Feed-forward Control

Cheng-Liang Chen

PSE

LABORATORY

Department of Chemical Engineering National TAIWAN University

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A Process Heater with Feedback Control

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A Simple Pure Feedforward Control

Considering Inlet Temperature As Main Disturbance
EB: Q Cp (To Ti) = F Hv Ef f Ti = MAIN disturbance To = desired outlet temp Q Cp (To Ti ) F = H v Ef f

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Pure FF Control for Multiple Disturbances

Considering Variation of Inlet Temperature, Process Flow Rate, and Fuel Heating Value Disturbance 1: variations of inlet temperature Disturbance 2: variations of process ow rate Disturbance 3: variations in fuel heating value
F = H Ep To Ti v ff QC

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Pure FF Control for Multiple Disturbances

Considering Variation of Inlet Temperature, Process Flow Rate, and Fuel Heating Value Disturbance 1: variations of inlet temperature Disturbance 2: variations of process ow rate Disturbance 3: variations in fuel heating value
F = H Ep To Ti v ff QC

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Pure FF Control for Multiple Disturbances

Considering Variation of Inlet Temperature, Process Flow Rate, and Fuel Heating Value Disturbance 1: variations of inlet temperature Disturbance 2: variations of process ow rate Disturbance 3: variations in fuel heating value
F = H Ep To Ti v ff QC

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Dynamic Adjustment for FF Control Action

Fo(s) ds + 1 ds = e Fi(s) g s + 1 d 1 d/g ds = + e g g s + 1

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FF Control with Additive/Multiplicative FB Trim

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FF Control with Additive FB Trim

Most important disturbances are compensated by FF Why feedback trim ?
 Error in process model  Un-measurable disturbances

FB signal should be scaled so that when it is in the center of its range it represent zero correction to the FF signal Process gain of the FB loop may vary inversely with process ow rate
Kp = To Kp measurement controller output H v Ef f = Ti + F Q Cp To = F = outlet temperature fuel H v Ef f Q Cp 1 Fp

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FF Control with Multiplicative FB Trim

FB signal: a multiplying factor, K If FF controller is exact no correction is necessary K = 1 Temperature controller output should be scaled so that 0 100% of signal range represents a limited range of correction Example: K = 0.75 1.25 FB can correct FF results by a factor 25%

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FB Adjust FF Controllers Reference Value

To : setpoint (reference value) of the FF controller To adjust To by FB trim to keep To having desired value

Process gain of the FB loop is a constant value of 1.0 under any kind of load condition

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Experimental Approach for FF Control

Dynamic Eect of Load Change to Controlled Variable

dTo(t) T + To(t) = K Q(t d ) dt To(s) K ed s G (s) = = Q(s) T s+1

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Experimental Approach for FF Control

Dynamic Eect of Manipulated Variable to Controlled Variable

dTo(t) Tp + To(t) = KpF (t dp) dt To(s) Kpedps Gp(s) = = F (s) Tp s + 1

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Experimental Approach for FF Control

Desired: No Response of Controlled Variable to Load Change

without FF: To(s) = G (s)Q(s) use of FF: To(s) = G (s)Q(s) + Gp(s)F (s) = G (s)Q(s) + Gp(s)GF (s)Q(s) = [G (s) + Gp(s)GF (s)] Q(s) = 0
=0

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Experimental Approach for FF Control

Desired: No Response of Controlled Variable to Load Change

= GF (s) = =

G (s) Gp(s) K Kp

K ed s T s+1 Kp edp s Tp s+1 dp )s

Tps + 1 (d e T s+1

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Dynamic Compensation
Possible barriers to implementing perfect FF control:  Other disturbances might exist  Process model may be incorrect  There had been no consideration of process dynamics Abstract view of the process: two external inuences  Load (disturbance)  Control eort

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Required dynamic compensation:

H (s) = [A(s) + B (s)C (s)] C (s) = A(s) B (s)

(perfect control)

Suppose

A(s) =

KpAeTdAs TpAs + 1

B (s) =

KpB eTdB s TpB s + 1

KpA TpB s + 1 (TdATdB )s C (s) = e KpB TpAs + 1 dead time term

FF gain lead/lag term

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C (s) = GF (s) = KpA TpB s + 1 (TdATdB )s e KpB TpAs + 1 dead time term

FF gain lead/lag term

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Implementation of Feedforward Control

Test each of the process paths: load and process dynamics by FOPDT models Take the ratio of the two TFs Add feedback to compensate for un-measured disturbances or errors in process models Relax FB controller from the tuning if FB were used alone (lower gain, longer reset, no D)  No D action in FB (load upset is taken by FF)  Primary purpose of FB is to correct for steady-state errors in FF controller  Responsibility of FB controller is not as great as if it were controlling the process alone

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Step Response of Lead-lag (with/without Dead Time) Function

Lead/Lag Only with Dead Time

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Fine Tuning The FF Controller

A FF control system by itself will rarely provide perfect compensation for the measured disturbance combined with FB FB control acts only after the fact (it must see an error to make a correction) the closer to perfect compensation the FF makes the less correction required by FB controller

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Incremental Change and Incremental Response

Suppose dynamic compensation consists only of dead time Eect of reducing dead time in the compensator: Reducing dead time in the compensator incremental fuel change incremental response of outlet temperature

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Incremental Eect of Various Adjustments

Load: increase in feed rate Make adjustment in a direction that will give a positive incremental fuel change to compensate for the short-term fuel deciency

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Incremental Eect of Various Adjustments: Summary

A change in only dead time will result in an incremental process response relatively soon after load change A change in only lead-lag ratio will result in an incremental process response that is somewhat father out in time from the time of load change A change in lag time (constant lead-lag ratio) will result in an incremental process response that is the fastest away in time

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Eect of Composite Adjustments

Fine Tuning:  Observe initial response to a load change of the FF control system  Determine the direction and relative time scale of the required incremental corrective process response  Adjust dynamic compensating terms accordingly Example: Composite Adjustments  Decrease dead time to start the increased fuel response sooner  Decrease lead-lag ratio to give less fuel increment once its response is begun  Decrease lag time (maintaining a constant lead/lag ratio) to cause a faster approach of the fuel to nal equilibrium

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Feed-forward: Balance Equation Approach

EX: A Mixing Process with Simple FB Control

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Steady-State Feed-forward Scheme

Steady-state overall mass balance 0 = q 5 + q1(t) + q2(t) + q 7 q6(t) 0 = q 5 + q1(t) + q2(t) + q 7 q6(t) ( = const.) q1(t) = q6(t) q2(t) 1000

Steady-state mass balance on component A and the feed-forward relation: 0 = q 5x5 + q2(t)x2 + q 7x7 q6(t)x6(t) 1 q6(t) = [q x5 + q 7x7 + q2(t)x2] x6(t) 5 1 [850 + 0.99q2(t)] = x6(t) 1 q1(t) = [850 + 0.99q2(t)] q2(t) 1000 set x6
FY11A FY11B

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Steady-State Feed-forward Scheme

1 q1(t) = set [850 + 0.99q2(t)] q2(t) 1000 x6
FY11A FY11B

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FF Control with Dynamic Compensation

1 q1(t) = set [850 + 0.99q2(t)] q2(t) 1000 x6
FY11A FY11B

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FF Control with Dynamic Compensation and FB Trim

Feedback trim: adjusting desired X6 Question: additive FB or multiplicative FB ?

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FF Control: Block Diagram Approach

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Pure Feed-forward Control

X6 = G1 Q1

X6 = G2 Q2

Q1 = GF C M

M = GF TO

TO = H2 Q2

X6 = G2 Q2 + G1 Q1 GF C M GF TO H2 Q2

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= [G2 + G1GF C GF H2] Q2

G2 GF (s) = G1G

0 (desired)

F C H2

let

G1 GF C = G2 =

KP1 ed1s 1s+1 KP2 ed2s 2s+1

(mf/%CO)

(mf/gpm) (%TO/gpm) 1s + 1 (d2d1)s e 2 s + 1 dead time

lead/lag

H2(s) = KT2 GF = KP2 KP1 KT2

%CO/%TO

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Feed-forward Control with Feedback Trim

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Summer FY-11C: OUT = KxX + Ky Y + Kz Z + B0

FB signal: X ; FF signal: Y ; bias: B0 Kx = 1; Ky = 1; B0 = (KP2 /KT2 KP1 )40% Steady-state value of q2(t) Range of transmitter for q2 Steady-state value of the ow Steady-state output from FF Bias to cancel SS FF signal Steady-state value of q1(t) Range of transmitter for q1 Output from summer must be Output from FB is forced to be Ky = 0: FF is turned o 1000 gpm 0 2500 gpm 40% (KP2 /KT2 KP1 )40% (KP2 /KT2 KP1 )40% 1900 gpm 0 3800 gpm 50% 50%

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FF Control for Boiler Drum

Single-Element Control

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FF Control for Boiler Drum

Two-Element Control

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FF Control for Boiler Drum

Three-Element Control

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FF for Distillation Column

Simple Feedback Control

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FF for Distillation Column

Feed-forward Control Scheme

: :

lbm/hr; Btu/lbm

qs = qt q1 = qt m = qt K h = f1(P ) = f2(P ) signal characterizers

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FF Control on A Distillation Column

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FF Control for Distillation Feed

FF Control Handles Two Upsets Simultaneously
Variables: feed composition and ow-rate to a distillation column excessive impurities to appear in bottoms product Temperature of the two-component mixture in lower-bottoms sump has a direct relationship to impurity concentration (sucient correlation often exists even for multi-component mixtures) F, z, F z : feed, fraction of light, ow of lighter component Steam ow-rate should be nearly proportional to Fz temperature controller adjusts the ratio to compensate for possible errors in measurement, model

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Most dicult part: dynamic compensation

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FF Control on Heat Exchanger

Energy Balance: WsHs = WpCp (T2 T1)
Ws = KCp (T2 T1 )

Dynamic Compensation: change in product ow is faster than change in heat transfer FB Temperature Control:
 Providing setpoint (T2 ) in the FF computation  Force temperature to reach its setpoint without steady-state oset

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FF Control on Evaporator
Mass and Energy Balances: (W : mass rate, kg/h; x: weight fraction; E : economy, kg vapor/kg steam) 1st eect: 2st eect: W0x0 = W1x1 W0 = W1 + V1 W1x1 = W2x2 W1 = W2 + V2 W2 = (x0/x2)W0 W 0 = W 2 + V1 + V2
0 W0 1 x x2

= V1 + V2
EWs 1 E 0 F 0 x0 1x
2

0F0

Ws =

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Feed density and feed solids weight fraction is related signal characterizer f (0) : x0 vs. 0 Feed ow signal (F0) is dynamically compensated with lead/lag function  Product density does not respond with equal speed to changes in feed-rate and steam ow  Changes in steam ow produce a slower response because of thermal time lags associated with heat transfer surfaces a predominant lead function  Density normally does not vary as fast as feed ow feed-density dynamic compensation is not included FB trim is provided by density controller to provide desired setpoint, x 2 , in feed-forward model

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FF Control on Evaporator