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

5

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) + Le(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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