BITS Pilani

K K Birla Goa Campus

Development of Empirical Models from

Process Data
 Topics to be covered

• Introduction to Black box (empirical models)

• Fitting first and second order models using step
tests
• Graphical techniques
• Fitting integrator model to step response data

21/02/2020 AMOL DESHPANDE BITS Pilani, K K Birla Goa Campus

 Empirical (Black box)models
(Process identification)
• Process (Theoretical models) simulation vs Process
(system) Identification (empirical models)

• Simulation
• Model is known (from balances)
• Response (y(t) is then generated

• Identification
• Model is determined from
actual experimental data
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 Empirical models

• Steady state models

• Can be used for Instrument calibration, process optimization,
specific instances of process control

• Dynamic models
• Can be used for understanding the process behaviour during
upset conditions

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 Fitting first order model using step
tests
• Process reaction curve
• Output response of a process to a step change in input

• For the process to be approximated by a first or second

order linear model, model parameters need to be
obtained by inspecting process reaction curve

• First order model

• For step response

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 Fitting first order model using step
tests
• Graphical construction to estimate the model
parameters (Gain and time constant)
• Gain (K)
• Ratio of steady state output
to change in input

• Time constant (τ)

• Slope of a tangent line
(at t = 0)
• 63.2% method

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 Example 7.2

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 Limitations of approximating to first
order process
• Only very few experimental step responses exhibit first
order behaviour
• Output data are corrupted with noise
• Process input may change in an unknown manner
• Difficult to generate perfect step input

Departures from ideal response curve (Fig 7.3) are

common

To account for higher order dynamics, a time delay

term can be included
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 FOPTD model
• Fitting of FOPTD (First order process with time delay)

Parameters
• K = ratio of steady state change
in y to input step change M
• Intersection of Tangent line at
point of inflection and time axis
 Time delay
• Intersection of tangent line with
steady state response line
(y=KM), corresponds to time
(t=θ + τ)  Time constant can be
calculated 9

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 FOPTD model
• Tangent methods – uses single point to estimate time
constant
• Use of several points (i) from response can also be used to
determine time constant

• Semi-log response of output vs (ti – θ) will be a straight line

with slope (-1/τ)

• Major disadvantage of FOPTD model – It is difficult to find

the point of inflection (due to noise, etc.) 10

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 Sundaresan and Krishnaswamy
(S&K) method
• It avoids using point of inflection construction

• Two times t1 and t2 estimated from step response curve

• t1  35.3 % of response

• t2  85.3 % of response

• Time delay and time constant are calculated as

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 Graphical techniques for second
order models
• Fitting second order model to the data – relatively better
approximation

• Limiting cases

τ2/τ1 = 0  first order

τ2/τ1 = 1  critically
damped case
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 Smith’s method

• Times at which response reaches

20% and 60%

• Using Fig. 7.7, value of damping

coefficient and time constant
can be determined

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 Example 7.3

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 Fitting an integrator model to step
response data
• First order process to a step change

• For short times (t < τ), the exponential term can be

approximated

• Response

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 Fitting an integrator model to step
response data
• Step response of the integrating element

• Response (in time domain)

• First order model can be approximated as an integrating

element with a single parameter

Ramp-like response to a step change in input 16

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 Fitting an integrator model to step
response data
• Approximate short term
response to FOPTD
model

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 Other methods of model
development
• Development using linear and non-linear regression

• Neural network model

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 Using Excel Solver to Fit Transfer
Function Models
• use y (data) vs. y (predicted)
• column 1 is data (taken at different times), or y1
• column 2 is model prediction (same time values as
above), or y2
• target cell is S (y1 - y2)2 , to be minimized
• specify parameters to be changed in reference cells
(e.g. t1 = 1, t2 = 2)
• open solver dialog box to check settings
• click on < solve > (calls optimization program)
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 Problem 7.1

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 Problem – 7.2

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 Problem – 7.4

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 Problem – 7.7

24/02/2020 AMOL DESHPANDE BITS Pilani, K K Birla Goa Campus