CHAPTER 7: THE FEEDBACK LOOP

When I complete this chapter, I want to be able to do the following.

Identify the major elements in the feedback loop Select appropriate candidate variables to be controlled and manipulated Evaluate the control performance data using standard measures of dynamic performance

CHAPTER 7: THE FEEDBACK LOOP

Outline of the lesson.

Typical loop elements Relating variables to control objectives - Examples Typical control performance measures Five approaches to feedback control

CHAPTER 7: THE FEEDBACK LOOP

The Concept: We show limited detail in the piping and instrumentation (P&I) drawing. We see the sensor location, variable measured, connection to the final element (valve) and the location of the final element.
v1

TC A

v2

CHAPTER 7: THE FEEDBACK LOOP

The Reality: Many elements in the loop affect the safety, reliability, accuracy, dynamics and cost. Engineers need to understand the details!

v1 4-20 mA T A

4-20 mA

v2 3-15 psi

CHAPTER 7: THE FEEDBACK LOOP

What affects the response to the computer? Make a step (without feedback control)

Sensor & transmitter

input and A/D conversion

computing network

I/P conversion

final element

electronic transmission

output and D/A

electronic transmission

pneumatic transmission

THE PROCESS

CHAPTER 7: THE FEEDBACK LOOP

Class exercise: Given the following dynamics, sketch the responses for a step in manual station to the displayed value.

CHAPTER 7: THE FEEDBACK LOOP

Class exercise: Given the following dynamics, sketch the responses for a step in manual station to the displayed value. What you see (from the display) is not always what is occurring!!

CHAPTER 7: THE FEEDBACK LOOP

The engineer must decide what measurement to control and what valve to adjust (and provide the equipment to support the decisions).

CHAPTER 7: THE FEEDBACK LOOP

The engineer must decide what measurement to control and what valve to adjust (and provide the equipment to support the decisions). CV to control ? Use seven categories of control objectives!
control objective 1) Safety 2) Environmental protection 3) Equipment protection 4) Smooth plant operation and production rate 5) Product quality 6) Profit optimization 7) Monitoring and diagnosis process variable sensor

Concentration of reactant A in the effluent

Analyzer in reactor effluent measuring the mole % A

CHAPTER 7: THE FEEDBACK LOOP

The engineer must decide what measurement to control and what valve to adjust (and provide the equipment to support the decisions).

MV to adjust ?
1. Causal relationship 2. Automated 3. Fast dynamics 4. Compensate for large disturbances 5. Can adjust quickly with little adverse affect on process performance

CHAPTER 7: THE FEEDBACK LOOP

The engineer must decide what measurement to control and what valve to adjust (and provide the equipment to support the decisions).
Input variables that affect Selected adjustable flow the measured variable disturbances Feed temperature Solvent flow rate Feed composition, before mix Coolant inlet temperature Manipulated valve

We could use either valve. We will revisit this choice later (Chapter13)

adjustable

Flow of pure A Flow of coolant

Flow of pure A

vA

CHAPTER 7: THE FEEDBACK LOOP

The figure shows the feedback loop Well see the calculation in the next chapter. Explain, including the feedback concept.

Class exercise on the feedback loop: Using the methods just described, select ONE variable to be controlled and for that variable, ONE valve to be manipulated.
Flue gas
AT 1 FT 1 TI 1 PI 4

PI 5 TI 5

feed

TI 2

PT 1 TI 3 TI 4

TI 6

TI 7

TI 9

TI 10

FT 2

burner

TI 8

FI 3

TI 11

air

PI 2

PI 3

PI 6

fuel

Class exercise on the feedback loop: Using the methods just described, select ONE variable to be controlled and for that variable, ONE valve to be manipulated.
Flue gas
AT 1 FT 1 TI 1 PI 4

PI 5 TI 5

feed

TI 2

PT 1 TI 3 TI 4

TI 6

TC
TI 9 TI 10

TI 7

FT 2

burner

TI 8

FI 3

TI 11

air

PI 2

PI 3

PI 6

fuel

Class exercise on the feedback loop: Using the methods just described, select ONE variable to be controlled and for that variable, ONE valve to be manipulated.
Flue gas
AC
FT 1 AT 1 TI 1 PI 4

O2
TI 2

PI 5 TI 5

feed

PT 1 TI 3 TI 4

TI 6

TI 7

TI 9

TI 10

FT 2

burner

TI 8

FI 3

TI 11

air

PI 2

PI 3

PI 6

fuel

CHAPTER 7: THE FEEDBACK LOOP

Music: I cannot define good music, but I know what I like. Control Performance: We must be able to define what we desire, so that we can design equipment and controls to achieve our objectives.

Controlled Variable

Set point 1.5 entered by person 1

0.5

Controlled variable, value from a sensor

0 5 10 15 20 25 Time 30 35 40 45 50

2 Manipulated Variable 1.5 1 0.5 0

Manipulated variable, usually a valve

10

15

20

25 Time

30

35

40

45

50

CHAPTER 7: THE FEEDBACK LOOP

Controlled Variable

Lets be sure we understand the variables in the plot. We will see this plot over and over and over !

1.5

0.5

0 0

10

15

20 25 30 Time

35

40

45 50

2 Manipulated Variable 1.5 1

0.5 0 0

10

15

20

25 30 35 Time

40

45 50

CHAPTER 7: THE FEEDBACK LOOP Set point Change = IAE = |SP(t)-CV(t)| dt 0

A B
1

1.5

0.5

B/A = Decay ratio

0 0 5 10 15 20 25 Time 30 35

Return to set point, zero offset

40 45 50

Rise time
2 1.5

C/D = Maximum overshoot of manipulated variable

C

1 0.5 0

10

15

20

25 Time

30

35

40

45

50

CHAPTER 7: THE FEEDBACK LOOP Disturbance Response = IAE = |SP(t)-CV(t)| dt 0

Maximum CV deviation from set point

0.8 0.6 0.4 0.2 0 -0.2

10

15

20

25 Time

30

35

40

45

50

-0.5

-1

-1.5

10

15

20

25 Time

30

35

40

45

50

CHAPTER 7: THE FEEDBACK LOOP Disturbance Response Often, the process is subject to many large and small disturbances and sensor noise. The performance measure characterizes the variability.
S-LOOP plots deviation variables (IAE = 5499.9786) 20 Controlled Variable 10 0 -10 -20

Variance or standard deviation of CV

0 100 200 300 400 500 Time 600 700 800 900 1000

20 Manipulated Variable 10 0 -10 -20

Variance or standard deviation of MV

0 100 200 300 400 500 Time 600 700 800 900 1000

CHAPTER 7: THE FEEDBACK LOOP

To reduce the variability in the CV, we increase the variability in the MV. We must design plant with MVs that can be adjusted at low cost.

Controlled Variable

20 10 0

-10 -20 0 100 200 300 400 500 600 700 800 900 1000 Time

Manipulated Variable

20 10 0

-10 -20 0

100 200 300 400 500 600 700 800 900 1000 Time

CHAPTER 7: THE FEEDBACK LOOP Class exercise: For each of the performance measures below, determine a good value, i.e., large/small, positive/negative, etc. Offset IAE Decay ratio Rise time Settling time MV overshoot Maximum CV deviation CV variance MV variance

Can we achieve good values for all at the same time? What are the tradeoffs?

Class exercise: Comment on the quality of control for the four responses below.
S-LOOP plots deviation variables (IAE = 17.5417) 1.5 1 0.5 0 -0.5 3 S-LOOP plots deviation variables (IAE = 43.9891) Controlled Variable Controlled Variable 2

A
0 20 40 60 Time 80 100 120

B
0 20 40 60 Time 80 100 120

-1

2 1.5 1 0.5 0 -0.5 Manipulated Variable 0 20 40 60 Time 80 100 120

4 3 2 1 0 -1

Manipulated Variable

20

40

60

80

100

120

S-LOOP plots deviation variables (IAE = 34.2753) 1.5 Controlled Variable 1 0.5 0 -0.5 0
Controlled Variable 1.5

Time S-LOOP plots deviation variables (IAE = 24.0376)

C
20 40 60 Time 80 100 120

0.5

D
0 20 40 60 Time 80 100 120

-0.5

1 Manipulated Variable

1.5

0.5

Manipulated Variable

0.5

-0.5 0

20

40

60 Time

80

100

120

-0.5

20

40

60 Time

80

100

120

Class exercise: Comment on the quality of control for the four responses below.
S-LOOP plots deviation variables (IAE = 17.5417) 1.5 1 0.5 0 -0.5 3 S-LOOP plots deviation variables (IAE = 43.9891) Controlled Variable Controlled Variable 2

A
0 20

B
0 20

Generally acceptable

40

60 Time

80

100

120

-1

2 1.5 1 0.5 0 -0.5 Manipulated Variable

4 3 2 1 0 -1

Too oscillatory
Time

40

60

80

100

120

Manipulated Variable

20

40

60 Time

80

100

120

20

40

60

80

100

120

S-LOOP plots deviation variables (IAE = 34.2753) 1.5 Controlled Variable 1 0.5 0 -0.5 0
Controlled Variable 1.5

Time S-LOOP plots deviation variables (IAE = 24.0376)

C
20

0.5

D
0

Too slow

40

60 Time

80

100

120

-0.5

1 Manipulated Variable

1.5

Gets close quickly; Gets to set point slowly

20 40 60 80 100 Time

120

0.5

Manipulated Variable

0.5

-0.5 0

20

40

60 Time

80

100

120

-0.5

20

40

60 Time

80

100

120

CHAPTER 7: THE FEEDBACK LOOP We can apply feedback via many approaches 1, No control - The variable responds to all inputs, it drifts. 2. Manual - A person observes measurements and introduces changes to compensate, adjustment depends upon the person. 3. On-Off - The manipulated variable has only two states, this results in oscillations in the system. 4. Continuous, automated - This is a modulating control that has corrections related to the error from desired. 5. Emergency - This approach takes extreme action (shutdown) when a dangerous situation occurs.

CHAPTER 7: THE FEEDBACK LOOP, WORKSHOP 1

The control valve is used to

introduce a variable resistance to flow. What is the body of the valve? Describe three bodies and what factors are important in selecting. What is the actuator? What power source is used? What happens when the power source fails?

CHAPTER 7: THE FEEDBACK LOOP, WORKSHOP 2

Recommend the correct failure position (open or closed) for each of the circled control valves.
PI 1

AT 1 FT 1 TI 1

PI 4

PI 5 TI 5

feed
PT 1 TI 3 TI 4

TI 2

TI 6

product
TI 9 TI 10

TI 7

FT 2

TI 8

FI 3

TI 11

air

PI 2

PI 3

PI 6

fuel

CHAPTER 7: THE FEEDBACK LOOP, WORKSHOP 3

Find at least one variable that could be handled by each of the five approaches; no control, manual, on/off, continuous, and emergency.
PI 1

AT 1 FT 1 TI 1

PI 4

PI 5 TI 5

feed
PT 1 TI 3 TI 4

TI 2

TI 6

product
TI 9 TI 10

TI 7

FT 2

TI 8

FI 3

TI 11

air

PI 2

PI 3

PI 6

fuel

CHAPTER 7: THE FEEDBACK LOOP, WORKSHOP 4 Select several pairs of controlled and manipulated variables for the following process.
vS
Solvent Pure A

CA0 CA

vA

A B

V TCout
vc

FC TCin

CHAPTER 7: THE FEEDBACK LOOP

When I complete this chapter, I want to be able to do the following.

Identify the major elements in the feedback loop Select appropriate candidate variables to be controlled and manipulated Evaluate the control performance data using standard measures of dynamic performance

Lots of improvement, but we need some more study! Read the textbook Review the notes, especially learning goals and workshop Try out the self-study suggestions Naturally, well have an assignment!

CHAPTER 7: LEARNING RESOURCES

SITE PC-EDUCATION WEB - Instrumentation Notes - Interactive Learning Module (Chapter 7) - Tutorials (Chapter 7)

CHAPTER 7: SUGGESTIONS FOR SELF-STUDY 1. Find a sample process in each of your previous courses and select a pair of controlled and manipulated variables - Heat Transfer (heat exchanger) - Fluid Mechanics (flow in a pipe - Mass Transfer (stripper, distillation) - Reaction Engr. (packed bed reactor) 2. Compare the measures of control performance in this chapter with the seven control objectives given in Chapter 2. 3. Describe the actions you would take if you measured a disturbance and did not want to wait for feedback corrections.