AdvContFound2013.

book Page iii Sunday, September 9, 2012 4:29 PM

Advanced Control
Foundation:
Tools, Techniques and Applications

Terrence Blevins
Willy K. Wojsznis
Mark Nixon
AdvContFound2013.book Page ix Sunday, September 9, 2012 4:29 PM

Contents

Acknowledgments vii

About the Authors xvii

Foreword xxi

Chapter 1 INTRODUCTION 1

Chapter 2 MAXIMIZING RETURN ON CONTROL SYSTEM INVESTMENT 7

2.1 Economic Incentive, 9
2.1.1 Ammonia Plant Example, 13
2.2 Reducing Process Variation – Achieving Control Objectives, 19
2.2.1 Single Loop Control, 19
2.2.2 Multi-Loop Techniques, 21
2.3 Advanced Control , 29
2.3.1 Pulp Bleaching, 29
2.3.2 Primary Reformer Temperature Control, 30
2.4 Balancing Complexity with Benefits, 32
Bibliography, 33

Chapter 3 EVALUATING CONTROL SYSTEM PERFORMANCE 35

3.1 Evaluating Control Performance, 38
3.2 Improving Control Utilization, 42

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x ADVANCED CONTROL FOUNDATION: TOOLS, TECHNIQUES AND APPLICATIONS

3.2.1 Transmitter Problems, 43

3.2.2 Incorrect Tuning , 44
3.2.3 Valve/Actuator Diagnostics, 46
3.2.4 Changing Process Gain, 47
3.2.5 Incorrect Split Range Setup, 49
3.2.6 Loop Interaction, 51
3.3 Addressing Process Variability, 52
3.3.1 Changing Process Gain and Dynamics, 54
3.3.2 Unmeasured Process Disturbances, 54
3.3.3 Process Dynamics, 56
3.3.4 Loop Interaction, 56
3.3.5 Changing Limit Conditions, 57
3.3.6 Quality Parameter – Lab Measurement, 57
3.4 Application Example, 58
3.5 Workshop Exercises – Introduction, 62
3.6 Evaluating Control System Performance Workshop, 64
3.7 Technical Basis , 65
3.7.1 Control Performance Monitoring Infrastructure, 66
3.7.2 Control Performance Evaluation Algorithms, 68
Bibliography, 75

Chapter 4 ON-DEMAND TUNING 77

4.1 Process Identification, 77
4.1.1 Simulation of Loop Response, 86
4.2 On-Demand Tuning Workshop, 89
4.3 Technical Basis, 90
4.3.1 Basics of Relay Oscillation Tuning, 92
4.3.2 Model-Based Tuning, 101
4.3.3 Robustness-Based Tuning, 104
4.3.4 Some Alternate Tuning Approaches, 109
Bibliography, 110

Chapter 5 ADAPTIVE TUNING 113

5.1 Adaptive Control – Examples, 114
5.1.1 Continuous Reactor Control, 114
5.1.2 Batch Reactor, 114
5.1.3 Hydrogen to Nitrogen (H/N) Ratio in Ammonia
Production, 116
5.1.4 Neutralizer, 117
5.1.5 Plant Master Control, 119
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CONTENTS xi

5.2 Application Example, 119

5.2.1 Enabling Model Identification, 120
5.2.2 Applying Models to Loop Tuning, 123
5.3 Adaptive Tuning Workshop, 125
5.4 Technical Basis, 126
5.4.1 Model-Free Adaptive Tuning, 127
5.4.2 Model-Based Recursive Adaptive Tuning, 132
5.4.3 Discrete Fourier Transform Adaptation Technique, 133
5.4.4 Adaptive Tuning with Model Switching and
Parameter Interpolation, 134
Bibliography, 142

Chapter 6 FUZZY LOGIC CONTROL 145

6.1 Application Example, 150
6.2 Fuzzy Logic Control Workshop, 152
6.3 Technical Basis, 153
6.3.1 Introduction to Fuzzy Logic Control, 153
6.3.2 Building a Fuzzy Logic Controller, 156
6.3.3 Fuzzy Logic PID Controller, 161
6.3.4 Fuzzy Logic Control Nonlinear PI Relationship, 165
6.3.5 FPI and PI Relationships, 167
6.3.6 Automatic Tuning of a Fuzzy PID Controller , 169
Bibliography, 170

Chapter 7 NEURAL NETWORKS FOR PROPERTY ESTIMATION 171

7.1 Example – Pulp and Paper Industry, 173
7.2 Property Estimator Application Example, 176
7.3 Neural Networks for Property Estimation Workshop, 182
7.4 Technical Basis, 183
7.4.1 Data Collection, 185
7.4.2 Identification of Input Delay, 186
7.4.3 Input Sensitivity, 187
7.4.4 Determining Input Weights, 188
7.4.5 Nodes in the Hidden Layer, 190
7.4.6 Correction for Process Changes, 191
Bibliography, 192
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xii ADVANCED CONTROL FOUNDATION: TOOLS, TECHNIQUES AND APPLICATIONS

Chapter 8 INTELLIGENT PID 195

8.1 Recovery from Process Saturation, 197
8.2 Control Using Wireless Transmitter, 199
8.3 Application Examples, 206
8.3.1 Control of a Bioreactor Using Wireless Devices, 207
8.3.2 Compressor Surge Control , 210
8.4 Intelligent PID Workshop, 215
8.5 Technical Basis, 217
8.5.1 Wireless Control , 217
8.5.2 Recovery from Process Saturation, 218
8.5.3 Extension to Include Rate, 220
Bibliography, 221

Chapter 9 CONTINUOUS DATA ANALYTICS 223

9.1 Application Example, 237
9.1.1 Defining Model Inputs, 239
9.1.2 Model Building, 241
9.2 Viewing Data Analytics On-line, 245
9.3 Continuous Data Analytics Workshop, 247
9.4 Technical Basis, 248
9.4.1 Data Formatting for Predictive Model Development, 249
9.4.2 Process Monitoring and Predictive Algorithms Review, 250
9.4.3 Data Preprocessing and Scaling, 254
9.4.4 PCA Modeling and On-line Fault Detection, 256
9.4.5 PLS Modeling and On-line Prediction, 258
Bibliography, 260

Chapter 10 BATCH DATA ANALYTICS 261

10.1 Batch Production Challenges, 262
10.1.1 Role of Data Analytics in Facing Batch Production
Challenges, 264
10.1.2 Batch Analytics Overview, 268
10.1.3 Application of Batch Analytics to Specialty Chemicals Produc-
tion , 271
10.2 Data Analytics Application Example – Modeling and On-line
Operation, 275
10.2.1 Defining Model Input, 278
10.2.2 Viewing Data Analytics On-line , 282
10.3 Batch Data Analytics Workshop, 285
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10.4 Technical Basis, 286

10.4.1 Feedstock Property Modeling, 287
10.4.2 Data Preprocessing and Validation, 290
10.4.3 Multi-stage Batch Modeling, 291
10.4.4 Alignment of Batch Data and On-line Model , 294
10.4.5 Data Arrangement – Unfolding, 298
10.4.6 PCA Modeling and On-line Fault Detection, 299
10.4.7 PLS Modeling and On-line Quality Prediction, 303
Bibliography, 305

Chapter 11 SIMPLE MPC 307

11.1 MPC as a Replacement for PID, 309
11.2 Commissioning MPC, 310
11.3 MPC Replacement for PID with Feedforward, 316
11.4 MPC Replacement for PID Override, 317
11.5 Using MPC to Address Process Interactions, 318
11.6 Application Examples, 320
11.6.1 Evaporator Control, 321
11.6.2 Dryer Control, 322
11.6.3 Rotary Kiln Control, 324
11.6.4 Pulp Brightness Control, 327
11.6.5 MPC Control at Changing Production Rate, 328
11.6.6 Batch Reactor Control, 331
11.7 MPC Application Development Procedure , 333
11.7.1 Process Analysis and MPC Configuration Design, 335
11.7.2 Process Testing, 336
11.7.3 Process Model Generation, 337
11.7.4 Controller Generation, 338
11.7.5 MPC Simulation and Tuning Validation, 339
11.7.6 MPC Control Evaluation and Tuning Adjustment, 339
11.8 Simple MPC Workshop, 340
11.9 Technical Basis, 340
11.9.1 The Basics of Process Modeling , 345
11.9.2 Process Model Identification, 349
11.9.3 Unconstrained Model Predictive Control, 351
11.9.4 Integrating Constraints Handling, Optimization and Model
Predictive Control, 356
Bibliography, 361
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Chapter 12 MPC INTEGRATED WITH OPTIMIZATION 363

12.1 Application Example – Multiple Effect Evaporator, 365
12.1.1 Evaporator Process Overview, 366
12.1.2 Project Motivation and Design Considerations, 367
12.1.3 Why Use Model Predictive Control?, 367
12.1.4 Model Predictive Control Strategy Development , 368
12.1.5 Model Development and Verification, 370
12.1.6 MPC Operation, Tuning and Optimization, 371
12.1.7 Dealing with Major Process Constraints , 372
12.1.8 Evaporator Flush Control , 373
12.1.9 Solids Measurement, 374
12.1.10 Operational Results , 374
12.1.11 Summary, 375
12.1.12 Recent Work and Future Opportunities, 375
12.1.13 Acknowledgments, 376
12.2 Application Example – CTMP Refiner, 376
12.2.1 Process Description, 377
12.2.2 Electrical Energy Consumption Model, 378
12.2.3 Process Model Identification, 379
12.2.4 MPC Control Strategy, 380
12.2.5 Results, 383
12.2.6 Summary, 384
12.2.7 Acknowledgments , 385
12.3 Application Example – Heavy Oil Fractionator, 385
12.4 MPC Integrated with Optimization Workshop, 408
12.5 Technical Basis, 408
12.5.1 MPC Operation Overview, 410
12.5.2 On-line Multi-objective Optimizer Functionality
Overview, 416
12.5.3 Multi-objective MPC Optimization Background, 417
12.5.4 Multi-objective Optimization Function for Infeasibility Han-
dling , 419
12.5.5 Multi-objective Optimization Function for Extending LP Func-
tionality , 422
12.5.6 System Functionality for Multi-objective Optimization, 424
12.5.7 Unconstrained MPC Controller Supervised by the
Optimizer, 430
12.5.8 Constrained MPC Controller Integrated with the
Optimizer, 433
Bibliography, 434
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CONTENTS xv

Chapter 13 ON-LINE OPTIMIZATION 437

13.1 Why Optimization – A Look at Boiler Load Allocation , 438
13.2 Energy Optimization in a Pulp and Paper Mill, 446
13.2.1 Introduction to Cogeneration, 447
13.2.2 Introduction to Energy Management, 448
13.2.3 An Integrated Real-time Energy Management System, 449
13.2.4 Integrated EMS Case Study, 450
13.2.5 Summary of Results, 460
13.2.6 Summary, 463
13.3 On-line Optimization Workshop, 465
13.4 Technical Basis, 466
Bibliography, 468

Chapter 14 PROCESS SIMULATION 471

14.1 Process Simulation Techniques, 471
14.2 Developing a Process Simulation from the P&ID, 473
14.3 Simulating Process Non-linearity , 480
14.4 Other Considerations, 483
14.5 Process Simulation Workshop , 486
14.6 Theory – Simulation Based on Step Response , 488
Bibliography, 493

Chapter 15 INTEGRATING ADVANCED CONTROL INTO A DCS 495

15.1 Integrating with Plant Systems, 501
15.2 Network and System Setup, 505
15.3 Application Example, 507
Bibliography, 509

Appendix A 511

Glossary of Terms 517

Index 527