Process Application
Feedback Control
Feedback Control
Feedback Control System
Feedback Control System
Feedback Control System
Feedback Control System
Feedback Control System
Feedback Control System
Feedforward Control
• Fig. shows the conventional feedback loop, which measures the distillate concentration and after
comparing it with the desired setpoint, increases or decreases the reflux ratio. A feedforward control
system uses a different approach. It measures the changes in the inlet feed stream (disturbance)
and adjusts the reflux ratio appropriately. Fig shows the feedforward control configuration.
• Fig shows the general form of a feedforward control system. It directly measures the disturbance to
the process and anticipates its effect on the process output. Eventually it alters the manipulated
input in such a way that the impact of the disturbance on the process output gets eliminated. In
other words, where the feedback control action starts after the disturbance is “felt” through
the changes in process output, the feedforward control action starts immediately after the
disturbance is “measured” directly. Hence, feedback controller acts in a compensatory manner
whereas the feedforward controller acts in an anticipatory manner.
Process Dynamics and Control
Control of Heat Exchangers
Introduction
To develop a comprehensive control strategy for any control loop, it
is important to identify the process variable of interest—called the
“controlled variable,” the manipulated variable, and the different
disturbance variables that directly affect the controlled variable.
Heat Exchanger
Control of Heat Exchanger
Consider the heat exchanger shown in figure (on the previous
page). The shell side fluid is the process fluid that is required to be
heated to a certain temperature setpoint. The resulting
temperature is measured at the outlet of the heat exchanger T1out
(controlled variable).
Heating is achieved by passing steam through the tube side. The
more steam passing through the tubes, the more heat is transferred
to the process fluid, and vice versa. Control of the steam flow F2
(manipulated variable) is achieved by throttling a modulating valve
installed on the steam inlet side.
Control of Heat Exchanger (contd..)
Three major disturbances can affect the process fluid outlet
temperature:
I Changes in process fluid flow rate, F1
I Changes in process fluid inlet temperature, T1in
I Changes in steam pressure, causing a change in steam flow
rate, F2 .
The control objective is to maintain process fluid outlet
temperature T1out at the desired setpoint regardless of
disturbances, by manipulating the steam flow rate F2 .
Feedback Control of Heat Exchanger
Cascade Control of Heat Exchanger
Feedforward Control of Heat Exchanger
Feedforward Control of Heat Exchanger (contd..)
Unlike feedback control, feedforward takes a corrective action when
a disturbance occurs. Feedforward control doesn’t see the process
variable. It sees only the disturbances and responds to them as
they occur. This enables a feedforward controller to quickly and
directly compensate for the effect of a disturbance.
To implement feedforward control, an understanding of the process
model and the direct relationship between disturbances and the
process variables is necessary.
Control of Heat Exchanger - Integrated Approach
Control of Heat Exchanger - Integrated Approach
An integrated approach that uses feedback, feedforward, and
cascade control is shown in previous page. This approach is more
than capable of accommodating heat exchanger control
requirements:
I A feedforward loop will handle major disturbances in the
process fluid
I A cascaded-flow control loop will handle issues related to
steam pressure and valve problems
I A feedback loop will handle everything else.
Combining the three techniques to optimize heat exchanger
temperature control is necessary to minimize process variance,
maximize product quality, and ensure energy efficiency in
petrochemical industries.
References
I [Link]
Process Dynamics and Control
Control of Distillation Columns
Introduction
Distillation columns have to be carefully operated in order to
achieve the required production rates and product quality. The
three main objectives of column control can be stated as:
1. To set stable conditions for column operation.
2. To regulate conditions in the column so that the product(s)
always meet the required specifications.
3. To achieve the above objective most efficiently, e.g.: by
maximising product yield, minimising energy consumption,
etc.
Introduction (contd..)
Process variables like temperatures, pressures, flow rates, levels
and compositions must be monitored and controlled in any
distillation process. These process variables within a distillation
system affect one another, whereby a change in one process
variable will result in changes in other process variables. Thus, in
column control one should be looking at the whole column and not
focusing on any particular section only.
Some General Guidelines
I Column pressure — normally controlled at a constant value.
I Feed flow rate — often set by the level controller on a
preceding column.
Feed flow rate is independently controlled if fed from storage
tank or surge tank.
I Feed temperature — controlled by a feed preheater. Prior to
preheater, feed may be heated by bottom product via
feed/bottom exchanger.
I Top temperature — usually controlled by varying the reflux.
I Bottom temperature — controlled by varying the steam to
reboiler.
I The compositions — controlled by regulating the reflux flow
and boiled-up (reboiler vapour).
Pressure of Distillation Column
Pressure is often considered the prime distillation control variable,
as it affects temperature, condensation, vaporisation,
compositions, volatilities and almost any process that takes place
inside the column.
Column pressure control is frequently integrated with the
condenser control system.
Condenser and Pressure Control
The 3 main methods of pressure and condensation control are:
1. vapor flow variation,
2. flooded condenser, and
3. cooling medium flow variation.
Condenser and Pressure Control (contd..)
Vapor Flow Variation
The simplest and direct method for column producing a vapor
product. The pressure controller regulates the vapor inventory and
therefore the column pressure. An important consideration here is
the proper piping of the vapor line to avoid liquid pockets.
Condenser and Pressure Control (contd..)
Vapor Flow Variation
Condenser and Pressure Control (contd..)
Flooded Condenser
This method is used with total condensers generating liquid
product. Part of the condenser surface is flooded with liquid at all
times. The flow of condensate from the condenser is controlled by
varying the flooded area. Increasing the flooded area (by reducing
flow) increases the column pressure (less surface area for
condensation).
Condenser and Pressure Control (contd..)
Flooded Condenser
Condenser and Pressure Control (contd..)
Coolant Flow
Pressure can also be controlled by adjusting the flow of coolant to
the condenser. Operation using cooling water can cause fouling
problems at low flow condition, when cooling water velocity is low
and outlet temperature is high.
Condenser and Pressure Control (contd..)
Coolant Flow
Condenser and Pressure Control (contd..)
Other Methods
I Pressure control using inerts — when column pressure falls,
an inert gas is admitted to raise the column pressure.
I Venting excess gas to flare.
Temperature Control
Column temperature control is perhaps the most popular way of
controlling product compositions. In this case, the control
temperature is used as a substitute to product composition
analysis.
Ideally, both top and bottom compositions should be controlled to
maintain each within its specifications.
Temperature Control
Controlled Variables
Manipulated Variables
Disturbances
Pairing of Variables
Control Loops
References
I [Link]
I [Link]