to manipulate the flow-rate of the
outlet stream.
o On the contrary, in figure 3.5 (b), the measurement (liquid level) is used to manipulate the
flow-rate of the inlet stream.
Select the control configuration: Feedback control strategy
Controller
Differential pressure ϵ
Fi (ft3/min), Ti (oF)= const. hs
(dp) cell
- + Set point
- h Fi (ft3/min), Ti (oF)= const. h
hs
Differential pressure
+ Set point (dp) cell
ϵ
T
T h
h Controller
Q
Q
Condensate F (ft3/min), T (oF)

3 o
Condensate F (ft /min), T ( F)
Fst (Ib/min)
Fst (Ib/min) Steam
Steam
(a) (b)
Fig.3.5 Liquid level control configurations for stirred tank heater system (a) feedback with outlet flow-rate as manipulated
variable, (b) feedback with feed flow-rate as manipulated variable
Select the control configuration: positive and negative feedback control
o Feedback control can either be implemented as negative feedback or positive

feedback.
o Negative feedback: Refers to the desirable situation in which corrective action taken
by the controller forces the controlled variable towards the set point value.
o Positive feedback: On the other hand, if positive feedback control is implemented, the
controlled value is forced further away from the set point.
o Controller in this case makes the control worse.
o To illustrate this further, consider the blending process in figure 3.6.

o Suppose that the mass flow-rate w1 is

Control valve
constant but the mass fraction x1 Mixture of A and B Pure A
X1 X2=1
varies with time. w1 w2
o Stream 2 has a mass flow-rate of w2

h
and is composed of pure A.
X
o Stream 2 flow-rate can be w
Fig.3.6 blending system

manipulated to keep the composition
of the outlet stream within a desired
range, which is the control objective.
o If the nominal value of the inlet stream composition is x1 , what would be the nominal flow-
rate of stream 2 required to produce the desired composition xsp in the outlet stream?
o A steady state material balance is considered to determine the required stream 2 flow-
rate.
Overall balance: w1 + w2 − w = 0..................................(3.1)
Component A balance: w1 x1 + w2 x2 − wx = 0.........................(3.2)
Since x2 = 0, combining eq.1 and 2 gives:
xsp − x1
w2 = w1 .................................(3.3)
1 − xsp
o The overbar denotes the nominal steady state values.
o Equation 3.3 is the design equation for the blending process.
o Provided that the assumptions made on the blending process are correct and that the inlet
composition is equal to the nominal value, the value of stream 2 flow-rate computed
according to equation 2 will produce the desired concentration.
o But what happens if the concentration in the inlet stream changes with time, how can the
outlet concentration remain at or near the desired value?
o As previously discussed, one way to achieve this would be to use a feedback control
configuration.
o Option 1: In using such a strategy, the outlet composition can be measured and the
measurement then used to adjust the flow-rate of stream 2.
o The control can be implemented by an operator (manual control) or more conveniently

and economical, the control may be automated (automatic control).
o In implementing this strategy, a simple control algorithm or control law can be used, that
is;
w2 (t ) = w2 + K c  xsp − x(t )  ..................................(3.4)
o Kc is a constant called the controller gain.
o Equation (3.4) is a representation of how the flow-rate of stream 2 should be varied from its
nominal value in order to keep the outlet composition at or near the desired value as the inlet
composition varies.
o In the blending process considered here, positive feedback control will take place when Kc<
0.
o Stream 2 flow-rate will increase in this case when outlet composition increases.
o This will in turn increase exit composition further away from the desired value.
o Option 2: Measure stream 1 composition 𝒙𝟏 and manipulate stream 2 flow-rate 𝒘𝟏 .

o A control law for method 2 can be derived based on equation 3.3.
ഥ𝟏 is replaced with 𝒙𝟏 𝒕 yielding

o 𝒙
xsp − x1 (t )
w2 = w1 ...........................................(3.5)
1 − xsp
o Equation 3.5 describes how stream 2 should be varied when there is a change in stream 1
composition.
o Note that option 2 is feedforward scheme.
o Hence, whenever feedback control is implemented, it is important to ensure that negative

feedback is used.
o One of the main advantages of feedback control is that corrective action occurs irrespective
of the source of disturbance.
o As an example, consider the blending process control scheme shown in figure 3.7.
o Disturbance in outlet composition can be caused by either a change in feed-rate 𝒘𝟏 or a

change in inlet composition 𝒙𝟏 .
o During operation of the process, it may not be known which disturbance is responsible for the
change in outlet composition.
o Feedback control, however, can ensure disturbances in either 𝑤1 or 𝑥1 are accommodated.

Feedback versus feedforward control configuration
Composition
controller
AC
Control
Mixture of A and B valve Pure A
X1 X2=1
w1 w2
AT
h Composition
analyser/Transmitter
X
w
Fig.3.7 Feedback control for blending system
o The ability to handle disturbances of unknown origin is the main reason why feedback
control is the dominant control strategy in most industrial processes.
o Feedback control also reduces the sensitivity of the controlled variable to unmeasured
disturbances and process changes.
o This means that the controlled variable will be less sensitive to unmeasured disturbances
and process changes such as impeller speed in the case of blending process.
o The fundamental disadvantage of feedback control is that no corrective action is taken by

the controller until after the disturbance upset the process. That is, after controlled variable
deviates from set-point.
o An important advantage of feedforward is that the corrective action is taken before the
controlled variable deviates from the set-point.
o Ideally, it is desired that the corrective action by the feedforward control completely
cancels the effect of the disturbance.
o However, ideal cancellation is not possible but the presence of feedforward can
significantly reduce the effect of measured disturbances.
o There are, however, three main disadvantages of feedforward control.

o 1) The disturbance variable must be measurable or accurately estimated.
o 2) in the case of unmeasured disturbances, no corrective action is taken by the controller.
o In figure 3.8, no corrective action will be taken by the controller for unmeasured 𝑤1 .
o This situation could in theory be dealt with by measuring both 𝑤1 and 𝑥1 and adjusting
𝑤2 accordingly.
o Such a control scheme could also improve the quality of the control.
o However, in industrial applications, it is not economical to install instrumentation and

measure every possible disturbance.
Composition Composition controller

AC
analyser/Transmitter
AT Control
Mixture of A and B valve Pure A
X1 X2=1
w1 w2
X
w
Fig.3.8 Feedforward control scheme for blending system
o A more practical approach would be to use a combination of feedforward and feedback

control configuration.
o Feedback in this case will provide corrective action for unmeasured disturbances while
feedforward reacts to eliminate measured disturbances before its effect on the controlled
variable.
o Consequently, industrial applications typically uses a combination of feedforward and

feedback control.
o 3) Another setback for a feedforward control configuration is that a process model is

typically required for unmeasured disturbances.
o The inferential control configuration for the distillation column shown in figure 3.3 is a
special case of feedforward control.
o A process model is used in this case to link the unmeasured distillate composition to the
accurately measured tray temperatures.
o In addition to feedback and feedforward control configurations, another type of a control

scheme is the inferential control configuration shown in figure 3.3.

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THE COPPERBELT UNIVERSITY

School of mines and minerals sciences

o Figure 3.4 (b) is an example of Fi (ft3/min), Ti (oF)

feedforward control configuration.

o In this control scheme, the

measured prior to its effect on the Ts

Condensate F (ft3/min), T (oF)

o Feedback control can either be implemented as negative feedback or positive

o Controller in this case makes the control worse.

o To illustrate this further, consider the blending process in figure 3.6.

o Suppose that the mass flow-rate w1 is

o Stream 2 has a mass flow-rate of w2

Fig.3.6 blending system

o Equation 3.3 is the design equation for the blending process.

o The control can be implemented by an operator (manual control) or more conveniently

o Kc is a constant called the controller gain.

o Option 2: Measure stream 1 composition 𝒙𝟏 and manipulate stream 2 flow-rate 𝒘𝟏 .

o A control law for method 2 can be derived based on equation 3.3.

ഥ𝟏 is replaced with 𝒙𝟏 𝒕 yielding

o Note that option 2 is feedforward scheme.

o Hence, whenever feedback control is implemented, it is important to ensure that negative

o Disturbance in outlet composition can be caused by either a change in feed-rate 𝒘𝟏 or a

o Feedback control, however, can ensure disturbances in either 𝑤1 or 𝑥1 are accommodated.

o The fundamental disadvantage of feedback control is that no corrective action is taken by

o There are, however, three main disadvantages of feedforward control.

o 1) The disturbance variable must be measurable or accurately estimated.

o 2) in the case of unmeasured disturbances, no corrective action is taken by the controller.

o However, in industrial applications, it is not economical to install instrumentation and

Composition Composition controller

o A more practical approach would be to use a combination of feedforward and feedback

o Consequently, industrial applications typically uses a combination of feedforward and

o 3) Another setback for a feedforward control configuration is that a process model is

o In addition to feedback and feedforward control configurations, another type of a control

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