Although pneumatic hardware is used to implamnent this intriguing aay ‘of pverida and feacfoward loop configurations, the principios that are Ulustrated are vali for practialy eny type of contrl mochanism. The ‘icevsson presents the mathematical structure for each configuration, ‘but atthe samo time Is closely orented to situations that anse on the ‘ertrates on overnde techniques: a further intllment wil discuss boty ‘ovtride and feedforward compensation. Designing Override and Feedforward Controls P.S BUCKLEY. .| du Pont de Nemouts & Co Ipereased use of override controls in recent years has Sli mre mate operon wih ret throughput and fewer shutdowns. Following erie Spossued tesments of dilation eamas and hema! reacts (Refs. ty 2,3, and 4) the Dreent discos datibes ecbiques for compen fating ordinary fesdback loops wih overnide and feedforward crete to produce priical working nso, This means systems easier to design, toi Stal to calla and to operate ‘Normal procure in many plans regis that the operator hae a setpoint sation for adjusting the Setpoint and observing the response. of measured ‘elables to uch adjustment. I he must know wh In override ha ken charge ofa valve, a concoller uputinieston and valve loudng signal ora di {Great presse and slarm light may be included. Manual sotomatis icing may 90 be equed forthe operate. "bu the malenance mechanic wil eed 8 man ual-o-tomale switch to disable loop for eaibra thon and perforaance ches, Figure 1. This switch tray be located na rack ares oie eh0ush (0 the eonsofoom to be retonably acento the operator in case of emergency. If there are overrides thd ferdforware compensators suchas are wat fin Figure, the naeument mechanic may Wish Lo Sale them sothey wil got its te valve while te is working. Figre 2 shows how thsi done by locating the minilto-evtomaic sieh after the feedforward compensator and before the ovis, ‘wih an aviary Bypass ovitch around the late. “Te same esc may be obsind by placing the rmanualsoatntiesvitch afterall verdes and “ {ecdforward compensators, but themethod in Figure Tie safer For added sary, the bypass switch is 1 fated Behind the rack-area panel 89 that only the Iechaniccan get oi easly. ‘So much forthe iaterfaces betwen the plant eon trols and the people who work with them. Its ap- propriate to etarine the anatomy of basic conte Fes for the porpose of relating them t overrides and fesiforward compensation for a cea understanding ofthese techniques. Proportional rset contol ‘Manufacturers usually achieve integral (est) ection by postive fedback, Figute 3. internal feedback paths ate castomary, but some controles have witchplter and connections for providing external feaback: The contoller equations are (9) = K,[0413)~ 8411 Oph) 0) 49) Pr) = ee where 0, is controller output presue, ps 2 ie controlrsetpoit sigma, ps yi meanured variable Sal st pi oedback pressure, rin eeset chamber snd asom son aw MORO pa ta ‘Kis conoller proportional za fi Laplacian operator network time constant withthe reset needle valve estilo) providing acousterestance andthe Volume of the reset chamber providing acoustic ca Pactnce. ‘Sabstituine Equation 2 ino Equation 1 and re: ducing yields 64) ___ Kes +0) Tf) -80) a8 ‘he clasicalproportiana-rest controler equation, ‘Note fom Figure 3 tht wil flow through the cost eee abe a8 long is W,# 8. But fom Equation I, Ye 9 st longas by # Jy Thus the contrition fom th propoiana pat ofthe con troller is zero when the deviation of the measured Varable fy from setpoint 820, and the dir sence between Oye an 9, the alo zero, ° ‘Antest windup fer proportional rset ‘Sontolor with signal selectors "When signal selectors are inserted inthe output path 1 eet fedack ae All about windup tafalve ee her er Youd do irre om Tie ep net ag ac 1s taken downstream ofthe lst selector a shown in Figure 4, Equation ? mast be replaced by Oty = 200) ne) = = where 0,3) ie the vale signal TE 6, #0, meaning that one of the foreign sig- nals bas taken over a signal selector, sustitution of Equation # into Equation 1 yes 24s) = K0q() ~ Os] + a) ned “Thus inearal (rest action ceases, andthe controler ‘output i the deviation (rrr) muliped bythe gin tnd added tothe vale loading signa, the ater de- layed by the value ofthe time constant When over fide tion does not exit meaning that no foreign ‘Signals ste taking over selectors, ,— and nor- smal reset action continues. a) sions windup for Mating toga) onsale with sana electors The equation fr the integral controller af Figure $ 8) = 45) ~ Os) + 0) 6 ue to cnn ne of el so 1 Sena pedi ee > eee i Pe ! i i long se 49a9) cra o IF @= 0, meaning that no ovevide condition x- ins, O19) = 4a 1) =) 0) +969 4g HO ve cin hese #8 iy PH =869 009g sod nettion hs ae Antrest windup fr cascade loops In cacade loops, providing antireset windup for the ‘aster controle ie more ofa problem. One solution 4s to stain reetfenback forthe master controler from the output of the secondary. measurement ‘transmitter, Figure 6. Assuming both controle: 0 be propordonatese, ther equations for contol ‘wimeot override would be 849) = Kal) ~0mi(9] + 22°, 10) ae FIG 8. foc pope mit nde, contort ain where tq) i the reset time constant of the master ontrote, and 0.6) = Kl) ~ Ons] + part (pdmatyconvoller) signal flow cagram, Figure 7. Note tht the dynamics ofthe slave loop are inthe rese feedback path ofthe master control Ter Itheslve-loop natral frequency is high com. red with T/sq-laveloop dynamice will have ‘eglible efct'dn the masteloop reset fedback ‘Steh might be the cae ifthe sive loop were a fom ta If te toy the tetm tg> [(l — ai woul bee erteron for subilty The circuit would be i Proved as shown in Fgute 12 ifthe folowing net ork were inserted (olan “The familia three-mede contol trarsfer function esancr i constrained fo we the coriguration of Figure to ‘Author Buckley will conclude this discussion of oversde-feedorward design notes in fortheoming feue of Control Engineering a 1 Ove Can Dilsnn Clune? F-S, ck 2. “PotansGnc fr Sten bare Comoe” PS 3. Sfotste Cnt ors Gna Rear” PS bat. 4 Pianeta More Hmnl Scabaion” Bek, tuamenatoe Teale Ra TT 3. 1, Moti io Fy lag sed‘The tie Ie reminicent of an eae arle ("Making it With Flies [Apr page 68), which told how and why classe fliic techniques are finally being Nberete. Tho present author takes matters a ite further Vier-Logie ts th tade name of a hybrid av-loge device that has all he basic advantages of the pure icc logic Block but dows nat depend on ‘complex and sensitive flow phenomens. Ths dscussion of to principle ‘of operation of Visi-Logie shows how moving part ai logic 1s "domna he Job" in meny ndustnes Making It With Moving- P. G MESNIAEFF. Control Enameerng ‘The Now paths through pure Mudie devices ae ex cally clove sn tolerance. This makes them susceptible fo the impurities preset in most industriel aie sup- plies. Normally air pressure has fo be narowly coh- {role requiring the use of leds apd vestritor to thatch up the characteristics of various devices. ko, Tn many cases i takes expensive specialists to set UP Foie contol spstems and Keep them operational “These Tactors influenced Double A Products Co. in Manchester, Mich, to abandon iis contentions product line of fuidic Topic Socks in. November 196 in favor of new concept ealed Visi-Logic. A ingle, universal logic module has eight identi ‘vee input NOR logic gates and external connes- ‘ons forall inputs and outputs, The NOR gates use five contol ridges (o accomplish the logic function “The loer state of euch NOR gate i viable through the ler plastic medule, hence the name Visi-Logie ‘The concept can Se best Undetsood by examining the smallest Subpast of thy module, one of he cone } ne sac nono he siti Sem eRe og Ck (alleles Part Air Logic trol idge (Figure 1A). Each control ide is a iru lar chamber having upper and lower halves separat- cl by a chaphrapm. With no essure on the Upper ‘de, aie Rows unimpeded over the ridge on the bo tom sie, Whea contrel ai oessure is aplit tothe Upper side the resultant force exceeds that of the lower side and the diaphragm snaps downward gaint the cide, blocking ow through that char ter Figure 1B shows a NOR gate with its ve ridges. Wath no signal applied to aay of the three input ors ir from supply moves through two paths In {he contol section H ener through a essa, passe fs over the control ridges, and vents to atmosphere through the second Feastor. (Because the 0 Fe tor atest are equal, the presire between them nell the soppy pressure This afeat enough to thainain «closed dlphragi on the vent ridge, bet ‘ot enough to lose the output rie) In he supply Section, ar at supply pressure i directed 10 she out ° © E rt ae" rae Tg Loreen phragm tf te ee a amr ike ge se eee NOR eta a sc ‘ipa ip tone ae€" "hemlet mov sin ee lee se CONTROL ENGINEERINGIn the feet part of this “how-to approach, in the August issue, author Buckley described a varety of practical overide confaurations He used ‘oumatic herdware for lop Implementation, but pcinted out thatthe techniques ilstrated were equally applicable to othe: forms of conto hardware. In this issue, he begins with the fund ental distinctions between feedlorward and overide signals, then gives further examples. Designing Override and Feedforward Controls—!! PS, BUCKLEY, € 1 du Pont de Nemours & Co, “The purpose in using eter or both fedforward and ‘override cireits 1 compensate fedback loops i to Produce practical working controls, as pointed ot in fhe previous artle (CE, Aug, p. 48). The choke Tetwoan the two techniques if hat ithe sue ies in their basic contol eet, Feedforward compensa tion comes in Randy when there are sources of ds- turbance such at indicated in Figure 13." Here the Feedforward signals are applied in response 0 the Aisturbance forthe parpose of relieving the burden fn the main contol ‘Suppose that the problem js 10 control the top tempeature ofa datilation column by manipulating the rex rate, Ifthe column feed fate changes, row refx ral wil be needed t0 maintain the same {emperature, To accomplish coatol of foptempera~ tre under thee conditions tis often the practice to ‘escade refi to-fed rat contol In this way the feciforward compensation desis job of wiping ot hrestened disturbance to temperature ard the Controller does not experience a substantia rempersture err TH contract, overrides re used when constraints ‘on the process must be compensated, The faction ‘ofthe override is thea to change the contrl mode by ‘Mbstittiag one algritsn for another. This tech igue often reduces toa simple matter of suiting oT ne inal channel and opening up another, Figure 13. “Thus fesdforwatd signals augment controller ac- tion under disturbances, and overide signals limit excursions of varibles beyood constrains, but this Aistinetion may become blurted in complex control schemes, Feedlonward and antreset windup Problems aise when its proposed toad fealfor. Id signals to the output of the controle, 3 own in Figure 13. If controler reset feedback is igure names pk op rm el of thai, a taken fom controller output ahead ofthe summer (Gasted ine), the feedforward signal wil operate Properly but there wll be a problem of eat winds. Gp the other hand sf feeTorward is udded direct to controler output abead of reset Feedback (slid Tine), the controler will have an oft between mea sured variable and setpoint equal to the magnitude ofthe feedforward signal ‘One way to sold this difculty is by use of the ‘modiied summer, a¢ shows ia Figure 13. The high pss ier with tne constant 1, actin the fedor. ‘vard path to eliminate de components. The equation ‘Ofsummer outputs 04) = 019) + Oy) se sel where ©13scontroer output dia eeaforward signal eter time constant ‘This areangement permits proper action of the sotraet windup cout shown ts “overrides” in Figure 13.'To see Why this fe tru, assume thatthe Imanval-automatic swtch is ia the automatic posi tion ad thatthe main eaatol loop i i normal on {Tol This means that ©, — ©, Recalling Equation i in Part (August, page 48): 04s) K [Oy ~ 0,0] +O, ) and replacing the bracketed poston with errors) elds en= Kae) Us pearance ona= 2,0 Combining Equations 1A, 15, al 16 yes ost ums kop Hohe et prt farce CONTHOL ENGINEERING1G. 1, Diagram teat ‘Seraining ee ote sep en espns reso, oso ME Ray einttle iy am gestion 18 is shown in the signal ow diagram of Figure 14. Note that it. — fe. Equation Is re ‘certo tl eu) = "Kad +8,,() (9) ‘Reset action thus operates on the error signal and not on the feedforward signal, permitting proper contol ston. Now consider the case where there i no high pass 1.1. Sia tie dam ering he gt te mde ee eigen al, ent nergy | Orerdes + a 4 ec wy of elon compen comme ee fof exer ter operating on the fetforward signal (0 hich is added dicey to ©, 3 eu ene,0) 2 Combining Baan 1,16 a2 yi o.o)= "fey 40,45] aD nbere reset action Becomes a function ofboth error 4nd feedforward, an prope controls not posible. ‘The other method of feedforward without interfering wih Teedback action ivoles two summers, Figure 15. The fecdforward signal is to the controler output seal the reset fedback signal. Here the summer 208 G1 stat mtd ating ee ne ‘be modibed sumer of Figure 13 *ph. anoleoe 11.16, Sommers met placed eu uth of cer Ieee ppm Iban be te er oe Stuer ea te 1617, Api i te cent of Fe 6c ‘Growin amme by non mcr ‘must te accurately adjusted 10 preveat an offset in the feedback contol. ‘Combining Equations A and 20 with uy 2a Bye ‘yields ‘ Se) = Ka + 2) 878) 0,4 0) which reduces to Equation 19. Agua, the reset a: tion is operating a the error sigeal, and not on the Feedforward sgaal ‘Summers in contalor output pth In casts where I: relationship Between the tke ‘over signal and the normal como signal is de- ‘ied, subatitute summers for the selective clays that tre shown in the previous article. The normal mes Threinent signal, rather than = “oven” signal, then becomes the ource of ovecrideaeion “Consider the prportonsl-rset temperature con wlle of Figure 16 For temperatures above the set- Poin, an entra control action sought that wl en Sire tat the airto-open control vale wil be closed ft temperature 7, The fst. desi sep isto bias the summer suc iat ©, — ©, when the low limiter (LL) ott fe ai. Ky is then selected such that (ST : Kone 20 where (ATi. span in deg C of temperature “Ti setpoint in dep C Rij etn f proportional amplifier (lay) Finally, the proportional relay bias should be adjust- ‘liso that when temperature T reaches Tis ut- put 3 psig The limiter wil Keep the sumer out- ‘pt from changing when TT Whoa TT the oqtrles equation becomes idctial with Equation Vand the summer equation is 48) = 041 ~ Kona) 5) ‘Combining Equations 1, 2, and 25 yields #1 [K.O,10)— (K+ Kon oy or) 20 a CConveatonal stability calealations should be made folasure that Ky Will ot case itd With this syslem, is aflen posible to Use a highs cc temperate innt te bigies thon Tt ite ‘verde setion, Tis means that for = T-there sa ‘ormal proportional action plus a noma rest. This ievcrally permite higher vale of K+ Kogt the fystem can be nesry unstable for lige signals so Tong sit drop into @ move stable state a8 T ap proaches Ty TW Kon i bigh enough, simpli cireit can be sed in which the low limiter (LL) and summer are replaced by alow seleeior (LS), Figure 17, In this ‘ate the principle stated above fe geerll followed in that the low end ofthe overtie span, is reat. than Ty This citi, n commen with that of Figure 16, fsponds only to high inl ‘Wen blsteral extra control sein witha speci- fod zones of measurement span i deised, the revit of Figure T8 i suggested. The occasion may arise, for entmple ia controling pH of @ plant waste ‘ream, and may be needed ‘S"To compensate parally for the nonlinear cla- tionship between pH and reactant flow ratios and 1 provide low loop gain inthe viesty ofthe st- point, ith the high gaia Tor large deviations from etpoiat. Ta Figuee 18, if ©, is 9 psig for example, and ex- tra control action is sired when ©, exceeds 12 pig ‘ori less than 6 aig, the high limite (HL) would be ‘et fo acura ns tbe al ot Shem ses Arc tanto terior Srerseese ohrae Ms | ee iy ee eg aefp ee I 7 (ee it sin pnd weer rane an Dod chapman ne 1G. 19, Crs targa ep haart of Ts it ota popes soe od Soe ner fet at 12 and LL at 6 peg. Then a8 long a8 lies between 6and 12 psig, One ~ 4, andthe outpa of fhe summing relay with gaia wil be the sime a8 ©, ‘The equation forthe deci is ©, =Korlon@,1+@ and fr large deviations from setpoint, 045) = Korl- Ou] + 6) 8) Ifthe valve i to drive fl-open a8 Q. 2005 fom 121 15 psi, and fullclosed at ©., goes from 6t0 3 ‘ia, Koy should be chosen sch that 2 Koe= 24 For Oy greater than 12 psig or Fess than 6 pig, the ‘Great obeys uation 26 "To see what happens when the proportonaleset controler of Figore 18 replace by & Moating on troller arin Figure 19, Equations 6,7, and 28 are combined, noting that Equation 78 applies to large ‘evistions fom setpoint: uty eh + ff eu) = 9) Equation 29 shows that for large devitions from ‘sipoin, the circuit behaves ike sm integrator when G.21, Mad of sign oe ode ore wh ty Ione ie ak of cng aren vie ol Sea psec Seeks rea crated a Pu uray, ee Seer 8, varies, and like 4 proportionaleset controler ‘wien Oy varies, For smal deviations i setpoint, the Girt "bonaves lke ab integrator whether the hangs are in @, or in Oy ‘An increasingly important application of overides ib that of error-dependent, oF measurement depend ft, variable pain. Tn this techoigue the manipulted ‘ariable i alg the messred variable. ‘The technique becomes useful when the cootoller is proportional est with gaia les than unity. Such 1 device may aot hold the measured variable within eseribed limits, To improve matters, circuits elle Eyota overrides" are used that augment the con- tell gin Tor Iarge deviations from setpoint, yet permit ow psn inthe viiity ofthe setpoint ‘One method of implementing this eor-depeadent tin has been shown io igute 18; a somewhat less Expensive method iss bilateral version of Figure 17, Shown in Figure 20, This circuit has frequently been Sseful in controling distillation-olumn base levels via feod rate where avaliable base holdup most be Stall for process reasons ‘With proportional bands up to 200 percent (coa- toller ghin'K, = 05, Koy is set at “6, The high selector (HS) auto overie is set to work for a level lransmiter span of 11-13 psig, and the low selector (LS) auto override in the range 51 pi. Setpoint is 30 pig. Inthe level transmitter spun of 711 Psa, orm controller gin prevails [An override controler shouldbe faster than & noe ‘mal contoler This may not always be posible thea, for example, the avaiable instrument i Proportionareset type wit long rest time, The wl Uaton suggests use of & reset Bypass contoler at angemeat, Figure 21 ‘A high-gain diflerential relay is used to detet the Aierence between secondary stpoin. and the soe ‘ondary variable. "As Tong as thee is sigiiant eae vaive is bypassed, A Sor tcuns sal te ile rly cats of fd normal eet action begins