*[lnt 6peration by Dr AA, 2008 Page 2.

2 -#
Inferential Control
Prof. Dr. Arshad Ahmad
Process Control and Safety Group,
Universiti Teknologi Malaysia
Lack of Measurement Lack of Measurement
*[lnt 6peration by Dr AA, 2008 Page 2.2 -#
Page (3)
Lack of Measurement Lack of Measurement
! Control theory is quite matured
! PID " cascade " feed forward " MPC
! Without accurate measurement, good control cannot
be established.
! Weakness in measurement
! lack of appropriate on-line instrumentation
! reliability of on-line instruments
! Long delay, fouling, drifts
! Indirect approaches have been used.
Page (4)
Indirect Control Indirect Control
! Example
! Control of conversion by fixing the resident time in a reactor
! Level and flow control
! Control of composition by fixing the tray temperature in
distillation column
! Pressure and temperature control
! Indirect strategy is good for normal condition
! Any upsets or serious disturbance leads to control
degradation
*[lnt 6peration by Dr AA, 2008 Page 2.2 -#
Page (5)
Benefits Benefits
! faster return of information
! upsets can be detected quicker
! remedial action can be taken before it is too late.
! more consistent production
! reducing human involvement
! better process regulation
! operator's time will be better spent
Page (6)
Effect of Deadtime on Control Effect of Deadtime on Control
Performance Performance
Time
!
p
=1.5
!
p
=0.5
Deadtime
-Inherent process behaviour
-Delay in sampling/or measurement
*[lnt 6peration by Dr AA, 2008 Page 2.2 -#
Page (7)
Traditional Practice: Indirect Traditional Practice: Indirect
Control Control
FT
FC
RSP
TT TC
Tray 10
Composition in Distillation Columns are indirectly controlled
By controlling selected tray temperatures
Page (8)
Choosing a Proper Tray Choosing a Proper Tray
Temperature Location Temperature Location
76
78
80
82
84
86
3 3.5 4 4.5 5
Mole Percent Propane
T
e
m
p
e
r
a
t
u
r
e

(

C
)
Tray 18
Tray 10
! A tray temperature used for inferential
control should show strong sensitivity.
*[lnt 6peration by Dr AA, 2008 Page 2.2 -#
Page (9)
Feed Composition Affects Feed Composition Affects
Composition/Temperature Correlation Composition/Temperature Correlation
75
80
85
90
95
3 4 5
Mole Percent Light Key
T
e
m
p
e
r
a
t
u
r
e

(

C
)
Heavy
Light Feed
Page (10)
Feedback Correction for Feedback Correction for
Feed Composition Changes Feed Composition Changes
FT
AC
AT
FC
RSP
TT TC
RSP
Tray 10
*[lnt 6peration by Dr AA, 2008 Page 2.2 -#
Page (11)
Inferential Estimation Inferential Estimation
Problems:
- lack of measurement
for product composition
- indirect control of product
purity subject to uncertainty
Measure other process variables
Relate these variables to the variable
of interest
Apply as inferential estimator
Use in control loop
Page (12)
Inferential Control Inferential Control
! Uses easily measure process variables (T, P, F)
to infer more difficult to measure quantities
such as compositions and molecular weight.
! Can substantially reduce analyzer delay.
! Can be much less expensive in terms of capital
and operating costs.
! Can provide measurements that are not
available any other way.
*[lnt 6peration by Dr AA, 2008 Page 2.2 -#
Page (13)
Overall Picture Overall Picture
Page (14)
Better frequency Better frequency
*[lnt 6peration by Dr AA, 2008 Page 2.2 -#
Page (15)
Example: Inferential Reactor Conversion Control Example: Inferential Reactor Conversion Control
T
out
T
in
b ) T (T a X
Data Plant on
Based ip Relationsh Linear Develop
) T (T
) H ( C
C
X
) T (T C ) H ( C X
: Balance Energy c Macroscopi
in out A
in out
rxn A
p
A
in out p rxn A A
o
in
+ ! =
!
!
=
! = !
This is based on steady state relationships !
Using T
out
and T
in
, knowing a and b, conversion
Can be estimated
Page (16)
Example: Molecular Weight of a Polymer Example: Molecular Weight of a Polymer
FT
DPT
TT
)] ( [
)] ( , [ ) (
) , ( ) (
0 3
2 0
1
T f M
T T f T
F P f T
wt

=
=
! =
*[lnt 6peration by Dr AA, 2008 Page 2.2 -#
Page (17)
Available Techniques
Available Techniques
! First Principle Models
! Regression Models
! Linear Regression
! Multiple Linear regression
! Linear black-box model
! E.g. ARX, FIR
! Nonlinear models
! e.g. neural networks
Page (18)
Inferential Control 1: Soft Sensor Inferential Control 1: Soft Sensor
PID controllers still being employed.
Model serves as soft-sensor
*[lnt 6peration by Dr AA, 2008 Page 2.2 -#
Page (19)
Soft sensor Soft sensor
Filtering
algorithm
Process
M - M
^
^
M
Simplified
model
Measurements
Predicted
measurements
M
Estimates
Inputs
-
+
error
Measurement
Page (20)
Soft Sensors Based on Neural Soft Sensors Based on Neural
Networks Networks
Output
Input
3
Input
2
Input
1
Node
Weight
! Neural network (NN) provides nonlinear correlation.
! Weights are adjusted until NN agrees with plant data
! NN-based soft sensors are used to infer NO
x
levels
in the flue gas from power plants.
*[lnt 6peration by Dr AA, 2008 Page 2.2 -#
Page (21)
Inferential Control (Block Diagram) Inferential Control (Block Diagram)
Controller
Process
Plant
Inferential
Estimator
y
4, set point
y
1
,y
2
,y
3
...
~
y
4
Process model
Page (22)
Summary of Inferential Control Summary of Inferential Control
! Advantage
! Enable the use of a desired control loop despite the lack of
measurement devices.
! Free from dependence on delayed data (off-line analysis),
leading to better control.
! Disadvantage
! Knowledge on the process must be known.
! Wrong estimation leads to wrong control action and hence
detrimental to process operation.
! How to Improve?
! Provide measured data periodically (off-line analysis etc.)
! Better Model