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Some processes, such as the heat exchanger described earlier, are easy to model. But this is not always the case, particularly when mass and heat transfer coefficients must be used over a wide range of operating conditions. Therefore item 3 may be of considerable importance in the more complicated processes. The feedforward system cannot be all-inclusive. Some load components are so slight, or invariant, or ill defined, that their inclusion is not warranted. If payout and ease of operation are important, which is to be expected, the control system had best remain simple. To this extent, certain terms such as heat losses and ambient temperature effects are usually neglected. Yet their variation can induce a measurable offset. If offset is intolerable, some means must be provided for recalibration while the system is operating. In general, this can be done most directly by readjusting the set point, which is already scaled in terms of the controlled variable. Other adjustments could be made, such as the coefficient K in the heat-exchanger control system, but with less predictable results.
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The Role of Feedback
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Regardless which term is trimmed to remove offset, the procedure amounts to manual feedback. Automatic feedback is perfectly capable of effecting the same result, if the controlled variable can be measured with sufficient reliability. (This qualification is significant in that feedforward control is occasionally used because a feedback measurement is unavailable.) Proportional feedback trim is insufficient to eliminate offset, for the same reason that it was insufficient in a conventional control loop. T h e presence of feedforward control components within the feedback loop induces no substantial change in the mode settings required of the feedback controller; the process is just as dificult to control as it was without feedforward-only the amount of work required of the feedback controller has been markedly reduced. Reset, then, is necessary if offset is to be eliminated altogether. Whether proportional and derivative are useful modes depends on the nature of the process. If rapid load changes outside the forward 100~ may be encountered, proportional and derivative action could be advantageous. If the process is fundamentally non-self-regulating, as in level control, proportional action is essential. Finally, if the process is fairly easy to control because of the absence of dead time, derivative may be useful in improving the dynamic load response-but this is unusual. In general, mindful that feedforward control is warranted only on the most demanding and most difficult applications, reset is the only useful feedback mode. Experiments conducted on a heat exchanger, which is
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not particularly difficult to control, indicated that proportional and derivative feedback modes responded too slowly to contribute anything to the load response of the system, either with or without dynamic compensati0n.l On the other hand, feedback can be detrimental by promoting oscillation in an otherwise stable system. To this extent, the settings of the feedback controller, regardless of what modes have been selected, ought to be relaxed. Inasmuch as reset controllers are not available as standard products from most manufacturers, proportional-plus-reset is the usual recommendation.
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Where to Introduce Feedback
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This is not always an easy question to resolve. The feedback controller may be asked to perform a number of different services. In the heatexchanger application it can be useful in correcting for heat loss, in which employment it should add an increment of heat to the process at all loads; this would amount to a zero adjustment. Or its principal function might be to correct for variable steam enthalpy, in which case it should apply a span adjustment by setting the coefficient K. In another process, linearity could be the largest unknown factor. But a single feedback controller can hardly be called upon to do all these things. When no one source of offset is outstanding, the argument for readjusting the set point of the feedforward system is irresistable. Figure 8.15 shows how the feedback controller would fit into this arrangement. Feedback is added simply by replacing the manual set station with a feedback controller; no additional computing elements are needed. Startup may proceed in orderly fashion in manual, simply by setting the output of the feedback controller equal to its set point. No guesswork is involved, since this is the known operating region for the system. When in automatic, there is ultimately only one set-point signal, because the controller output is now a variable. Another feature of this configuration is that it displays the inherent inaccuracies of the forward loop. The difference between the set point and the output of the feedback controller is the offset which would have appeared if feedback had not been used. A plot of controller output vs. load could conceivably identify the principal sources of error in the comRemote
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FIG 8.15. In general, the feedback controller should reposition the set point of the feedforward system.
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