Process Solutions

Advanced Control Overview

Process Solutions

Contents
Advanced Control Overview
Levels of process control
Benefits

MVC Overview
MVC Techniques
Model Based Predictive Control

Horizon strategy & prediction

M d l reconciliation
Model
ili ti
Target CV trajectory & control
O ti i ti
Optimization

Process Solutions

Levels of Process Control

Basic regulatory
Advanced regulatory (intermediate regulatory)
Multivariable model based
Multivariable,
Constrained economic optimization
Increasing complexity and costs and
diminishingg benefits
f

Process Solutions

Basic Regulatory
Si
Single
l sensing
i element
l
- single
i l final
fi l controll
element
Single Input Single Output (SISO)

Simple cascades, ratio control

Primary goal:
Operational
p
stabilityy
FC

Process Solutions

Advanced Regulatory
Pressure or temperature compensation
Feed-forward based on measurements
Simple process calculations based on
measurements
Heat and material balance
Simple inferential estimations,
estimations duty control

Multiple Input Single Output (MISO)

Primary
Pi
G
Goals:
l
Enhanced Stability
Enhanced performance

Process Solutions

Example of Advanced Regulatory Control:

Coil Outlet Temperature Control

Process Solutions

Multivariable, Model based

Simultaneous consideration of:
many controlled variables (CV)
by adjusting many manipulated variables (MV)
optionally observing feedforward variables (DV)

Internal model of process behavior

ppredicts future paths
p
of controlled variables.

Multiple Input Multiple Output (MIMO)

Process Solutions

Example of Different Kinds of Control:

Distillation Tower
PC
FC
H2 & CH4
C3 Refrig.

TI
LC

CVs

FC
FC
AI

FC

FC
Ethylene

AI

C2 Feed

DVs

AI
Non-Linear
Level Control

LC

AI

RMPCT
CV:
Product Qualities
Reflux Drum Level
Compressor Limits
Valve Positions
Tower Flooding
MV:
Pressure
Reflux Flow
Top Product Flow
Reboiler Duty
DV:
Feed Flow
Feed Quality

FC
MVs

Reboiler
Duty Control

Ethane Recycle

FC
C3 refrig.

C3 refrig. pres.

Calculated CVs
Ethylene
Quality Calc.

AI
T,F,P

Bottom Product
Quality Calc.

AI
AI

Tower Flooding
Calculation

T,F,P,DP

Process Solutions

Constrained Economic Optimization1

Premise
Some of controlled variables are not controlled to
setpoints

Required to be maintained between high and low ranges

User specifies
i i an objective
bj i function
i
Assign costs or values to variables
Translates into a direction to move the manipulated
variables

Optimizer finds best position (corner)

within space constrained by controlled and
manipulated variable limits

Process Solutions

Constrained Economic Optimization2

Optimizer is a steady state controller
Calculates one set of MV moves to maximize or
minimize objective function.
Generally too aggressive to implement directly in
closed
l d loop
l
Typically used in conjunction with a multivariable
control engine to implement solution

Process Solutions

Levels of Process Control

Optimization

Local LP/QP
Optimization

Multi-unit LP/QP
Optimization

Model Based
Control

Smith
predictors
etc.

Multivariable
predictive
control

Advanced
Regulatory
Control

Feedforward
control

Dynamic
decoupling

Basic
Regulatory
Control

g
Single
PID

Rigorous model based

Optimization

E.g.
Profit Controller or
[DMC] +

On-stream
Analyzers

Constraint
Control

Cascade

Different technologies aavailable

ailable at each level
le el

Process Solutions

Benefits of Advanced Control

Advanced control can improve plant profitability
in a number
u be of
o ways
w ys
Setpoint control

Reduced variability
y allows closer operation
p
to the
constraint (i.e. less give-away)

Quicker grade changes

Increased plant flexibility

Basis for more sophisticated advanced controls

O i i i
Optimization

Process Solutions

Incentives for Advanced Control

(Constraint Control)
Variable
Constraint Limit

$
$
Poor control

Advanced
Control

Good Regulatory
Control

Time

Process Solutions

Incentives for Advanced Control

(Quicker Grade Changes)
Quality

Quality Transition

Minimise transition time

Time

Process Solutions

Incentives for Advanced Control

(Optimization Platform)
MV 1 High
MV 1 Low
MV 2 High
g

best operating region

Constrained Optim
Optimum
m
MV 2 Low

Process Solutions

Multivariable Control Overview

Process Solutions

Multivariable Control Definition

Simultaneous control of more than one controlled
variable (CV) by the co-ordinated adjustment of
more than one manipulated variable (MV)
Controller mayy use additional feedforward or
disturbance variable (DV) information to improve
control performance
p

Process Solutions

Why Use MVC Techniques

When the process is interactive
CVs are affected significantly* by multiple MVs.
Metric for interactive process: RGA (Bristol)

MV Rangeability
g
y
Common CV constraints
competing control sub-strategies

Ease of use / configuration

MV / CV relationships
l ti hi are similar
i il in
i gain
i andd dynamics
d
i

Process Solutions

Debutanizer Column 1

Cooling water

Interaction:

CV1

Increase in reflux (MV1)

causes:

TI
F
C

in top temperature
in distillate
in base temperature

L
C
MV1

F
C

Distillate

CV4

DV1

Feed

in base product

F
C
CV5

CV Controlled variable
DV Disturbance (FF) variable
MV Manipulated variable

L
C
CV2

MV2

Steam
Base
product

TI

CV3

Process Solutions

Debutanizer
ebuta e Column
Co u
2

Cooling water

Interaction:

CV1

Increase in steam (MV2)

causes:

TI

in distillate
in bottom temperature

MV1

F
C

Feed

F
C
CV5

L
C
CV2

MV2

Steam
Base
product

TI

CV3

Distillate

CV4

DV1

in base product

Both steam and

reflux affect
most column
variables

Reflux

F
C

in top temperature

L
C

Process Solutions

Dynamic Interaction
2

CV1

1
CVs

2
1
0
-11
-2

CV2

MV1

MVs
MV2

Process Solutions

Debutanizer
ebuta e Column
Co u
3

Cooling water

CV1

MV Rangeability

TI

Reflux

With explicit pairing

pairing:
CV1 paired to MV1 (in Manual)
CV2 paired to MV2
Is it possible to control
both CV1 and CV2 ?

L
C

F
C

MV1

F
C

Distillate

CV4

DV1

Feed

F
C
CV5

L
C
CV2

TI

CV3

MV2

Steam
Base
product

Process Solutions

Debutanizer
ebuta e Column
Co u
4

Cooling water

CV1

MV Rangeability

TI

Without explicit pairing:

Is it possible to control
CV1 and CV2 ?

Reflux

F
C

MV1

F
C

Feed

F
C
CV5

L
C
CV2

MV2

Steam
Base
product

TI

CV3

Distillate

CV4

DV1

Probably not to two

setpoints
Probably to within two
ranges

L
C

Process Solutions

Debutanizer
ebuta e Column
Co u
5

Cooling water

CV1

C mm n Constraints
Common
C nst ints

TI
CV4 and CV5 constraints
to maximizing
fractionation.
CV4 and
d CV5 also
l
constraints to maximizing
feedrate

L
C

Reflux

F
C

MV1

F
C

Distillate

CV4

MV3

Feed

F
C

MVC (with an optimizer)

allows objectives to be
prioritized.

CV5

L
C
CV2

MV2

Steam
Base
product

TI

CV3

Process Solutions

Model Based Predictive Control (MBPC)

SPs
PV1
PV2
PNn

MBPC

OP1
OP2
OP3
OPm

Process Solutions

Model Based Predictive Control 2

SPs
PV1
PV2
PNn

MBPC

OP1
OP2
OP3
OPm

Optimizer

Prediction

Controller

MVs

Process

Model

CV
CVs

+
-

Process Solutions

Model Based Predictive Control 3

CV Targets

Optimizer

Prediction

Controller

MVs

Process

CVs
+

Model
Prediction Model Error

Process Solutions

Model Based Predictive Control 4

Control structure is flexible, hence can be used for
control problems that are
square (#MVs = #CVs)
over-specified (#MVs > #CVs) (Fat control problem)
under-specified (#MVs < #CVs)

Applicable
pp
to manyy types
yp of process
p
control
problems
implement, even for relatively
Not too difficult to implement
large problems
Robust technology insensitive to model error

Process Solutions

Prediction (future)
CV Targets

Optimizer

Prediction

Controller

MVs

Process

CVs
+

Model
Prediction Model Error

Horizon Strategy

12

Process Solutions

Now

10

Unforced Response
V
Value

8
MV
CV

Settling
g Time

History
y
0
0

10

15

20

Time Intervals

25

30

35

Process Solutions

(SISO) Prediction Models 1

(Parametric models)
Laplace Domain model:

(
1S + 1)e sDT
Y( s ) =
U (s)
(2 S + 1)(3S + 1)
Discrete Time model:

(
b1Z 1 + b2 Z 2 ....bn Z n )Z d
U ( z)
Y( z ) =
1 + f1Z 1 + f 2 Z 2 .... f n Z n

Process Solutions

(SISO) Prediction Models 2

2.5

2
1.81

1.86
1.73
1
73
1.62

1.5

1.99
1.97 1.99
1.95
1.90
1.99
2.00
1.98
1.96
1.93

Finite step response model

MV

Value

1.47

CV

1 26
1.26

0.97

0.57

0.5

Unit MV Change at t = 1

Deadtime
Lag
G i
Gain

=2
=3
=2

0
0

10 Time Intervals 15

20

25

Process Solutions

(SISO) Prediction Models 3

MV stepped one unit at t = 1

A
0 . 00
0 . 00

0 . 57

0 . 97
1 . 26

1 . 47
1 . 62

1 . 73
1 . 81

1 . 86

.......
2 . 00

[1 ]t = 1

0 . 00
0 . 00

0 . 57

0 . 97
1 . 26

1 . 47
1 . 62

1 . 73
1 . 81

1 . 86

.......
2 . 00

Process Solutions

(SISO) Prediction Models 5

A
0 . 00

0 . 00
0 . 57

0 . 97
1 . 26

1 . 47
1 . 62

1 . 73

1 . 81
1 . 86

......

2 . 00

0 . 00
0 . 00
0 . 57
0 . 97
1 . 26
1 . 47
1 . 62
1 . 73
1 . 81
.......
2 . 00

0 . 00

0 . 00
0 . 57

0 . 97
1 . 26

1 . 47
1 . 62

1 . 73

1 . 81
1 . 86

.......
2 . 00

0 . 00

0 . 00
0 . 00

1 . 14
1 . 95

2 . 53
2 . 95

3 . 24

3 . 46
3 . 61

.......
4 . 00

0 . 00

0 . 00
+ 0 . 57

0 . 16
0 . 68

1 . 06
1 . 32

1 . 52

1 . 65
1 . 75

.......

2 . 00

Process Solutions

(SISO) Prediction Models 6

12

Now
Unforced Response

10

Valu
ue

6
MV
CV

Settling Time

History
0
0

10

15

20

Time Intervals

25

30

35

Process Solutions

Prediction Models 7
MV 1
CV 1

CV 2

CV 3

MV 2

MV 3

DV 1

Process Solutions

Model Reconciliation 1
CV Targets

Optimizer

Prediction

Controller

MVs

Process

CVs
+

Model
Prediction Model Error

Process Solutions

Model Reconciliation 2
12

N
Now

10

Bias update

Value

6
MV

Reconciled CV trajectory

CV
CVrev

Settling Time

Hi t
History

0
0

10

15

20

Time Intervals

25

30

35

Process Solutions

Control
CV Targets

Optimizer

Prediction

Controller

MVs

Process

CVs
+

Model
Prediction Model Error

Process Solutions

Desired CV Trajectory
12

N
Now

R
Reconciled
il d CV trajectory
t j t

SP

10

Value

Error Vector

MV
Now/SS
CV
Target
Error

Settling Time

History
0
0

10

15

20
Time Intervals

25

30

35

40

Process Solutions

Move Calculation (Simplified)

Prediction:

A
YT
Y
E
U
UT

[Y ] = [ A] [U ]
Controller Error:

[E] = f ([YT ], [Y ])

Prediction matrix
Target
g CV vector
Unforced CV vector
Error vector
MV hi
history vector
MV future vector

Least
Least squares error
error control solution:

[UT ] = [A

AT [E ]

Process Solutions

Horizon With Control (one MV move)

12

Now

Forced CV trajectory
j
y

SP

10

Value

Error Vector

MV
Now/SS

CV
Target
Error

Future MV move

Settling Time

History
0
0

10

15

20
Time Intervals

25

30

35

40

Process Solutions

Horizon With Control (seven MV moves)

12

Now

Forced CV trajectory

SP

10

Value

Error Vector

MV
Now/SS

CV
Target
Error

Future MV moves

Settling Time

History
0
0

10

15

20
Time Intervals

25

30

35

40

Process Solutions

Move Calculations
Planningg multiple
p future MV moves allows
Improved control performance

Multivariable system (dynamic decoupling)

Complex dynamics and dead-times

Game plan of where MVs will move

Can defer MV movement

Least squares method is very aggressive / unstable

No mechanism to tune controller performance
Alternatives

Modify
y reference trajectory
j
y
Use movement suppression for MVs
Use alternative solution strategy

Process Solutions

Optimization1
CV Targets

Optimizer

Prediction

Controller

MVs

Process

CVs
+

Model
Prediction Model Error

Process Solutions

Optimization2
Starting point for optimizer
Current values of the MVs
Steady state (unforced) values for the CVs

Based on MV and DV moves until current time

Optimizer solves for a set of new MV steady state

values (one step controller) taking into account
MV constraint limits
CV constraint limits
An objective function (direction of steepest decent)

Based on economics for the process

Process Solutions

Optimization3
MV 2

Contour of equal cost

MV 1 Low

MV 1 High
MV 2 High

Current position

MV 2 Low

Direction: from economics

MV 1

Process Solutions

Optimization4
Alternative solution technologies
QP (Quadratic)
LP (Linear)

Alternative implementation strategies

SP targets downloaded to controller
MV targets ssuperimposed
perimposed on control plan

Alternative methods of adjusting speed

Step sizes
tunable time horizon