Feedforward and Ratio Control

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1 Feedforward and Ratio ISA Mentor Program Presentation by: Gregory K. McMillan Standards Certification Education & Training Publishing Conferences & Exhibits

2 Presenter Gregory K. McMillan is a retired Senior Fellow from Solutia/Monsanto and an ISA Fellow. Greg was an adjunct professor in the Washington University Saint Louis Chemical Engineering Department Greg received the ISA Kermit Fischer Environmental Award for ph control in 1991, the Magazine Engineer of the Year Award for the Process Industry in 1994, was inducted into the Process Automation Hall of Fame in 2001, was honored by InTech Magazine in 2003 as one of the most influential innovators in automation, and received the ISA Life Achievement Award in Greg is the author of numerous ISA books on process control, his most recent being Advances in Reactor Measurement and and Good Tuning: A Pocket Guide - 4 th Edition. Greg has been the monthly Talk columnist for magazine since Greg is the founder and co-leader with Hunter Vegas of the ISA Mentor Program for users. Greg s expertise is available on the web sites: 2

3 Feedforward Multiplier vs Summer When there is no secondary flow or speed controller, the feedforward summer in the primary controller is used to directly manipulate a valve position or power input signal. A secondary controller is too slow for pressure control. When there is a flow or speed controller, Ratio control is predominantly used where a secondary flow or speed controller setpoint is manipulated to follow a leader flow or speed that is multiplied by a desired ratio. Ratio control is used to assist primary PIDs for composition, level, ph, temperature, & quality control. In Ratio control the leader and follower flow first go to a Ratio block whose output is the input to a Bias/Gain block whose output is the cascade setpoint for a flow or speed controller. The setpoint () of each block (ratio or bias) can be set by operator (auto mode) or automatically corrected by a primary PID (cascade mode). The manipulation of the primary PID of the Bias and Ratio is effectively a feedforward summer and feedforward multiplier, respectively. The use of the ratio and bias/gain blocks provide the operator visibility and accessibility in ratio control particularly important for understanding and procedural automation during startup, changes in products and abnormal operations. The Bias is manipulated for volumes with back mixing due to agitation, turbulence or boiling (e.g., vessels and columns). The actual and desired Ratio are displayed. During startup until the process is at its normal operating point, the primary controller is often in manual. In this case the operator runs with a manually set bias and ratio without correction.

4 Ratios Here, There and Everywhere Blend composition control - additive/feed (flow/flow) ratio Column temperature control - distillate/feed, reflux/distillate, reflux/feed, steam/feed, and bottoms/feed (flow/flow) ratio Combustion temperature control - air/fuel (flow/flow) ratio Drum level control - feedwater/steam (flow/flow) ratio Extruder quality control - extruder/mixer (power/power) ratio Heat exchanger temperature control - coolant/feed (flow/flow) ratio Neutralizer ph control - reagent/feed (flow/flow) ratio Reactor reaction rate control - catalyst/reactant (speed/flow) ratio Reactor composition control - reactant/reactant (flow/flow) ratio Sheet, web, and film line machine direction (MD) gage control - roller/pump (speed/speed) ratio Slaker conductivity control - lime/liquor (speed/flow) ratio Spin line fiber diameter gage control - winder/pump (speed/speed) ratio Header pressure control letdown/user (flow/flow) ratio For level and pressure, the mass flow theoretical ratio is simply 1

5 Cascade Ratio or Cascade Bias Correction by Primary PID output Follower Flow or Speed Cascade Bias Correction Original Relationship per Process Flow Diagram (PFD) Cascade Ratio Correction Leader Flow or Speed Automatic correction of cascade Ratio Setpoint (feedforward multiplier) creates a gain factor in the open loop gain that is proportional to flow. For plug flow processes this multiplier gain factor cancels out a process gain that is inversely proportional to flow. For back mixed processes, the process time constant being inversely proportional to flow cancels out process gain nonlinearity in the PID tuning where the PID gain is proportional to the process time constant divided by the process gain. In this case the correction of the cascade ratio creates a residual nonlinearity that adversely affects PID tuning The primary PID output scaling is more critical and prone to error when correcting a ratio The PID output scaling can be as simple as -50% to +50% of secondary PID scale when correcting a Bias Finally, many corrections in are simply associated with offsets from bias errors in the flow measurements or unmeasured loads When in doubt which is best, automatically correct the Bias Setpoint You can slowly adapt the uncorrected Ratio or Bias by use of a generic integral only controller to reduce the correction by primary PID

6 Loop and Load Disturbance Dynamics Block Diagram Feedforward correction should arrive at this point at same time as the Load Upset Y fraction of small lag that is equivalent dead time is a logarithmic function of the ratio of the small to largest lag (Y = 0.28, 0.88 for ratios = 1.0 and 0.01, respectively)

7 Header Feedforward and Decoupler (Linear Valves) Definition of Loop Lag and Leader Lag: Loop Lag is Primary Loop s time constant in path of follower flow or speed to primary process output (primary time constant in self-regulating process and secondary time constant in an integrating process) Leader Lag is Leader s time constant in path of leader flow or speed to the primary process output (load is positive for user pulling steam from header and negative for user pushing steam into the header) Disturbance 1 Flow Load1 (kpph) Disturbance 2 Flow Load2 (kpph) FF1 Delay => Load1 Delay Loop Delay DEADTIME DEADTIME FF2 Delay => Load2 Delay Loop Delay FF1 Lead = Loop Lag (block diagram Secondary Lag FF1 Lag = Load1 Lag If Load Delay is less than Loop Delay, often a delay can be inserted in the PID that is triggering the disturbance. The before the delay is used as the feedforward signal so that Loop Delay is now less than Load Delay. This is an important often overlooked technique! LEAD/LAG If Load1 nonlinear valve must be used as an inference of flow a signal characterizer (SG) would be needed on FF1 SG would use installed flow characteristic of load valve. SG Y outputs would be 0 F1 max (kpph) SG X inputs would be 0-100% position where F1 max is max Load1 valve flow Letdown Flow To Lower Header (kpph) ADD LEAD/LAG FF1 FF0 FF2 FF Gain 0.8 to 1.0 Header FF FF Scale 0 FF max (kpph) where FF max is max letdown valve flow Header PID PV (psig) PID Header PID OUT 0-100% (% of F max ) FF2 Lead = Loop Lag FF2 Lag = Load2 Lag Header PID (psig) If letdown valves are not linear, a signal characterizer (SG) would be needed on PID OUT SG would use installed flow characteristic of letdown valve. SG Y outputs would be 0-100% signal SG X inputs would be 0-100% max letdown valve flow ANALOG OUTPUT Valve Signal 0-100% (% of F max )

8 Dynamic & Adaptive Feedback Correction of Ratio Examples of Follower to Leader flow ratio corrected by Primary ler output: Reboiler Flow to Column Feed ratio corrected by Temperature ler Receiver Distillate Flow to Column Feed ratio corrected by Temperature ler Reagent Flow to Neutralizer Feed ratio corrected by ph ler Follower Reactant Flow to Leader Reactant Flow ratio corrected by Composition ler Follower PV Follower Flow or Speed (e.u.) Leader Flow or Speed (e.u.) Leader PV AUTO Ratio RATIO Actual Ratio PV after correction CAS Ratio Uncompensated Follower Flow or Speed (Leader PV x Ratio) Follower Delay => Leader Delay Loop Delay DEADTIME Primary PID PV (e.u.) PID Primary PID OUT Follower Lead = Loop Lag Follower Lag = Leader Lag Primary PID (e.u.) Gain AUTO Bias CAS Bias LEAD/LAG BIAS/GAIN Dynamic Compensated Follower Secondary AUTO (e.u.) Zero Correction Secondary CAS (e.u.) (Corrected Follower Flow or Speed ) Secondary PID PV (e.u.) (Follower PV) PID Secondary PID OUT 0-100% -0.5xF max to 0.5xF max Bias Correction (e.u.) 0.5xR norm to 2.0xR norm Ratio Correction PID Adaptive PID OUT Gradual Adaptation by PID Integral Only ler ANALOG OUTPUT Valve Signal 0-100% (% of F max )

9 Dynamic & Adaptive Feedback Correction of Bias Definition of Loop Lag and Leader Lag: Loop Lag is Primary Loop s time constant in path of follower flow to primary process output (primary time constant in self-regulating and secondary time constant in an integrating process) Leader Lag is Leader s time constant in path of leader flow to the primary process output Examples of Follower to Leader flow ratio corrected by Primary ler output: Reboiler Flow to Column Feed ratio corrected by Temperature ler Receiver Distillate Flow to Column Feed ratio corrected by Temperature ler Reagent Flow to Neutralizer Feed ratio corrected by ph ler Follower Reactant Flow to Leader Reactant Flow ratio corrected by Composition ler Follower PV Follower Flow or Speed (e.u.) Leader Flow or Speed (e.u.) Leader PV AUTO Ratio RATIO Actual Ratio PV after correction CAS Ratio Uncompensated Follower Flow or Speed (Leader PV x Ratio) Follower Delay => Leader Delay Loop Delay DEADTIME Primary PID PV (e.u.) PID Primary PID OUT Follower Lead = Loop Lag Follower Lag = Leader Lag Primary PID (e.u.) Gain AUTO Bias CAS Bias LEAD/LAG BIAS/GAIN Dynamic Compensated Follower Secondary AUTO (e.u.) Zero Correction Secondary CAS (e.u.) (Corrected Follower Flow or Speed ) Secondary PID PV (e.u.) (Follower PV) PID Secondary PID OUT 0-100% 0.5xR norm to 2.0xR norm Ratio Correction -0.5xF max to 0.5xF max Bias Correction (e.u.) PID Adaptive PID OUT Gradual Adaptation by PID Integral Only ler ANALOG OUTPUT Valve Signal 0-100% (% of F max )

10 Header System Feedforward PX, PX, PX 2-3, PX 2-2, PX 3-3, PX 3-2 are Deadtime and Lead/Lag blocks in series for dynamic compensation of feedforward signals PY, PY 2-1, PX 3-1 are Add blocks where generator flows are negative and user flows and decoupling flows are positive signals Decoupling flows from lower header letdown valves typically do not need dynamic compensation if valves are in same proximity of header Feedforward signals are in same engineering flow units (kpph) with Feedforward scale in PID set to be max flow of manipulated letdown valve All letdown valves must be precise (0.1% resolution 0.2% deadband) fast valves (4 sec T86 86% response time) with linear flow characteristics Generators 3-3 PX 3-3 Users 3-2 PX PY (kpph) Hi 3-1 Cogen 3-1 Lo Hi Pressure Header Generators 2-3 PX 2-3 Users 2-2 PX PY Norm FF (kpph) PC 2-1a PT 2-1 Hi PC 2-1c PC 2-1b RY 2-1 Hi Signal Selection Vent Boiler 2-2 Med Pressure Header Generators PX Users PX + PY Norm FF (kpph) PC a PT Hi PC b Vent Lo Pressure Header

11 Liquid Reactor of Reactants with Feed Maximization Reactant LY ZC OUT Leader Reactant A Level for LT Follower Optimum Residence Time PT TT PC process recirculation ZC is an enhanced PID VPC Vent TC ZC Reactant B Dynamic compensation of reactant ratio control is not needed because reactants arrive at the same point at the same time in reactor if equal reactant flow setpoint filters are used. Valve Position ler ZC pushes coolant valve to max position to maximize reactant feed rate. The ZC setpoint is the maximum position. The ZC should have smart integral action to prevent interaction and limit cycles. The correction for a valve position less than setpoint should be slow to provide a slow approach to optimum. The correction for a valve position greater than setpoint must be fast to provide a fast getaway from the point of loss of control. Directional setpoint rate limits with dynamic reset limit in an enhanced PID that tempers integral action can achieve these optimization objectives. jacket recirculation TT AT TC Return CTW AC Makeup CTW Product

12 Column 1 Top Temperature : Small Distillate Flow Relative Advantages: Internal reflux control inherently compensating for changes in reflux temperature and inherent decoupling of energy and material balances Relative Disadvantages: Slower control of bottoms composition (problematic for stripping columns) RX /Feed Dynamic Z Column 1 Follower Leader Flow RX Flow Feedforward Leader Feed Sump Reflux TT LT TC Distillate/Feed Loose Level Z Receiver Bias Correction RY Dynamic Follower Flow LT Bottoms Tight Level Distillate

13 Column 2 Top Temperature : Large Distillate Flow Relative Advantages: Faster temperature control since independent of level control Relative Disadvantages: Moderate interaction between energy and material balances Reflux Z Receiver LT Loose Level RX /Feed Dynamic Leader Follower Z Feed Flow Feedforward Column 2 Sump TT Leader Flow LT TC Reflux/Feed Loose Level Bias Correction RY RX Follower Flow Dynamic Distillate Bottoms

14 Column 3 Bottom Temperature : Large Bottoms Flow Relative Advantages: Fastest temperature control Relative Disadvantages: Severe interaction between energy and material balances and possibly less process sensitivity from manipulation of separation (vapor rate) Reflux Z Receiver LT Loose Level RX RY /Feed Dynamic Leader Follower Z Feed Flow Feedforward Column 3 Sump Leader Flow TT LT Reflux/Feed TC Loose Level Follower Flow RX Dynamic Distillate Bias Correction Bottoms

15 Column 4 Bottom Temperature : Small Bottoms Flow Relative Advantages: Fast temperature control if level control is tight but this may not be possible due to level inverse response (good steam/feed ratio is critical) Relative Disadvantages: Moderate interaction between energy and material balances and possibly less process sensitivity from manipulation of separation (vapor rate) Reflux Z Receiver LT Loose Level RX RY /Feed Dynamic Bias Correction Leader Follower Z Feed Flow Feedforward Column 4 Sump Leader Flow TT LT Reflux/Feed Leader Flow TC Tight Level Follower Flow Bias Correction RX Dynamic RY RX Dynamic Bottoms Distillate Bottoms/Feed Follower Flow

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