Detection of model-plant mismatch in closed-loop control system

The performance of model-based control systems depends a lot on the process model quality, hence the process model-plant mismatch is an important factor degrading the control performance. In this paper, a new methodology based on a process model evaluation index is proposed for detecting process model mismatch in closed-loop control systems. The proposed index is the ratio between the variance of the disturbance innovation and that of the model quality variable. The disturbance innovations are estimated from the routine operation data by an orthogonal projection method. The model quality variable can be obtained using the closed-loop data and the disturbance model estimated by adaptive Least absolute shrinkage and selection operator (Lasso) method. When the order of the disturbance model is less than 2 or the process time delay is large enough, no external perturbations are required. Besides, the proposed index is independent of the controller tuning and insensitive to the changes in disturbance model, which indicates that the proposed method can isolate the process model-plant mismatch from other factors affecting the overall control performance. Three systems with proportional integral (PI) controller, linear quadratic (LQ) controller and unconstrained model predictive control (MPC) respectively are presented as examples to verify the effectiveness of the proposed technique. Besides, Tennessee Eastman process shows the proposed method is able to detect process model mismatch of nonlinear systems.     

Model predictive control with adaptive disturbance prediction and its application to fatty acid distillation column control

This paper describes the results of a joint university-industry study to control a fatty acid distillation sequence, which is plagued with severe disturbance problems. In order to solve the disturbance problem, a model predictive control algorithm is modified in terms of disturbance prediction. Assuming that the dynamics of the unmeasured disturbances is generated by an auto-regressive form, the dynamics of the disturbance can be adaptively identified by using time series data of prediction errors and inputs. Using an identified disturbance model with a process model, future outputs are predicted. Control actions are determined so that the predicted output is as close to the target value as possible. This modified model predictive control aglorithm is applied to a ratio control scheme for three distillation columns. The control system developed has been in use sucessfully for more than six years to produce commercial products.     

Performance assessment using a model predictive control benchmark

Model predictive control (MPC) technology has been widely implemented throughout the petroleum, chemical, metallurgical and pulp and paper industries over the past three decades. The focus of this paper is the assessment of single-input, single-output MPC schemes against a new performance standard. The proposed MPC benchmark is shown to be useful both as a model diagnostic and as a tuning guide during commissioning. A formal assessment procedure is presented which emphasizes the use of routine operating data plus knowledge of the deadtime to determine when it becomes worthwhile to invest in re-identification of the plant dynamics and re-installation of the MPC application.     

From data to diagnosis and control using generalized orthonormal basis filters. Part II: Model predictive and fault tolerant control

Given a state space model together with the state noise and measurement noise characteristics, there are well established procedures to design a Kalman filter based model predictive control (MPC) and fault diagnosis scheme. In practice, however, such disturbance models relating the true root cause of the unmeasured disturbances with the states/outputs are difficult to develop. To alleviate this difficulty, we reformulate the MPC scheme proposed by K.R. Muske and J.B. Rawlings [Model predictive control with linear models, AIChE J. 39 (1993) 262–287] and the fault tolerant control scheme (FTCS) proposed by J. Prakash, S.C. Patwardhan, and S. Narasimhan [A supervisory approach to fault tolerant control of linear multivariable systems, Ind. Eng. Chem. Res. 41 (2002) 2270–2281] starting from the innovations form of state space model identified using generalized orthonormal basis function (GOBF) parameterization. The efficacy of the proposed MPC scheme and the on-line FTCS is demonstrated by conducting simulation studies on the benchmark shell control problem (SCP) and experimental studies on a laboratory scale continuous stirred tank heater (CSTH) system. The analysis of the simulation and experimental results reveals that the MPC scheme formulated using the identified observers produces superior regulatory performance when compared to the regulatory performance of conventional MPC controller even in the presence of significant plant model mismatch. The FTCS reformulated using the innovations form of state space model is able to isolate sensor as well as actuator faults occurring sequentially in time. In particular, the proposed FTCS is able to eliminate offset between the true value of the measured variable and the setpoint in the presence of sensor biases. Thus, the simulation and experimental study clearly demonstrate the advantages of formulating MPC and generalized likelihood ratio (GLR) based fault diagnosis schemes using the innovations form of state space model identified from input output data.     

ILC strategy for progress improvement of economic performance in industrial model predictive control systems

A novel approach to progress improvement of the economic performance in model predictive control (MPC) systems is developed. The conventional LQG based economic performance design provides an estimation which cannot be done by the controller while the proposed approach can develop the design performance achievable by the controller. Its optimal performance is achieved by solving economic performance design (EPD) problem and optimizing the MPC performance iteratively in contrast to the original EPD which has nonlinear LQG curve relationship. Based on the current operating data from MPC, EPD is transformed into a linear programming problem. With the iterative learning control (ILC) strategy, EPD is solved at each trial to update the tuning parameter and the designed condition; then MPC is conducted in the condition guided by EPD. The ILC strategy is proposed to adjust the tuning parameter based on the sensitivity analysis. The convergence of EPD by the proposed ILC has also been proved. The strategy can be applied to industry processes to keep enhancing the performance and to obtain the achievable optimal EPD. The performance of the proposed method is illustrated via an SISO numerical system as well as an MIMO industry process.     

Modelling of uncertain systems with application to robust process control

A method for black-box identification of uncertain systems is presented. The method identifies a nominal model and an uncertainty model set, consisting of unfalsified uncertainty models. Minimisation of a Chebyshev criterion leads to computationally favourable linear programming problems and allows the possibility to include a priori information in the form of linear constraints without making the computations more complex. Using data compression via correlation computations solves the computation problem associated with identifying unfalsified uncertainty models. The application of set-valued uncertainty models to robust process control is illustrated in a simulation study of robust model predictive control of a distillation column.     

A pulp mill benchmark problem for control: application of plantwide control design

A heuristic for design of plantwide control strategies is introduced and applied to the millwide control of a previously presented pulp mill benchmark. Two control strategies (decentralized control and unit-based model predictive control) are compared according to their capacity to reduce the total error and maximize the operating profits. The control strategies are studied through closed-loop simulations of the process including several disturbances and setpoint changes in the digester, oxygen reactor, bleach plant, recausticizing plant and lime kiln.     

Sliding mode predictive control: A survey

This paper reviews the development and application of sliding mode predictive control (SMPC) in a tutorial manner. Two core design paradigms are revealed in the combination of sliding mode control (SMC) and model predictive control (MPC). In the first case, MPC is used in the reaching phase to ensure a sliding mode is attained. In the second case, MPC is used to solve the existence problem and define the required performance in the sliding mode. The two approaches are discussed in detail from the perspectives of both theory and application. Finally, some future challenges and opportunities in the area of SMPC are summarized.     

An optimal hierarchical control scheme for smart generation units: An application to combined steam and electricity generation

Optimal management of thermal and energy grids with fluctuating demand and prices requires to orchestrate the generation units (GU) among all their operating modes. A hierarchical approach is proposed to control coupled energy nonlinear systems. The high level hybrid optimization defines the unit commitment, with the optimal transition strategy, and best production profiles. The low level dynamic model predictive control (MPC), receiving the set-points from the upper layer, safely governs the systems considering process constraints. To enhance the overall efficiency of the system, a method to optimal start-up the GU is here presented: a linear parameter-varying MPC computes the optimal trajectory in closed-loop by iteratively linearizing the system along the previous optimal solution. The introduction of an intermediate equilibrium state as additional decision variable permits the reduction of the optimization horizon, while a terminal cost term steers the system to the target set-point. Simulation results show the effectiveness of the proposed approach.     

An application of model predictive control to the dynamic economic dispatch of power generation

Two formulations exist for the problem of the optimal power dispatch of generators with ramp rate constraints: the optimal control dynamic dispatch (OCDD) formulation based on control system models, and the dynamic economic dispatch (DED) formulation based on optimization. Both are useful for the dispatch problem over a fixed time horizon, and they were treated as equivalent formulations in literature. This paper first shows that the two formulations are in fact different and both formulations suffer from the same technical deficiency of ramp rate violation during the periodic implementation of the optimal solutions. Then a model predictive control (MPC) approach is proposed to overcome such a technical deficiency. Furthermore, it is shown that the MPC solutions, which are based on the OCDD framework, converge to the optimal solution of an extended version of the DED problem and they are robust under certain disturbances and uncertainties. Two standard examples are studied: the first one of a ten-unit system shows the difference between the OCDD and DED, and possible ramp rate violations, and the second one of a six-unit system shows the convergence and robustness of the MPC solutions, and the comparison with OCDD as well.     

Experimental application of nonlinear model predictive control: temperature control of an industrial semi-batch pilot-plant reactor

This paper describes the application of nonlinear model predictive control (NMPC) to the temperature control of a semi-batch chemical reactor equipped with a multi-fluid heating/cooling system. The strategy of the nonlinear control system is based on a constrained optimisation problem, which is solved repeatedly on-line by a step-wise integration of a nonlinear dynamic model and optimisation strategy. A supervisory control routine has been developed, based on the same nonlinear dynamic model, to handle automatically the fluid changeovers. Both NMPC and supervisory control have been implemented on a PC and applied to a 16 l batch reactor pilot plant. Experiments illustrate the feasibility of such a procedure involving predictive control and supervisory control.     

Comparison of PI and MPC for control of a gas recovery unit

This study compares PI and MPC controls via a computer simulation for a gas recovery unit (GRU), which consists of three distillation columns operated in series: a de-ethanizer, a depropanizer and a debutanizer. In addition, the de-ethanizer feed is preheated by the bottoms product from the de-ethanizer, which causes additional process coupling. Rigorous models are developed for the columns including column pressure dynamics and heat transfer dynamics. The process is a highly coupled system and has interactive constraints that determine the feasible operating regions. A decentralized PI control system with override controls for the constraints was designed and implemented on the GRU simulator and was compared with an industrial MPC controller. The MPC controller was observed to outperform the decentralized control system due to its multivariable constraint control capability. Since the simulator is available to other university researchers, it can serve as a challenge problem for multivariable control and identification. Three MPC controllers with different strategies for controlling the bottom level of the first column were implemented on the GRU process. The first MPC controller does not directly control the level, the second one moves the setpoint to the PI level controller, and the third one controls the level directly by manipulating the flow. The results show that including level into the MPC controller improves composition control for cases in which the manipulated variable for the level control has a significant impact on compositions.     

Stability analysis of a multi-model predictive control algorithm with application to control of chemical reactors

We study a stabilizing multi-model predictive control strategy for controlling nonlinear process at different operating conditions. The control algorithm is a receding horizon scheme with a quasi-infinite horizon objective function that has finite and infinite horizon cost components. The finite horizon cost consists of free input variables that direct the system towards a terminal region which contains the desired operating point. The infinite horizon cost has an upper bound and steers the system to the desired operating point. The system is represented by a sequence of piecewise linear models. Based on the condition of the system states, the sequence of piecewise linear models is updated and the controller’s objective function switches form quasi-infinite to infinite horizon objective function. This results in a hybrid control structure. A recent approach in the analysis of hybrid systems that uses multiple Lyapunov functions is employed in the stability analysis of the closed-loop system. The stabilizing hybrid control strategy is illustrated on two examples and their closed-loop stability properties are studied.     

RTO: An overview and assessment of current practice

The practice of implementing real-time optimization (RTO) using a rigorous steady-state model, in conjunction with model predictive control (MPC), dates back to the late 1980s. Since then, numerous projects have been implemented in refinery and chemical plants, and RTO has received significant attention in the industrial and academic literature. This history affords us the opportunity to assess the impact and success of RTO technology in the process industries. We begin with a discussion of the role RTO serves in the hierarchy of control and optimization decision making in the plant, and outline the key steps of the RTO layer and the coordination with MPC. Where appropriate, we point out the different approaches that have been used in practice and discuss the success factors that directly relate to the success of RTO within an organization. We also discuss alternative approaches that have been used to alleviate some of the challenges associated with implementing RTO and which may be appropriate for those unwilling to commit to the traditional RTO approach. Lastly, we provide suggestions for improvement to motivate further research.     

Optimizing model predictive control of an industrial distillation column

The main scope of this work is the implementation of an MPC that integrates the control and the economic optimization of the system. The two problems are solved simultaneously through the modification of the control cost function that includes an additional term related to the economic objective. The optimizing MPC is based on a quadratic program (QP) as the conventional MPC and can be solved with the available QP solvers. The method was implemented in an industrial distillation system, and the results show that the approach is efficient and can be used, in several practical cases.     

Comparison of nonlinear control design techniques on a model of the Caltech ducted fan

In this paper we compare different nonlinear control design methods by applying them to the planar model of a ducted fan engine. The methods used range from Jacobian linearization of the nonlinear plant and designing an LQR controller, to using model predictive control and linear parameter varying methods. The controller design can be divided into two steps. The first step requires the derivation of a control Lyapunov function (CLF), while the second involves using an existing CLF to generate a controller. The main premise of this paper is that by combining the best of these two phases, it is possible to find controllers that achieve superior performance when compared to those that apply each phase independently. All of the results are compared to the optimal solution which is approximated by solving a trajectory optimization problem with a sufficiently large time horizon.     

An MPC approach to the design of two-layer hierarchical control systems

A methodology for the design of two-layer hierarchical control systems is presented. The high layer corresponds to a system with slow dynamics, whose control inputs must be provided by subsystems with faster dynamics placed at the low layer. Model Predictive Control laws are synthesized for both layers and overall convergence properties are established. The use of different control configurations is also considered by allowing the switching on/off of the subsystems at the low layer. A simulation example is reported to witness the potentialities of the proposed solution.     

Model reduction and model predictive control of energy-efficient buildings for electrical heating load shifting

In France, buildings account for a significant portion of the electricity consumption (around 68%), due to an important use of electrical heating systems. This results in high peak load in winter and causes tensions on the production-consumption balance. In view of reducing such fluctuations, advanced control systems (including the Model Predictive Control framework) have been developed to shift heating load while maintaining indoor comfort and taking advantage of the building thermal mass. In this paper, a framework for developing optimisation-based control strategies to shift the heating load in buildings is introduced. The balanced truncation method and a time-continuous optimisation method were used to develop a real-time control of the heating power. These two methods are well suited for control problems and yield precise results. The novelty of the approach is to use reduced models derived from advanced building simulation software. A simulation case study demonstrates the controller performance in the synthesis of a predictive model-based optimal energy management strategy for a single-zone test building of the “INCAS” platform built in Le Bourget-du-Lac, France, by the National Solar Energy Institute (INES). The controller exhibits excellent performance, reaching between 6 and 13% cost reduction, and can easily be applied in real-time.