Advanced Process Control:
An Overview
Sachin C. Patwardhan
Dept. of Chemical Engineering
I.I.T. Bombay
Email: sachinp@iitb.ac.in
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Automation Lab
IIT Bombay
Plant Wide Control Framework
Long Term Scheduling
and Planning Market
Demands /
Raw material
availability
On-line Optimization
Slow Parameter
Setpoints PV, MV drifts
Multivariable / Nonlinear Control
Advanced
Regulatory (PID) Control Control
MV PV
Fast Load
Plant Disturbances
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Automation Lab
IIT Bombay
Hierarchy of control system functions
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Automation Lab
Why On-line Optimization ?
IIT Bombay
Shift if operational priorities
Example: FCC Unit operated under
Maximization of Gasoline / LPG production
Maximization of ATF production
Maximization of profits
Minimization of energy consumption
Changes in operating conditions
Changes in feed quality (refinery: change in crude blend)
Changes in operating parameters
Catalyst degradation
Heat-exchanger fouling
Changes in separation efficiency
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Automation Lab
On-line Optimization
IIT Bombay
Steady State Model Updated Steady
State Model
Parameter Estimation
Cleaned input
Output Data On-line Steady
State Optimization
Steady State Data
Reconciliation
Set Points
Updated
Inputs
Outputs
Operational
Goals
PLANT
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Automation Lab
Why Advanced Control ?
IIT Bombay
Why advanced control?
Complex multi-variable interactions
Operating constraints
Safety limits
Input saturation constraints
Product quality constraints
Control over wide operating range
Process nonlinearities
Changing process parameters / conditions
Conventional approach
Multi-loop PI: difficult to tune
Ad-hoc constraint handling using logic programming
(PLCs): lack of coordination
Nonlinearity handling by gain scheduling
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Automation Lab
IIT Bombay
Example: Quadruple Tank System
dh1 a a3 k
1 2 gh1 2 gh3 1 1 v1
Tank3 Tank 4 dt A1 A1 A1
dh2 a a k
2 2 gh2 4 2 gh4 2 2 v 2
dt A2 A2 A2
dh3 a (1 2 )k2
3 2 gh3 v2
Tank 1 dt A3 A3
Tank
2 dh4 a4 (1 1 )k1
Pump 2 2 gh4 v1
dt A4 A4
Pump1
V2
V1
Manipulated Inputs : v1 and v2
Measured Outputs : h1 and h2
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Automation Lab
Multi-loop Control
IIT Bombay
Industrial Processes: multivariable (multiple
inputs influence same output) and exhibit strong
interaction among the variables
Conventional Control scheme: Multiple Single
Input Single Output PID controllers used for
controlling plant (Multi-Loop Control)
Consequences: Loop Interactions
Lack of coordination between different PID
loops
Neighboring PID loops can co-operate with
each other or end up opposing / disturbing
each other
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Automation Lab
Tennessee Eastman Problem
IIT Bombay
Primary controlled variables: Product concentration of G
Product Flow rate
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Automation Lab
IIT Bombay
TE Problem: Objective Function
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Automation Lab
IIT Bombay
TE Problem: Operating Constraints
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Automation Lab
Model Predictive Control
IIT Bombay
Multivariable Control based on On-line use
of Dynamic Model
Most widely used multivariable control scheme in
process industries over last 25 years
Dynamic Matrix Control (DMC) developed by Shell in
U.S.A. (Cutler and Ramaker, 1979)
Model Algorithmic Control developed by Richalet et. al.
(1978) in France
Used for controlling critical unit operations (such
as FCC / crude column) in refineries world over
Mature technology
Can be used for controlling complex large dimensional
systems
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Automation Lab
Advantages of MPC
IIT Bombay
Modified form of classical optimal control
problem
Can systematically and optimally handle
Multivariable interactions
Operating input and output constraints
Process nonlinearities
Basic Idea
Given a model for plant dynamics, possible
consequences of the current input moves on the
future plant behavior (such as possible
constraint violations in future etc.) can be
forecasted on-line and used while deciding the
input moves
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Automation Lab
MPC: Schematic Diagram
IIT Bombay
Disturbances
Optimization Inputs Outputs
Process
Dynamic
Prediction Dynamic
Model Model
MPC
Plant-model mismatch
Set point Trajectory
Dynamic Model: used for on-line forecasting
over a moving time horizon (window)
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Automation Lab
IIT Bombay
CSTR Example
Consider non-isothermal CSTR dynamics
dC A
f1 (C A , T , F , Fc , C A0 , Tcin ) feed flow rate
dt
coolant flow rate
dT
f 2 (C A , T , F , Fc , C A0 , Tcin )
dt
States (X ) C A T T Measured Output (Y ) T
Manipulated Inputs (U ) [F Fc ]T Feed conc.
Unmeasured Disturbances (Du ) C A 0
Cooling water
Measured Disturbances (Dm ) Tcin Temp.
If model is known, can we estimate CA from
measurements of T ?
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Automation Lab
IIT Bombay
CSTR: Multi-Loop PI Performance
Controlled Outputs
0.4 PID Pairing
CA - Fc
Conc.(mol/m3)
0.35
T-F
0.3
0.25
Linear
0.2
0 5 10 15 20 25 Plant
Time (min) Simulation
400
k c1 6.34
Temp.(K)
395
I ,1 0.2
390 k c ,2 0.0028
I , 2 0.3
385
0 5 10 15 20 25
Time (min)
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Automation Lab
IIT Bombay
CSTR: Multi-Loop PI Performance
Coolent Flow (m3/min) Manipulated Inputs and Disturbance
30
20
10
0 5 10 15 20 25
Time (min)
1.5
Linear
Inflow (m3/min)
1 Plant
Simulation
0.5
0 5 10 15 20 25
Time (min)
2.5
Inlet Conc. (mol/m3)
1.5
0 5 10 15 20 25
Time (min)
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Automation Lab
CSTR: LQG Performance
IIT Bombay
Controlled Outputs
0.45
0.4
Conc.(mol/m3)
0.35
0.3 Linear
0.25 Plant
0.2 Simulation
0 5 10
Time (min)
15 20 25
(No Plant
Model
398
Mismatch
396 Case)
Temp.(K)
394
392
390
388
0 5 10 15 20 25
Time (min)
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Automation Lab
CSTR: LQG Performance
IIT Bombay
Coolent Flow (m3/min)
Manipulated Inputs and Disturbance
30
20
10
0 5 10 15 20 25 Linear
Time (min) Plant
3
Inflow (m3/min)
Simulation
2
(No Plant
1 Model
0
0 5 10 15 20 25
Mismatch
Time (min) Case)
Inlet Conc. (mol/m3)
2.5
1.5
0 5 10 15 20 25
Time (min)
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Automation Lab
IIT Bombay
Linear MPC Applications (2003)
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Automation Lab
IIT Bombay
Industrial Application: Ammonia Plant
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Automation Lab
IIT Bombay
State Feedback Controller Design
Step 1 (Model Development) : Develop a discrete
time dynamic model for process under
consideration
Step 2 (Soft Sensing) : Design a state estimator
(soft sensor) using dynamic model and
measurements
Step 3 (Controller Design): Assume the states
are measurable and design a state feedback
controller
Step 3: Implement state feedback controller
using estimated states
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Automation Lab
IIT Bombay
Models for Plant-wide Control
Aggregate Production
Layer 4
Rate Models
Steady State / Dynamic
Layer 3
First Principles Models
Layer 2 Dynamic Multivariable Time
Series Models
Layer 1 SISO Time Series Models,
ANN/PLS/Kalman Filters
(Soft Sensing)
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Automation Lab
IIT Bombay
Mathematical Models
Qualitative
Qualitative Differential Equation
Qualitative signed and directed graphs
Expert Systems
Quantitative
Differential Algebraic systems
Mixed Logical and Dynamical Systems
Linear and Nonlinear time series models
Statistical correlation based (PCA/PLS)
Mixed
Fuzzy Logic based models
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Automation Lab
IIT Bombay
White Box Models
First Principles / Phenomenological
/ Mechanistic
Based on
energy and material balances
physical laws, constitutive relationships
Kinetic and thermodynamic models
heat and mass transfer models
Valid over wide operating range
Provide insight in the internal working of systems
Development and validation process:
difficult and time consuming
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Automation Lab
IIT Bombay
Example: Quadruple Tank System
dh1 a a3 k
1 2 gh1 2 gh3 1 1 v1
Tank3 Tank 4 dt A1 A1 A1
dh2 a a k
2 2 gh2 4 2 gh4 2 2 v 2
dt A2 A2 A2
dh3 a (1 2 )k2
3 2 gh3 v2
Tank 1 dt A3 A3
Tank
2 dh4 a4 (1 1 )k1
Pump 2 2 gh4 v1
dt A4 A4
Pump1
V2
V1
Manipulated Inputs : v1 and v2
Measured Outputs : h1 and h2
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Automation Lab
IIT Bombay
Data Driven Models
Development of linear state space/transfer
models starting from first principles/gray box
models is impractical proposition.
Practical Approach
• Conduct experiments by perturbing process
around operating point
• Collect input-output data
• Fit a differential equation or difference
equation model
Difficulties
• Measurements are inaccurate
• Process is influenced by unknown disturbances
• Models are approximate
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Automation Lab
Discrete Model Development
IIT Bombay
Excite plant around the desired operating
point by injecting input perturbations
Measurement
Noise
3.2
2.9
2.8 3
2.7
2.8
Measured Output
2.6
Manipulated Input
2.6
Process
2.5
2.4 2.4
2.3
2.2
2.2
2
2.1
2 1.8
0 2 4 6 8 10 12 14 16 18 20 0 5 10 15 20
Sampling Instant Sampling Instant
Unmeasured
Input excitation for Disturbances Measured output
model identification response
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Automation Lab
4 Tank Experimental Setup
IIT Bombay
Quadruple Tanks Setup
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Automation Lab
Identification Experiments IIT Bombay
on 4 Tank Setup
Input 1 Input 2
Output 2
Output 1
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Automation Lab
IIT Bombay
4 Tank Setup: Input Excitations
Manipulated Input Sequence
1
Input 1 (mA)
-1
0 200 400 600 800 1000 1200
1
Input 2 (mA)
-1
0 200 400 600 800 1000 1200
Time (sec)
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Automation Lab
Splitting Data for IIT Bombay
Identification and Validation
Input and output signals
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0
y1
-5
0 500 1000
1
0.5
u1
0
-0.5
0 500 1000
Samples
Identification Data Validation data
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Automation Lab
ARMAX:State Realization
IIT Bombay
x(k+1) = x(k) + u(k) + Le(k)
Y(k) = C x(k) + e(k)
= [0.6236 1 0 0
0.8596 0 1 0
0.0758 0 0 1
-0.5680 0 0 0]
= [ 0.0832 0.0040 L = [ 0.1541
0.0276 0.0326 0.0579
0.0268 -0.0184 -0.0307
-0.1214 0.0201 ] -0.0826 ] ;
C=[ 1 0 0 0]
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Automation Lab
OE Model: Validation
IIT Bombay
Measured and simulated model output
0
y1
-1
-2
oe221 Fits 87.07%
-3
Validation data
1100 1150 1200 1250 1300 1350 1400
Time
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Automation Lab
IIT Bombay
State Estimation (Soft Sensing)
Quality variables : product concentration, average
molecular weight, melt viscosity etc.
Costly to measure on-line
Measured through lab assays: sampled at irregular
intervals
Measurements available from wireless sensors are
at irregular intervals due to packet losses
For satisfactory control of such processes:
Quality variable / efficiency parameters should be
estimated at a higher frequency
Remedy: Soft Sensing and State Estimation
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Automation Lab
IIT Bombay
Inferential Measurement: Basic Idea
Since fast sampled (primary) variables (temperatures,
pressures, levels, pH) are correlated with the
quality variable, can we infer values of quality
variables from measurements of primary variables?
On line state estimation:
Feasible after availability of fast Computers
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Automation Lab
Model Based Soft Sensing
IIT Bombay
Fast-rate Low-cost Irregularly / Slowly
measurements from sampled Quality variables
Plant (Temperature / from Lab assays
Pressure / Speed)
Dynamic Model
(ODEs/ PDEs)
On-line Fast Rate Estimates of
Quality variables
Soft Sensing: Cost Effective Solution
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Automation Lab
Soft Sensing Approaches
IIT Bombay
Soft Sensing
Techniques
Static / Dynamic Model
Algebraic based State
Correlations Estimation
Principle Stochastic (e.g. Deterministic
Components Neural Kalman filters) (e.g. Luenberger
Analysis Networks Observers)
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Automation Lab
IIT Bombay
CSTR Example
Consider non-isothermal CSTR dynamics
dC A
f1 (C A , T , F , Fc , C A0 , Tcin ) feed flow rate
dt
coolant flow rate
dT
f 2 (C A , T , F , Fc , C A0 , Tcin )
dt
States (X ) C A T T Measured Output (Y ) T
Manipulated Inputs (U ) [F Fc ]T Feed conc.
Unmeasured Disturbances (Du ) C A 0
Cooling water
Measured Disturbances (Dm ) Tcin Temp.
If model is known, can we estimate CA from
measurements of T ?
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Automation Lab
IIT Bombay
“Closed Loop” State Observer
Open Loop Observer: Difficulties
1. Not applicable to unstable systems
2. Rate of convergence governed by spectral
radius of
Process +
u(k) Y(k) e(k )
Model -
yˆ (k )
Use of output prediction error to
1. Stabilize estimator for unstable processes
2. Improve rate of convergence for stable systems
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Automation Lab
IIT Bombay
Case Study-2 : Plug Flow Reactor (PFR)
Steam, Tjo
Tj-1, TR-1 Tj-2, TR-2
T T T Tj-5, TR-5
CA(1,t), CB(1,t)
CC(1,t), TR(1,t)
CAo, TRo
A B C
(Endothermic Reaction)
Tj(0,t)
(Shang et al., 2002)
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Automation Lab
IIT Bombay
Fixed Bed Reactor
Material Balances (Distributed Parameter System)
CA C
vl A k10 e E1 / RTr CA ……..Reactant A
t z
CB C
vl B k10 e E1 / RTr CA k 20 e E2 / RTr CB ……..Product B
t z
Energy Balances
Tr Tr H r1
vl k10 e E1 / RTr CA ……..Reactor Temp.
t z m Cpm
H r 2
m Cpm
k 20 e E 2 / RTr
CB
Uw
m Cpm Vr
Tj Tr
Tj Tj
T T
U wj
u ……..Jacket Temp.
t z mjCpmj
r j
V j
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Automation Lab
IIT Bombay
Simulation Result: Concentration profiles of product
B at different time instants
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Automation Lab
Experiment: Combined State and IIT Bombay
Parameter Estimation on Heater-Mixer Setup
3-15 psi
Cold Water Flow Input
CV-1
CV-2
Cold Water Flow
T Tank - 1
T
L
T
Tank - 2
Thyrister
4-20 mA Control
Input Unit
Signal
T
T
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Automation Lab
IIT Bombay
Example: Stirred Tank Heater-Mixer
dT1 F1 Q (I 1 )
(Ti 1 T1 )
dt V1 V1 C p
dh2 1
F1 F2 (I 2 ) F
dt A2
dT2 1 UA(T2 Tatm )
F1 (T1 T2 ) F2 (Ti 2 T2 )
dt h2A2 C p
Q (I 1 ) 7.979I 1 0.989I 12 0.0073I 13
F2 (I 2 ) 3.9 27I 2 0.71I 22 0.0093I 23
20
U 139.5 J / m Ks ; F (h ) k h2 h
I1 : % current input to thyrister power controller
I2 : % current input to control valve
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Automation Lab
Experimental result: Tank 1 temperature IIT Bombay
and heat loss parameter estimates
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Automation Lab
Controller Design
IIT Bombay
State Feedback Controller Design: Assuming state
are measurable, design a state feedback controller
such as LQG or MPC
Advantage: Multi-variable systems can be
controlled relatively easily
Separation principle ensures nominal closed loop
stability with state estimator-controller pair
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Automation Lab
Course Outline
IIT Bombay
System Identification: Development of On-line
Model Based Control Relevant Models from Input-
Output Data
Time series model development
Discrete State Realization
State Estimation (soft sensing) : Estimation of
unmeasured states (variables) by fusing Input-
Output data with dynamic model predictions
Luenberger observer design by pole placement
Kalman filtering
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Automation Lab
Course Outline
IIT Bombay
Online Model Based Control
Introduction to Classical Linear Quadratic Optimal
Control
Linear Model Predictive Control
Evaluation Scheme
Mid-semester exam (20 %)
End-semester exam (40 %)
Programming assignments and Project (20 %, tentative)
Quizzes (20 %, tentative)
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