Identification and Process Control

with Artificial Neural Networks and

PID Controller
Eduardo Viera.
 AGENDA
• Introduction .
• Process Description.
• Solution Presentation.
• Variable Selection.
• ANN Conformation.
• Actuator Model Estimation.
• Simulations and Results.
• Conclusion.
• Questions.
 Introduction
MISO (Multiple Inputs, Single Output Systems)
𝑥𝑛 (𝑡)
⋮
𝑥𝑛+1 (𝑡) 𝑦(𝑡)
Inputs System Output
(Physical Variables) (Process) (Final Control Element)

Fig 1 – MISO Block Diagram.

Problematics:
• Single control loop are difficult to implement,
• Changes in the output generate changes in all system
variables, because of multivariable dependency.
• Complex dynamic model of the process.
• Manual operation is key to keep the process controlled.
 Introduction
MISO (Multiple Inputs, Single Output Systems)
𝑥𝑛 (𝑡)
⋮
𝑥𝑛+1 (𝑡) 𝑦(𝑡)
Inputs System Output
(Physical Variables) (Process) (Final Control Element)

Fig 1 – MISO Block Diagram.

Considerations:
• Apply the knowledge and best practices of the operation.
• Apply system with “learning” capability.
• Focus the solution in control action without secondary and
cumulative effects as mechanical damage in main equipment.
• Keep controlled all the variables with a unique control action.
 Introduction
MISO (Multiple Inputs, Single Output Systems)
𝑥𝑛 (𝑡)
⋮
𝑥𝑛+1 (𝑡) 𝑦(𝑡)
Inputs System Output
(Physical Variables) (Process) (Final Control Element)

Fig 1 – MISO Block Diagram.

Solutions:
• Apply Artificial Intelligence as Artificial Neural Networks
(ANN).
• Integrate ANN with classic control strategies as PID
controller.
 Process Description
Case of study: BIDIRECTIONAL DUCT
CONTROL AI % SO2

PI VALVE PI TI

TI PI PI SI

DISTRIBUTION
RADIATIVE COOLING CHAMBER ACID PLANT
PI PI
LIRES
FI

TENIENTE CONVERTER BLOWING AIR INDUCED DRAFT FAN

ELCTROSTATIC PRECIPITATOR VTI
No. 1 Y No.2

Fig 2 – Gas Transportation Block Diagram.

• Metallurgical gases generation.
• Gases temperature reduction.
• Electrostatic Filtration.
• Gas Transport.
• Gas processing.
 Solution Presentation

Process Signals ANN + PID(t) Plant Model

-

Process Identification
Gain

VTI Control Loop

Fig 3 – Proposed Solution Block Diagram.

• System separated into Plant Identification and Actuator

Control Loop.
• Plant Identification has internal process.
• ANN response is the dynamic consign to keep the process
balanced.
 Variable Selection
• Key variables selection was based by the criticality of the
consequences because of his changes.
• Requirement of certain variables by other processes.
• Patterns in secondary variables by the change in some
variables.
Table 1 Entry Variables of ANN
Variable Type Signal Description Range Average Signal
Flow Blowing air (oxigen rich air) to CT [xxxx, xxx] zzz Input
Pressure Hood gases exhaust CT [xxxx, xxx] Zzz Input
Pressure Outlet electrostatic precipatator 1 [xxxx, xxx] Zzz Input
Pressure Outlet electrostatic precipatator 2 [xxxx, xxx] Zzz Input
Pressure Distribution chamber, VTI outlet [xxxx, xxx] Zzz Input
SO2 Sulfur dioxide concentration [xxxx, xxx] Zzz Input
Speed Speed rotor VTI [xxxx, xxx] zzz Output
 Variable Selection

Fig 4 – Graph SO2 Concentration and Blowing Air Flow to CT.

 Variable Selection

Fig 5 – Graph VTI Speed and Gas Train Pressure.

 Variable Selection

Fig 6 – Graphic VTI Speed and Trian Gases Pressure (Differential Pressure).
 Conformation of Artificial Neural Network
x1 Synapsis
wi1 In1
Cell Body Axon In2
x2 wi2 yi In3

xj wij ∑ f( ) In4 Speed

Output Set Point
In5
win In6
Inputs -1 Ɵi
In7
xn
Dentres Threshold

Fig 7 – Artificial Neuron Structure. Fig 8 – ANN Architecture.

• Inputs are represented by the input variables selected.

• Network type Feedfordward.
• Weight Connection calculated by “Backpropagation”
Algorithm.
• ANN has 7 input layer, 11 hidden layer, 1 output layer
 Actuator Estimation Model
• Developed through input and output data.
• Data obtained from the historical trends of the process
data.
• N4SID (numerical algorithms for subspace state space
system identification) Algorithm used.
• Model obtained in space-state form.
Actuator Estimation Model

Fig 9 – VTI Step Response .

𝑥(𝑡) = 𝐴𝑥(𝑡) + 𝐵𝑢
𝑦(𝑡) = 𝐶𝑥(𝑡) + 𝐷𝑢

Space-State Model
 Actuator Estimation Model

Fig 9 – VTI Step Response .

Accuracy Stabilization Overshoot Sample

Input Output
Model Time Time
99.1% X,X min 40.9% 13.3 min xxx RPM xxx RPM
 Simulation and Result
• Test with 3 scenarios:

Test with Random

Variables

Historical Records as
Scenarios
Inputs in the System

Scenario 2 and Real

VTI Response
Comparison and
Performance Index
 Simulation and Result
• Test with Random Variables.
• Random varibles generated based in a Gaussian
probability distribution.
• Simulation with a integrated solution.
 Simulation and Result
Scenario 1: Test with Random Variables.

Fig 10 – Result Simulation 1.

 Simulation and Result
Scenario 2: Test with Historical Records as Inputs in the
System.

Fig 11 – Result Simulation 2.

 Simulation and Result
Scenario 3: and Real VTI Response Comparison and Performance Index
.

Fig 11 – Result Simulation 2.

 Simulation and Result
Scenario 3: and Real VTI Response Comparison and Performance Index
.
𝑛 2
∞
𝑖=0 𝑂𝑖 − 𝐶𝑖
𝐼𝑆𝐸 = 𝑒 𝑡 2 𝑑𝑡 𝑅𝑀𝑆 =
0
𝑛

ISE - Integral Square Error RMS - Residual Mean

Square
76400
0,0123

59500

0,0109

ISE – SYS. WITH ANN ISE - MANUAL SYS. RMS –– SYS. WITH ANN RMS - MANUAL SYS.

Fig 11 – Result Simulation 2.

 Conclusion
• According the simulations, is possible to implement IA in process
without major interventions in the existent control systems.
• Settling times are shortest in comparison with manual control
actions.
• Large error are suppressed trying to achieve a little error in the
system output.
• Once ANN has been configured, easily this could by configured in
any PLC (keeping in mind the capability to handle float variables,
memory and process capacity).
• This kind of control strategies, could apply just in “steady state”and
cannot be used to start or shutdown a plant.