MVC

GE Energy
GENERAL PRODUCT DESCRIPTION

MVC
MULTIVARIABLE PREDICTIVE
CONTROL TECHNOLOGY
By
GE Energy - Optimization Services
Houston, Texas
1999-2004 GENERAL ELECTRIC COMPANY
Proprietary information contained herein is subject to all laws and regulations pertaining to intellectual property rights.
TABLE OF CONTENTS
OVERVIEW .........................................................................................................................................................................1
PRODUCT DESCRIPTION..............................................................................................................................................2
Generic Formulation.....................................................................................................................................................................2
Overall Functionality ....................................................................................................................................................................4
Manipulated Variable Limits .....................................................................................................................................................5
Model Update ..................................................................................................................................................................................7
External/Internal Setpoint Control.........................................................................................................................................7
Mode Control....................................................................................................................................................................................7
Controller Optimization Algorithm.........................................................................................................................................7
Controller Optimization Algorithm Infeasibility ...............................................................................................................8
Nonlinear Optimization Algorithm .........................................................................................................................................9
Economic Optimization Algorithm.........................................................................................................................................9
Controller GCOMP Function ...................................................................................................................................................10
Economic Optimizer GCOMP Function .............................................................................................................................10
Analyzer and Sensor Validation...........................................................................................................................................10
PCT Calculations..........................................................................................................................................................................11
MVC Fall Back .............................................................................................................................................................................11
Plant Testing..................................................................................................................................................................................11
Reduced Rigorous Model Building ......................................................................................................................................12
Tools ..................................................................................................................................................................................................13
1. MVC Configurator...............................................................................................................................................................................13
2. Identification Package........................................................................................................................................................................14
3. MVC Simulator .....................................................................................................................................................................................15
HUMAN-MACHINE INTERFACE .............................................................................................................................. 15

Engineers Interface ...................................................................................................................................................................15
Operator Interface......................................................................................................................................................................16
Performance Monitoring .........................................................................................................................................................16
MVC PROJECT EXECUTION DETAILS ................................................................................................................. 16

Procedure for Evaluating Economic Performance .....................................................................................................16
GE Energy
Process Simulator/In-house Controller Tuning ............................................................................................................17

Implementation ...........................................................................................................................................................................17
PRODUCTS...................................................................................................................................................................... 19
MVC Examples........................................................................................................................................................... 20
Cryogenic Plant Example........................................................................................................................................................20
Distillation Example....................................................................................................................................................................23
GE Energy
MVC Product Description
Page 1
WHAT IS MVC
The Houston branch of GE Energy - Optimization Services (formerly known as GE Continental Controls) has
developed a patented, on-line, real time, nonlinear multivariable control and optimization technology known as
MVC. The technology is a combination of process dynamics, thermodynamics and operating economics that
handles complex processes experiencing wide variability and unsteady state operation. MVC is unique in that
it can be run as a constraint pushing multivariable controller or as a true economic optimization driven
multivariable controller. The optimization can take place on a per unit basis or on multiple units with several
MVC controller modules operating under the overall optimization strategy.
OVERVIEW
MVC technology consists of:
1.
Reduced rigorous thermodynamic and kinetic process simulations tuned to actual plant performance,
which provide nonlinear predictive algorithms characteristic of the controlled processes and unit
operations.
2.
Rigorously calculated process dynamic responses to various disturbances that are calibrated to the actual
plant equipment through response tests.
3.
An economic optimization based on the predictive algorithms, nonlinear economic predictions and process
dynamics.
4.
On-line model adaptation combined with tuning algorithms, measurement drift compensation and priority
weighting that continuously adapts the controller/optimizer as the performance, equipment and
instrumentation changes.
The MVC code is programmed in C and C++ language and delivered in a compiled format. MVC is
implemented in a Pentium PC, or RISC workstation running under a Windows, NT or UNIX real time, preemptive,
multitasking, multithreaded operating system. Typically, MVC interfaces to the existing regulatory control
system via a software driver and some type of I/O hardware. MVC utilizes a real time information system
(RTIS) which provides a real time database, a data historian and a graphical user interface (GUI).
MVC may be implemented on a variety of platforms:
PLC based systems.

Distributed control systems (DCS).
This is shown in Figure 1. In the case of DCS implementation, MVC typically utilizes the real time database
(RTDB), application programming interface (API) and the GUI of the host system.
1999 - 2004 GENERAL ELECTRIC COMPANY
GE ENERGY
Page 2
Operator Console
Process Computer
MVC
Control Network
Regulatory PID & Logic
Control
Plant I/O
Controller
Typical APC/O System Architecture

Figure 1
PRODUCT DESCRIPTION
Generic Formulation
MVC is a multivariable controller/optimizer that contains a multivariable controller, and an economic
optimizer. In the controller mode, MVC manipulates multiple manipulated variables to control multiple
controlled variables within constraint limits. In the optimizer mode, MVC manipulates multiple manipulated
variables to optimize profit within constraint limits. In the optimization mode, MVC calculates the tradeoff
between throughput maximization and product pricing against the costs of feed, utilities and other operating
parameters .
The MVC controller is configured using manipulated, disturbance, constraint and setpoint variables.
Manipulated variables (MV) are the basic regulatory controller setpoints that MVC adjusts to maintain
control targets at user-defined or economically optimum values, while honoring constraints.
Disturbance variables (DV) are known to affect either setpoint or constraint variables.
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Constraint variables (CON) are maintained by MVC within either high and/or low limits by the controller.
Setpoint variables (SP) are maintained by MVC at a user defined value, or at an economically optimum
value as determined by the MVC optimizer.
The basic equation formulation is of the following form:

CVi = f(MV1, MV2, MV3, ... MVM DV1, DV2, DV3, .... DVP)
where:
CVi
MVn
DVk
M
P
=
=
=
=
=
setpoint or constraint variable

manipulated variable process value
disturbance variable process value
total number of manipulated variables
total number of disturbance variables
More specifically, the equations are of the form:

CVi = a0 + a1(MVterm1)y1 + a2(MVterm2)y2 + a3(MVterm3)y3 + ... am(MVtermm)ym +
+ a(m +1)(DVterm1)z1 + a(m +2)(DVterm2)z2 +a(m +3)(DVterm3)z3 + ... a(m + p)(DVtermp)zp
where:
yx
zx
m
p
a0
=
=
=
=
=
is the real/float exponent of MVtermx

is the real/float exponent of DVtermx
number of MVterms
number of DVterms
overall bias term
Note that the number of MVterms does not necessarily equal the number of MV's. In addition, the number of
DVterms does not necessarily equal the number of DV's.
MVterms are any quantities that contain at least one MV in some form. On the other hand, DVterms are any
quantities that are combinations of DV's in some form. The allowable forms of the general term MVtermx are
the following:
1.
2.
3.
4.
5.
MVy
MVy * DVz
MVy * MVz
exp ( MVy )
ln ( MVy )
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The allowable forms of DVtermk are the following:

1.
2.
3.
4.
DVz
DVz * DVY
exp ( DVz )
ln ( DVz )
When used in the control equations, MVterms

and DVterms are dynamically compensated
using first order or other dynamics. The
coefficients used in the equations are
developed from process simulators and are
updated using yield/conversion models,
empirical regression models, traditional step
testing, dynamic models or other methods.
The more positionally correct or accurate the
model, the better the predictive performance.
Also the more accurate the model, the less
initial dependence on bias. However, as
adaptive
conditions
change,
MVCs
functionality adjusts to the process to
maintain optimum control.
Controller Logic Diagram

Figure 2
CONTROLLER OUTPUTS & LIMITS
OPERATOR HI/LO LIMITS
NON-LINEAR
EQUATION COEFFICIENTS
OPERATOR
ON/OFF
SWITCHES
MV ROC
LIMITS
MV LIMITS
MODEL UPDATE BASED ON

CURRENT
CURRENT CV CONDITIONS
NON-LINEAR MULTIVARIABLE
CONSTRAINED CONTROLLER
OPTIMIZATION AND/OR
ECONOMIC OPTIMIZATION
CV SETPOINTS
CONSTRAINT
UPDATED NON-LINEAR
EQUATION COEFFICENTS
ECONOMIIC
VALUES
TUNING
PARAMETERS
NEW MV
As shown in Figure 2, the controller functionality consists of the following steps:
1.
Calculate appropriate manipulated variable limits.
2.
Using current plant data, update controller equations' a0 terms.
3.
Call the optimization algorithm.
4.
Generate new MV setpoints.
MVC Block Functional Diagram

Figure 3
Overall Functionality
ADAPTIVELY TUNED
NONLINEAR ECONOMIC
EQUATIONS RELATING
PROFIT TO CVs or MVs
Figure 3 shows the overall block diagram of

MVC illustrating the relationship between
economic
optimization
and
controller
optimization. In the controller mode, the user
specifies the controlled variable (desired
setpoints or SPs) targets. The controller will seek
to satisfy the SPs by manipulating MVs.
FEEDSTOCK & PRODUCT

PRICES
UTILITY FACTORS
In the optimizer mode, the user assigns

economic values to products, utilities and
penalties. MVC calculates the optimal SPs
continually. Hence, the concept of dynamic SPs,
illustrated in Figure 4 (where they are referred to
PROCESS CONSTRAINT
LIMITS
ADAPTIVELY TUNED
NONLINEAR DYNAMIC
PROCESS MODEL-BASED
EQUATIONS RELATING TO
MVs & CVs
PROCESS CONSTRAINT
LIMITS
PRODUCT SPECIFICATIONS
ECONOMIC
OPTIMIZATION
OPTIMAL CVs
OR MVs
MVC/O can be used either

in controller mode or in
optimizer mode. In the
optimizer mode one or
more controller modules
may be integrated for multiunit optimization strategies.
OPTIMIZER
CONTROLLER
NONLINEAR
OPTIMIZING
CONTROLLER
MV HI/LO V
ARIABLE
LIMITS DETERMINATION
NEW MVs
Dynamic
Optimal CV Effect
SETPOINTS
Figure 4
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in general industry terms as CVs), which states that given the process' range and nonlinearity plus wide
disturbance variability, the optimal CVs change as the process conditions change. Therefore, the economic
optimum moves dynamically as the process conditions change and is not fixed. This illustrates a key feature of
MVC in that the economic optimization is
dynamically updated with information from the
MISSED
process (the CVs, MVs and DVs) upon every
OPPORTUNITY
TRUE OPTIMAL CV
optimization cycle.
During each controller iteration, appropriate

upper/lower limits are calculated for each
manipulated variable. If the upper and lower limits
are set equal to the current setpoint, the
optimization algorithm considers this variable
fixed and will not adjust it when searching for a
solution. The following factors are considered in
choosing
the
appropriate
manipulated
upper/lower limits:
CV
Manipulated Variable Limits
CV SS TARGET
EXCESSIVE
COST
TIME
CV BASE CASE SS TARGET
Total Opportunities = a+b+c+d+ ...
On/Off Switch Status

Basic Regulatory Controller Mode
Basic Regulatory Controller Status
Operator High/Low Limits
Increasing/Decreasing Rate of Change ( ROC ) Limits
DCS High/Low Limits
Basic Controller Windup
Controller Output
On/Off Switch Status
If the individual MV on/off switch is turned off, the upper and lower limits are clamped equal to the current
setpoint.
Basic Regulatory Controller Mode
If the basic regulatory controller is not in computer mode, the upper and lower limits are clamped equal to the
current setpoint.
Basic Regulatory Controller Status
If the basic regulatory controller status is bad, the upper and lower limits are clamped equal to the current
setpoint.
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Operator High/Low Limits

These are the manually entered high and low limits for the MVC controller MV.
Increasing/Decreasing Rate of Change ( ROC ) Limits
An upper limit is calculated based on adding the increasing rate of change to the current basic regulatory
controller setpoint. A lower limit is calculated based on subtracting the decreasing rate of change from the
current basic regulatory controller setpoint.
DCS High/Low Limits
With a DCS system, there is provision to read the DCS basic regulatory controller high and low limits so that
they participate in the selection process.
Basic Regulatory Controller Windup
If the basic regulatory controller is wound up so that it cannot receive a higher setpoint, the upper limit will be
clamped equal to the current setpoint. However, the MVC controller will be able to receive a lower setpoint
consistent with other checks in this routine.
If the basic controller is wound up so that it cannot receive a lower setpoint, the lower limit will be clamped
equal to the current setpoint. However, the MVC controller will be able to receive a higher setpoint consistent
with other checks in this routine.
If the basic controller is wound up in both directions so that it cannot receive either a higher or lower setpoint,
the MVC controller upper/lower limits will be clamped equal to the current setpoint.
Controller Output
The controller output upper and lower limits are calculated based on:
The current controller output.

High/low controller output limits.
Controller action (reverse/direct).
The relationship between a change in MV setpoint and a change in controller output.
For individual MVs, this feature can be disabled.

Final MV Limits Comments
The final value for the MV is calculated as the most restrictive upper/lower value from each of the various
checks. If the operator upper limit is changed below the last operator upper limit and the controller was at that
limit, the controller will ramp down at the decreasing rate of change limit, or vice-versa for cases that involve
the lower operator limit. However, if the operator upper limit is set below the operator lower limit, the controller
will set the calculated upper/lower limits equal to the current setpoint. When run in advisory mode, the
calculated upper/lower limit is set equal to the operator high/low limit.
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Model Update
The a0 model update is the first key feature of MVCs adaptability. Upon each control cycle, new current
values of the setpoint and constraint process variables are received that enable the controller to "predict"
setpoint and constraint variables at the current time using past MV/DV history and the CV equation. Thus, the
controller can automatically update the CV equation on-line by adjusting the model bias, a0, through
comparison of the actual CV value with the predicted CV value. Normal process noise can cause the calculated
a0 to be noisy. Therefore, the user can filter the calculated a0. For discrete on-line and laboratory analyzers, the
goal/ultimate a0 value is updated from each validated analyzer value. The actual a0 value is filtered from the
current a0 up to the goal/ultimate a0 during each controller cycle.
External/Internal Setpoint Control

Often there are important operating parameters such as liquids recovery and component ratios that cannot be
directly controlled in a manner easy to understand and maintain. An example is the C1/C2 ratio of a cryogenic
demethanizer column. The C1/C2 ratio is one of the primary contractual parameters of the unit operation and is
a function of the top and bottoms compositions, both key CVs. In turn the top and bottom compositions are a
function of the key MVs: reboiler flow, heat transfer(Q), and reflux. MVC allows the target C1/C2 ratio to be set
by calling it an external setpoint, which the operator can adjust. This external setpoint is cascaded to the top
and bottom composition CVs, called the internal setpoints. MVC manipulates the MVs to achieve and maintain
these key CVs. In doing so the key parameters are controlled at the desired values.
Mode Control
If the process is run at several significantly different operating points, throughputs or "modes", then MVC has
the ability to store different sets of model coefficients and control objectives which can then be downloaded
into operation when the mode is changed. The download can be triggered either on demand by the operator
or automatically based on some set of pre-determined conditions. MVC's GUI can be configured to interact
with the user to initiate and display these mode changes.
Setpoint Trajectory
Figure 5
Controller Optimization Algorithm
Upper Bound
The controller optimization function combines
Requested SP
several controller objectives. The first is for
setpoint-defined variables. In this case, the
controller chooses a set of manipulated
Predicted
SP
variables that minimize the difference between
Lower Bound
the funnel boundaries and the predicted process
Exceeds
Violation
variable as shown in Figure 5. The user can
Boundary
Current PV
select the number of prediction points although
t
t
t
t
t
Now
it is generally set at 5. The actual prediction
SP Horizon
times are based on a maximum model time and
Future
the number of prediction points. Thus, if the
maximum model time is 50 and the number of
prediction points is 5, the predictive calculations
will be performed at 10, 20, 30, 40 and 50 minutes. The funnel boundaries are calculated from the difference
between the current predicted setpoint value and the operator-entered setpoint through a user-entered funnel
boundaries dead time and horizon. The dead time is chosen to equal the dead time of the "dominant" MV (the
1
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MV that is used to control that particular setpoint variable). The horizon is the length of the longest model time.
Longer horizons have the effect of slowing down the MV action. Even when the operator-entered target has
been constant for a long time, it is still necessary to calculate funnel boundaries. If the current process variable
is not at its setpoint, the controller will bring the process variable back to the operator setpoint within the funnel
boundary. In addition, the controller will minimize the difference between the new and last manipulated
variable setpoints. Since the combination of these setpoint and manipulated variable objectives may result in
conflicts, weighting factors for each manipulated and controlled variable determine how closely each objective
is enforced.
The user may also define certain manipulated variables as "Desired Manipulated Variables", also called DMVs.
These are the manipulated variables that one would like to have set at a predetermined value if there are
enough degrees of freedom available. In this case, instead of using the last manipulated variable setpoint in the
objective function, the value of the DMV, adjusted for the DMV rate of change (ROC), is used. This has the effect
of "driving" toward the DMV at a user specified DMV ROC. DMVs are often used to minimize energy
consumption for example, reflux and steam reboiler flows have economic values in $/BTU or $/lb so their
DMVs are set at the minimum of their range.
Controller Optimization Algorithm Infeasibility

MVC has been designed to robustly handle infeasible
solutions. When a constraint cannot be explicitly
satisfied, the multivariable controller optimization
algorithm becomes infeasible. Often, this is because the
controller cannot move the MV's fast enough because
of rate of change restrictions. Other times, it will never
get there because a particular MV is not available, i.e., it
is turned off, has a bad status, etc. If the optimization
algorithm ever returns with an infeasible solution, MVC
responds by internally turning off the constraints that
are defined in the nonlinear optimizer and
approximates those constraint limits using a
exponential function as shown in Figure 6.
Optimization Algorithm
Infeasibility
Figure 6
PENALTY
FUNCTION
The penalty function increases the farther away the

0
CONSTRAINT
constraint moves from its appropriate limit. This
Constraint Value
LIMIT
function value for each constraint is added to the
optimization function. This "penalizes" the controller
when it chooses MV values that violate a constraint limit. How quickly this function rises at the constraint limit
is user-tunable. This technique insures that MVC quickly returns to a feasible solution.
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Nonlinear Optimization Algorithm

MVC uses a nonlinear optimization algorithm that is
a version of the generalized reduced gradient
approach (GRG2). GRG2 is a time proven optimization
technology that has been used in literally millions of
applications. A functional diagram of GRG2 is shown
in Figure 7.
The first step in GRG2 is setting up the basic problem
definition. This requires defining the number of
manipulated/independent variables and (constraint
and optimization function)/dependent variables and
their appropriate limits. The heart of the algorithm is a
user-defined function called GCOMP, which is termed
the "model" in GRG2 terminology. GRG2 passes values
of the manipulated variables to the GCOMP function
and receives back values of the constraint and the
objective function. Based on these results, GRG2
chooses other sets of manipulated variables. This
process of GRG2 choosing manipulated variables and
GCOMP calculating constraints and the objective
function continues until the objective function has
been maximized/minimized within constraints or until
the algorithm fails to converge.
GRG2 Functionality
Figure 7
BASIC PROBLEM
DEFINITION
GRG2 CHOICE
OF MVs
CALCULATE OBJECTIVE
FUNCTION & CONSTRAINTS
IS
OBJECTIVE FUNCTION
MAX/MIN WITHIN TOLERANCE
AND CONSTRAINTS ?
NO
YES
OPTIMAL SET
OF MVs
Economic Optimization Algorithm

The economic optimization uses the same optimization method as the controller but in this case MVC
calculates the optimal SPs, then passes them to the controller where the optimal MV moves are calculated. In
both modes the constraints (CONS) are always honored.
In general the form of the optimization objective profit function is a scalar function, f:
f($) = Net Marginal Value of Products - Cost of Utilities - Penalty (if any)
Profitability is expressed as a function of all the process variables, including MVs, CVs, and DVs. Coefficients are
used in the profit equation for conversions that create consistent units of dollars per unit time for the entire
expression. Much more complicated objective profit functions can be accommodated to reflect plant
economics. Also, f is nominally a linear function of the process variables; however, since the dependent CVs are
related to the DVs and MVs via the nonlinear thermodynamic-kinetic +dynamic process model, f is actually a
nonlinear function of the independent variables.
Another important feature is that the terms of the objective profit function are updated on every optimization
cycle with the latest values of the CVs, MVs, DVs and CONS. Thus the optimization is dynamic, occurring as the
process and conditions change. There is a trade-off between product value and costs. Therefore, increasing
throughput, feed rate maximization or product specification limits strategies are not always the economically
optimum operating position.
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Controller GCOMP Function

After GRG2 chooses a new set of MVs, the MVC GCOMP function calculates:
The setpoint trajectory for each defined setpoint variable.

The predicted value of each constraint variable at a user defined point in the future.
The values of the setpoint process variables at the various points in the future.
The sum of the difference squared between the setpoint, as defined by the trajectory, and the predicted
process variable for each setpoint is then calculated at each future time. This information along with the last
MV setpoints, appropriate DMV's, and tuning factors is then used in calculating the controller objective function.
GCOMP is repeatedly executed with different values of the manipulated variables until the objective function is
minimized.
If the controller does not converge, the constraints are turned off in the GRG2 algorithm and MVC goes into its'
"penalty" mode as explained in the section Controlled Optimization Algorithm Infeasibility (on page 8). In this
mode, the constraint limits are approximated by an exponential function as shown in Figure 6. GRG2 then calls
GCOMP until the optimization function, with the penalty added, is minimized.
Economic Optimizer GCOMP Function

After GRG2 chooses a new set of MV's, the MVC GCOMP function calculates the predicted value of each
constraint variable at a user defined point in the future. Next, any intermediate calculations that use the new
manipulated variables are performed. The last step is the profit function calculation. GCOMP iterates
manipulated variable values until the objective function is maximized.
If the controller does not converge, the constraints are turned off in the GRG2 algorithm and MVC goes into its'
"penalty" mode as explained in the section Controller Optimization Algorithm Infeasibility (on page 8). In this
mode, the constraint limits are approximated by an exponential function as shown in Figure 6. GRG2 then calls
GCOMP until the optimization function, with the penalty added, is maximized.
Analyzer and Sensor Validation

MVC uses data that has been validated. MVC accommodates input filtering, identifies bad PVs, and corrects
invalid data by various methods, such as holding the last good value. If the status of a variable is bad, it is
ensured that the variable (MV or CV) is turned off and no action is taken on that variable. So that the effect of
the variable going bad will not affect other variables, the last good value of the variable that went bad is
maintained and used.
Central to these validation features is the fact that MVC does not rely on absolute data reconciliation of the
process inputs. Instead of calculating the reconciled actual absolute process readings and then dealing with
values that do not make sense or could cause controller infeasibility, MVC acts on the change in these inputs
over the controlled period. It is this change in the process that tells the control strategy to take the necessary
control actions to meet the objectives. This approach considerably reduces the complexity and computational
effort required to control the process and contributes greatly to the execution speed of MVC in both the
controller and optimizer modes.
The MVC data validation procedures ensure that all data is good before being used in the MVC model.
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PCT Calculations
GE uses inferential calculations of pressure compensated temperature for composition control. Pressure
compensated temperature is a common technique for correcting temperature for varying pressure. These
inferential correlations are produced from process simulations by holding composition constant and varying
pressure while noting temperature.
MVC Fall Back

MVC provides fallback handling. If there is a failure in the software, hardware, or loss of power, the basic
regulatory control (BRC) in the DCS shall not be affected. The DCS controllers return to their normal operator
mode so that the plant continues to operate in a safe, stable manner.
Plant Testing
A visit to the plant is required to:
obtain operating information

understand operating objectives
review the PFD/P&IDs
survey field instrumentation
locate process and equipment constraints
obtain and analyze the process dynamics
determine the operating envelope
demonstrate the potential for improved operation
Prior to Visiting the Plant

PFDs/P&IDs and historical operating data are obtained from the plant before the site visit. The operating data
typically includes hourly and daily averages, on-line analyzer data, laboratory analyses and log sheets for
representative periods of time. These help determine the plants variability and range of operation. Existing
regulatory control strategies are also reviewed. A detailed I/O list is prepared for verification in the field. From
these, and an understanding of the process, a plant test plan is prepared. The test plan normally includes a
series of setpoint changes in key manipulated variables and monitoring key disturbance variables. The plan is
reviewed by plant operations personnel for approval. All changes to the plan are subject to approval by client
personnel.
Also, prior to the plant test, plant models are built using third-party simulators. Empirical, yield/conversion,
furnace and reactor models may also be required. These models are later calibrated to the plant operation
using the data obtained during the plant test. Further data analysis and fine-tuning of the models takes place
during the controller model building phase.
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Plant Dynamics
For many processes, first order dynamics accurately describe how the process changes with time. This
simplified dynamic model is used because it is easier to tune. More complicated dynamics can be described by
sets of impulse coefficients obtained by linking dynamic identification tools to the regulatory control system.
This is restricted to processes controlled by some type of distributed control (DCS). Should the dynamic
identification tools be unavailable or infeasible, trends and logs can be configured on the DCS to save the
required data during the setpoint changes. This data can be statistically analyzed to obtain the initial dynamic
values. Where the plant controls are single loop pneumatic or electronic controllers, chart data are analyzed
and, along with experience, initial first order dynamic values are estimated and fine-tuned later during
commissioning.
Site Visit
During the site test, the plant will be moved to
determine process and equipment constraints and to
demonstrate improved operating positions. For
example:
Model Building and

Experimental Design
setpoint changes to lower the lean amine flow rate

can be used to determine the effects on absorption
efficiency and stripping steam requirement in a
treating unit
setpoint changes to feed flow or reflux can be used
to determine the effect on overhead and bottoms
compositions and dynamic response for a
distillation column.
Figure 8
The
non-linear
optimal
solution does not always lie
at a constraint boundary,
unlike linear solutions which
always
converge
at
a
constraint
boundary
by
definition.
Reduced Rigorous Model Building

Reduced rigorous models of the process are built using
three powerful tools. The first tool is experimental
design; the second is process simulation; and the third
is multiple linear regression and residual analysis. An
experimental design is first constructed relating the
controlled variables to the manipulated and
disturbance variables identified in the plant visit and
control strategy formulation stages of the project.
Then, a quadratic response surface methodology
(QRSM) experimental design is developed using a threelevel factorial-based design set.
A three level n factor

design where factor
x, factor y, and
factor n are tested in
x times y times n
experiments.
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The general form of the quadratic equation is:

n
f ( xi ) = a 0 + ai xi +
i =1
nn
i =1 j =1
ij
xi x j + aii xi2
i =1
Experiments are conducted using a commercially available process simulator such as HYSIM, T-SWEET, PRO II,
ASPEN PLUS, etc. Other simulation, yield/conversion, fundamental or empirical models can also be used stand
alone or in combination with these third party models. Each simulation is performed in a random order to
produce a set of data relating the controlled, manipulated and disturbance variables in "n" space. Figure 8
illustrates the multi-dimensional concept. This produces a thermodynamic-kinetic steady-state map of the
process throughout its relevant range of operation.
The associated mapped data is imported into a sophisticated statistical analysis package (e.g., Minitab). From
there the data is regressed using multiple linear regression with residual analysis techniques. This produces a
set of nonlinear steady-state gains or coefficients for each of the relationships relating CVs to MVs. The net
result is a set of nonlinear equations that are joined with first order dynamic terms and nonlinear economic
equations. These equations are solved by GRG2 in the MVC multivariable controller problem.
Two checks are performed to verify the accuracy and robustness of the models. First, the models used during
the plant testing stage are calibrated to the actual plant operation. Statistically valid and filtered operating
data from the tests, as well as historical data are used in the calibration. Next the models are checked for
convergence and sensibility with the process. The second step is the verification of the reduced models with
the plant data. This ensures that the models will always converge (be solvable) with process sensible results.
Perfect accuracy in the reduced models is not required. Process noise, drift and simulation inaccuracies mean
that perfection is not attainable. Furthermore, perfection is unnecessary as the models adapt on-line with
every prediction cycle. Even if the models were initially perfect, process drift would necessitate adaptation.
Tools
In addition to the tuning and reparameterization features inherent in the basic controller software, GE provides
three additional tools to maintain and update the MVC models.
1. MVC Configurator
GE has developed a tool kit to easily configure an MVC application. This configurator product was developed
to facilitate building a multivariable controller application. To the best of our knowledge, it is the most user
friendly, complete and sophisticated configurator currently available in the marketplace.
The MVC Configurator has a Windows-like menu driven GUI used for easy configuration of MVC control
strategies. It can run either on a Windows platform (9x, NT, 2000) or a UNIX platform. Using pull down menus,
tables, and fill-in-the-blank fields the user can configure the MVC database of SPs, CONs, MVs and DVs, limits,
constraints, tuning constants and model algorithms.
GE Energy
Page 14
2. Identification Package
The MVC identification package includes all functions for open and closed loop identification. Some features
are:
Automatic Identification of Single-loop Models

Direct Identification of Continuous Time Models
Robust Parameter Estimation
Time-sliced data
Modeling Outputs and Results

The identification software DynaminerTM, used with MVC, is an easy-to-use tool for developing dynamic
models from process data. It is a multivariable, dynamic modeling tool for identifying first and second order
Laplace models with deadtime.
To perform model identification, plant step test data is input into the DynaminerTM based identification
software. First and second order Laplace model coefficients and deadtime are identified. These models are
imbedded in MVC. Typically, first order Laplacian models with deadtime are used in MVC as the second order
effects are negligible.
DynaminerTM has multivariable capability and can accurately identify models from multiple inputs. Thus, these
inputs can be moved simultaneously during the plant step tests. This speeds the plant step test procedure and
processes that experience frequent disturbances represent no problems to this identification system.
Modeling Quality Check
The model identification software predicts control variable behavior based on manipulated variable values.
These model results can be compared to actual test data. This can be visually analyzed to check the quality of
the model and the model fit.
Data Input and Output File Requirements
The identification package input and output are compatible with Microsoft Excel tab delimited format. Thus,
data can be exported from Excel and results can be imported into Excel. This allows input data and results to
be easily viewed and manipulated in a powerful and familiar environment.
The identification software reads and writes both data sets and model sets. Data sets are test data and/or
predicted data generated from manipulated variables and models. Model sets are the model coefficient results
from identification.
Data Manipulation Tools
The identification software has a number of tools that improve results and make it easy to use:
One can specify that no model exists for a particular manipulated variable/controlled variable pairing. This
ensures that proper MV/CV relationships are established and improves model accuracy.
GE Energy
Page 15
The input data can contain multiple segments of continuous data. This allows test data from multiple test
sessions to be combined to improve model quality.
Sections of continuous data can be removed, such as a portion where an analyzer was being manually
calibrated.
These features help in identifying the complete controller matrix in a single step.
Software Type
This application runs on Intel-Windows 9x and Intel-Windows NT platforms. It has an easy-to-use command
line interface.
Steps/Tools to Build a Controller From Modeling Results
The instrument tag and controller structure configuration (identifying MVs, CVs, etc.) is usually done before the
model identification phase. After plant testing, the complete controller model matrix is identified and imbedded
in the controller and simulator equation files. The controller can then be run with the simulator to study the
response of the controller and establish initial tuning coefficients and clamps.
3. MVC Simulator
The MVC simulator is a real time, nonlinear, dynamic simulator which provides process I/O to the controller in
lieu of the DCS. It is used to verify the control strategy, make tuning adjustments to the controller and simulate
process noise. It can be configured to either have the same models as the controller (perfect model) or
different models (process model mismatch).
The MVC simulator is used to check out the controller prior to putting it in service, during FAT, and also for inhouse and client training. The MVC configurator is used to configure simulator process (models and other
information).
HUMAN-MACHINE INTERFACE
Engineers Interface
The engineers console has an HMI with features similar to those typically available in a DCS. Standard screen
offerings include:
Screens for system setup as well as entering and displaying relevant process variables, setpoints,
predicted versus actual values, ranges, alarms and data validation and filtering.
Data base historian with flexible real time and historical trending.
Interactive, dynamic process graphics with pop-up faceplate, embeddable trends, alarms and messages.
Standard and custom report generation.
Alarm handling including lists of active, acknowledged and cleared status alarms.
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Page 16
Process tuning screens for process time and feedback loop tuning.
Economic summary screens for easy entry or downloading of the latest prices and values.
Password protection for any or all screens, with optional protection for key screen data fields.
Other custom screens, such as constraint handling strategy displays, are included as required by the
application.
Operator Interface
MVC uses both the DCS operator console and a RTIS interface for its control functions. All control functions
reside on either station. The operator interface is a duplicate of the HMI interface.
GE has attempted to make the MVC HMI as user friendly as possible, so it can be easily understood by plant
operators. The operator should be able to take advantage of the benefits of MVC with ease. Tuning and
economic updates of MVC are readily performed by operations personnel. Certain functions, such as
reconfiguration or reparameterization, require intervention by plant engineers or operations supervisors. These
functions require special access to the MVC software, which is not normally granted to the operator and is
password protected.
Performance Monitoring
Each variable in MVC is defined as a tag. Current tag values and MVC predicted future values are displayed
in the HMI. If a tag is defined as a constraint (CV) and its predicted future value is outside its defined HI/LOW
limits, then an alarm is issued. Also, both values are displayed on an operator screen. MVC can be setup to
trend each variable so the operator can track the process performance. The RTIS provides statistical
monitoring software that can be applied to any results derived from the MVC solutions. This gives the user the
tool to determine model performance characteristics.
MVC PROJECT EXECUTION DETAILS

Procedure for Evaluating Economic Performance
GE has post audited several MVC installations to determine economic benefits. The procedure is as follows:
1.
Test the plant early in the project to establish the current operating performance.
2.
After FAT and MVC installation, use the MVC data logging capability to accumulate a period of
performance data before MVC operation (base case).
3.
After MVC SAT, accumulate a period of performance data for MVC advisory operation (open loop).
4.
After MVC commissioning, accumulate a period of performance data for MVC supervisory operation
(closed loop).
The data are analyzed, normalized and plotted for each period of performance (typically 2-5 days each). Using
plant economics, the benefits are calculated using the product values for all periods of performance. If weather
GE Energy
Page 17
conditions introduced significant process variations between tests, then a simulation may be required to adjust
the base case performance to the time of the MVC supervisory mode of operation.
Process Simulator/In-house Controller Tuning

GE has a process simulator that is used to test the controller at the FAT. This simulator is GE written software
that is different from the commercial process simulators used to create the reduced rigorous models such as
HYSIM, T-SWEET, PRO II, ASPEN PLUS, etc. This process simulator is used to dynamically simulate the PVs of the
setpoint and constraint variables as manipulated variable setpoints and disturbance variables are changed.
These mimic the actual instrument inputs of a live plant that are not available in a static testing environment.
This process simulator is built using the same process models that the controller uses. However, flexibility exists
to modify the models making them different from the controller models. In this way, one can test how the
controller behaves when there is plant-model mismatch.
With the use of a process simulator, the controller can be tuned and thoroughly tested without being on-line.
Typical tests include how the controller handles:
setpoint changes
constraints
different MV operator high/low limits
different MV rate of change limits
different MVC constraint/setpoint parameters
disturbances
With the simulator, it is possible to stand-alone test many different scenarios and learn how the controller
interacts with the process. The simulator provides the benefit of pre-testing the MVC controllers prior to tying
them into the plant control system.
Implementation
Figure 9 shows the overall block flow diagram of MVC implementation from project start through completion.
A summary of the steps is as follows:
1.
Perform a plant test to obtain current base case plant data, identify process dynamics and equipment
constraints, and understand plant operating objectives and economics.
2.
Run process simulations and tune models to the actual plant data, determine the control strategies,
and define the relationships of manipulated variables to controlled variables, and disturbances to
controlled variables.
3.
Configure the control strategy in a PC environment, workstation or workstation-based DCS operator

station.
4.
Interface/integrate MVC with the plant control and instrumentation. Instrumentation, analyzer and
control system changes will be made in parallel with steps 2 and 3 during the project.
GE Energy
Page 18
5.
Provide operator and engineering training with complete documentation.
6.
Install, test and tune the system.
7.
Post-audit the results and maintain the system.
Project Implementation
Figure 9
OBTAIN
DETERMINE
CREATE
PRODUCE
PROCESS
INFORMATION
SIMULATE
PROCESS
REPORT
RESULTS
BETTER PROCESS
PERFORMANCE
OPERATING
LOGS
CONTROL
STRATEGIES
DEFINE
ALGORITHMS
TRUE ECONOMIC
OPTIMIZATION
SURVEY
PLANT
CONFIRM
INSTRUMENTS
CONFIGURE
MVC and GUI
COMPETITIVE
OPERATIONS
TEST
PLANT
RECOMMEND
MODIFICATIONS
TRAIN and
DOCUMENT
EMPLOYEE
SATISFACTION
UNDERSTAND
ECONOMICS
CALCULATE
BENEFITS
INSTALL and
COMMISSION
HIGHER
PROFITABILITY
GE Energy
Page 19
PRODUCTS
GE has developed several software modules for various processes and unit operations that may be used alone
or in combination to optimize plant operations. Since no two process unit operations are exactly the same, the
modules require some customization to accommodate process differences. The control strategies, equipment
constraints, operating philosophies and plant economics are configurable. Some of the available software
modules include:
Absorption/Desorption
(Refrigerated and Lean Oil)
Air Separation Cold Box
Amine Gas/Liquid Treating
C2 & C3 Splitters
Compression, Centrifugal
Compression, Reciprocating
Cryogenic Demethanizer/Deethanizer
CO2 Recovery (Ryan-Holmes Rectified
Absorption)
Deethanizer
Ammonia
Methanol
Depropanizer
Debutanizer/Splitter
Deisobutanizer
Depentanizer
Nitrogen Rejection (Rectified Absorption)
Reformer Furnace
Solvent Recovery
Stabilizer - E/P Splitter
Sulfur (Claus) Recovery
Synthesis Converter
Ethylbenzene
Bisphenol-A
Power Generation Optimization with host steam
and tie-line control
If GE does not have a specific module solution available, one can be developed. Standard off-the-shelf process
simulations, yield/conversion models, empirical regression models, as well as client supplied process models,
are used to build the appropriate modules as part of the overall MVC strategy.
GE Energy
Page 20
MVC EXAMPLES
Cryogenic Plant Example
A cryogenic demethanizer is often a key processing element of the gas processing industry. A simple cryogenic
demethanizer flow sheet is shown in the attached diagram. The SP is the bottoms C1/C2 ratio. Though not a
direct controlled variable, maintaining lowest possible expander suction temperature, close to the column flood
points at minimum tower pressure, maximizes C2 recovery. However, in multiple cryogenic units, feed rate
balancing to maximize plant C2 and C3 recovery is an important factor. In this case, the C2 and C3 recovery is
included as SP variables.
The disturbances are feed related variables such as composition, temperature and flow rate. The three
manipulated variables are reboiler gas flow, C3 chiller level and tower pressure. The three constraints are
expander suction temperature, tower differential pressure, and recompressor discharge temperature. An
inferential variable, bottom pressure compensated temperature, is the SP variable for C1/C2 ratio. As the C1/C2
ratio is changed, the bottom PCT is adjusted and controlled to better manage C1/C2 ratio by its inherent
inferential nature. Table A is a listing of the significant variables employed in the MVC strategy, whereas Table
B is the multivariable control matrix.
The MVC multivariable controller manages the C1/C2/bottom PCT control by manipulating the reboiler flow
with some chiller level trimming as required. The expander separator temperature is constraint pushed to its
low limit by manipulating chiller level, with some influence and manipulation of the reboiler flow. The
demethanizer tower is maintained below its flood point by reboiler flow and tower pressure manipulation. The
recompressor discharge temperature maximum limit is maintained by manipulating its suction pressure, which
rides on the tower pressure.
This multivariable control strategy allows maintenance and stable control of bottom C1/C2 ratio specification.
For the ethane recovery mode, it ensures maximum C2 and C3 recovery as the expander separator
temperatures constraint is pushed against its limit without tower flooding implications. Daily variations in feed
disturbances are mitigated in a feed forward predictive fashion.
In multi-cryogenic plant applications of MVC technology, where optimal feed distribution is warranted, the
multivariable controller structure incorporates a C2 recovery SP variable for each cryogenic plant. The objective
of the optimization is to maximize total plant C2 recovery. This is incorporated by allocating feed to the most
efficient plant and thereby increasing the total recovered NGL. In addition this strategy guards against over
allocating feed to the most efficient plant by on-line predictions of C2 recovery in all plants. Thus, an optimal
balancing of gas distribution is obtained as individual plant C2 recoveries change.
TABLE A
VARIABLE NAME
TYPE
TAG
UNITS
Feed Composition
DV
FC
Mole %
Feed Temperature
DV
FT
Feed Rate
DV
FR
MMSCFD
GE Energy
Page 21
Reboiler Flow
MV
RF
MMSCFD
Chiller Level
MV
Level
Pressure
MV
PC
Psig
Bottom Temperature
SP
BT
C1/C2
SP
C1/C2
Mole/mole
C2 Recovery
SP
C2REC
C3 Recovery
SP
C3REC
Expander Suction
Temperature
CONS
EXPT F
Tower dP
CONS
DP
Psig
Recompressor Discharge
Temperature
CONS
DT
TABLE B
CRYO MULTIVARIABLE CONTROL MATRIX
SP/CON
Feed
Composition
Reboiler
Temp.
Chiller
Rate
Tower
Flow
Level
Bottom PCT
C1/C2
Expander Suction Temperature
Tower dP
Recompressor Discharge
Temperature
Pressure
X
X
The Cryogenic Demethanizer Flow Sheet shows both temperature and analyzer measurements for the top
and bottom products. Temperature measurements may be used to inferentially calculate the product
compositions. Periodic laboratory grab samples are often used to update and bias the temperature
GE Energy
Page 22
CRYOGENIC DEMETHANIZER FLOW SHEET
calculations. Alternatively, on-line analyzers with continuous or discontinuous composition measurements are
sometimes found on column product compositions, and in applications with high inlet variability, the inlet feed
composition is often available on-line.
GE Energy
Page 23
Distillation Example
Problem Description
This example considers the case of a binary or two-product fractionator. This type of unit is often found in the
separation and recovery sections of many processes. This example uses the depropanizer shown below in
Figure 10. The column SPs are the top and bottom compositions. The three MVs are the reflux rate, steam rate
and tower pressure. The DVs are the feed flow, temperature and composition, and tower pressure. To simplify
the problem, assume that only the inlet feed rate and composition are varying. Also, due to diurnal operation,
TOWER
MVPRESSURE
PC
RR
FC
LC
FC
SP
TF
MV REFLUX
AI
TC
DVFEED
Fractionator
DP
AI
FC
FR
OVERHEAD
LIQUID
PRODUCT
DELTA P
Figure 10
LC
SR
FC
MV STEAM
T
AI
BF
BC
SP BOTTOMS
LIQUID
PRODUCT
assume that ambient temperature variations, affect the column pressure. The CONs are the column differential
pressure (related to flooding), and the top and bottom specifications.
The top and bottom specifications are CONs due to the MVC concept of dynamic optimal CVs or SPs. The
economically optimal SPs move as the process and prices change. Therefore, the column specifications may
not always be the optimum SP targets. In this case, they are no longer treated as SPs, but rather become
operating constraints. This allows the optimizer to optimize the specification value up to the constraint
(specification) limit. In this way, non-specification values are acceptable as the optimum. Furthermore, if
operations permit, off-specification product may be accepted with some operating penalty. The penalty would
be included in the objective function and the optimizer could determine that the most profitable operation
includes an off-specification penalty. Each of these possibilities is accommodated by MVC. For simplification
GE Energy
Page 24
purposes, this example assumes that specifications cannot be violated, therefore any penalty function is
ignored.
The tower differential pressure is measured to calculate the tower flooding point. This is also a constraint that
cannot be violated, but note that it is a dynamic constraint in that the flooding point will vary with different
feed rates and operating conditions. Therefore, it is necessary to predict this constraint to avoid violating it in
current or future time periods.
The operating objective is to maximize profit given the current set of prices for products, feedstock and utilities,
while honoring process and equipment constraints. Table 1 is a summary of the relevant variables and
parameters pertinent to this example.
Table 1
Relevant Variables and Parameters
Variable Name
Type
Tag
Units
Current Value
Feed Rate
DV
FR
ft3/hr
11,696
Feed Composition
DV
FC
fraction light comp mole %
0.5
Steam Rate
MV
SR
lb/hr
25,660
Reflux Rate
MV
RR
ft3/hr
12,165
Bottom Composition
SP
BC
fraction C3 comp mole %
0.02
Top Composition
SP
TC
0.02
Top Pressure
CON
DP
lbs/in2
10
Bottom Composition
Specification
CON
BCS
0.05
Top Composition
Specification
CON
TCS
0.04
Bottom Flow Rate
CON
BF
lb-mole/sec
1.016
Top Flow Rate
CON
TF
lb-mole/sec
0.9936
GE Energy
Page 25
Optimization
The operating objective for this fractionator is to maximize profitability, expressed, with reference to Table 1, as
the scalar function, f
where:
f = 680275xBF + 680275xTF - 3.175xSR - 1501.8xFR
and
propane =$0.33/gal
butane =$0.38/gal
steam =$3.50/lb
reflux =$4.50/MMBTU
Profitability is expressed as a function of all the process variables, including MVs, DVs, and CVs. The coefficients
in the profit equation are cost conversion factors that create consistent units of dollars/day for the entire
expression. Much more complicated objectives can be expressed. Note that f is nominally a linear function of
the process variables. However, since the dependent CVs are related to the DVs and MVs via the nonlinear
thermodynamic-kinetic +dynamic process model, f is actually a nonlinear function of the independent
variables.
In addition the following constraints on the CVs and MVs must be satisfied:
BC 0.05 of C3
25,383 SR 25,927
TC 0.04 of C4
12,049 RR 12,282
The last two constraints, SR and RR, are the

minimum and maximum top and bottom
flows relating to the valve position limits
during the current execution cycle. The CON
bounds on the bottom composition (BC) and
top composition (TC) represent complex,
nonlinear constraints on the independent
variables as does the tower flooding process
constraint. This is due to the nonlinear nature
of the thermodynamic-kinetic +dynamic
model. Thus, as evidenced by the nonlinear
objective function and the nonlinear
constraints, it is necessary to employ the
nonlinear optimization algorithm, GRG2.
Controller Moves
When the controller is placed on-line and
receives its first round of data from the
process, it proceeds through the calculations
described in the previous section and
produces two predictive trajectories: one for
TC, one for BC. Likewise, the tower flooding
constraint is calculated one period ahead.
Assuming first order dynamics, the
Delta P < flooding point pressure

TC Setpoint
0.08
0.07
Desired SP Predicted SP Spec Limit
0.06
0.05
0.04
0.03
0.02
Figure 11
0.01
0
3
4
5
6
7
8
Trajectory Periods - Control Horizon
10
BC Setpoint
0.08
0.07
Desired SP Predicted SP Spec Limit
0.06
0.05
0.04
0.03
0.02
Figure 12
0.01
0
3
4
5
6
7
8
Trajectory Periods - Control Horizon
GE Energy
10
Page 26
trajectories would look like those in Figures 11 and 12. The dynamic analysis, done during the model
identification and development stage, identifies the dominant MV related to the corresponding SP. In this
example, the reflux ratio (RR) is the dominant MV related to TC, and the steam rate (SR) is the dominant MV
related to BC. So the model times and prediction points are set accordingly. For a column of this type in a gas
plant fractionation train, the time to steady state is typically 20 to 30 minutes. The number of prediction points
is set to 10.
GRG2, calls a series of calculations to solve for an optimal set of MVs that satisfy the SP objectives while not
violating the future BC, TC, SR, RR and delta P constraints. The MV moves are constrained by their high, low and
rate of change limits. Figures 13, 14 and 15 the MV trajectories.
S te a m R a te
2 6 ,0 0 0
2 5 ,9 0 0
F ig u r e 1 3
2 5 ,8 0 0
2 5 ,7 0 0
2 5 ,6 0 0
2 5 ,5 0 0
2 5 ,4 0 0
2 5 ,3 0 0
2 5 ,2 0 0
S t e a m R a t e H ig h L im it L o w L im it
2 5 ,1 0 0
2 5 ,0 0 0
3
4
5
6
7
T r a je c t o ry P e r io d s - C o n t r o lle r H o r iz o n
10
R e f lu x R a t e
1 2 ,3 0 0
1 2 ,2 7 5
F ig u r e 1 4
1 2 ,2 5 0
1 2 ,2 2 5
1 2 ,2 0 0
R e f lu x R a t e
1 2 ,1 7 5
H ig h L im it
1 2 ,1 5 0
L o w L im it
1 2 ,1 2 5
1 2 ,1 0 0
1 2 ,0 7 5
1 2 ,0 5 0
1 2 ,0 2 5
1 2 ,0 0 0
3
4
5
6
7
T r a je c t o r y P e r io d s - C o n t r o lle r H o r iz o n
10
To w e r P re s s u re
15
14
F ig u r e 1 5
13
12
11
10
9
8
7
T o w e r P r e s s u re P re d ic t e d T o w e r P r e s s u re
6
5
3
4
5
6
7
T r a je c t o ry P e rio d s - C o n t r o lle r H o r iz o n
10
GE Energy
Page 27
Upon each controller/optimizer execution cycle, predicted CVs are compared to actual CVs and, along with
MV/DV history, are used to update the model bias term a0. The new optimal CVs are predicted and the
trajectory re-projected one time period forward.
In this example, MVC determines the optimum top and bottom compositions, BCOPT and TCOPT. The appropriate
manipulated variables, SR and RR are calculated to produce the optimum compositions over a series of MV
moves that drive the BC and TC to their optimum composition positions. MVC produces a set of MVs that lead
to the optimum SPs. These SPs produce the maximum unit profit. In this case, minimizing the MVs while moving
the SPs toward their specifications limits is optimum. The results are shown below in Table 2.
Table 2
Optimal Targets
Name
Type
Tag
Units
Optimal Target
Steam Rate
MV
SR
lbs/hr
25,387
Reflux Rate
MV
RR
ft3/hr
10,697
Bottom Composition
SP
BC
0.049
Top Composition
SP
TC
0.039
GE Energy

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GENERAL PRODUCT DESCRIPTION

1999-2004 GENERAL ELECTRIC COMPANY

HUMAN-MACHINE INTERFACE .............................................................................................................................. 15

MVC PROJECT EXECUTION DETAILS ................................................................................................................. 16

1999-2004 GENERAL ELECTRIC COMPANY

Process Simulator/In-house Controller Tuning ............................................................................................................17

1999-2004 GENERAL ELECTRIC COMPANY

MVC Product Description

PLC based systems.

1999 - 2004 GENERAL ELECTRIC COMPANY

MVC Product Description

Typical APC/O System Architecture

1999-2004 GENERAL ELECTRIC COMPANY

MVC Product Description

The basic equation formulation is of the following form:

setpoint or constraint variable

More specifically, the equations are of the form:

is the real/float exponent of MVtermx

1999-2004 GENERAL ELECTRIC COMPANY

MVC Product Description

The allowable forms of DVtermk are the following:

When used in the control equations, MVterms

Controller Logic Diagram

MODEL UPDATE BASED ON

As shown in Figure 2, the controller functionality consists of the following steps:

Calculate appropriate manipulated variable limits.

Using current plant data, update controller equations' a0 terms.

Call the optimization algorithm.

Generate new MV setpoints.

MVC Block Functional Diagram

Figure 3 shows the overall block diagram of

FEEDSTOCK & PRODUCT

In the optimizer mode, the user assigns

1999-2004 GENERAL ELECTRIC COMPANY

MVC/O can be used either

MVC Product Description

During each controller iteration, appropriate

Manipulated Variable Limits

Total Opportunities = a+b+c+d+ ...

On/Off Switch Status

1999-2004 GENERAL ELECTRIC COMPANY

MVC Product Description

Operator High/Low Limits

The current controller output.

For individual MVs, this feature can be disabled.

1999-2004 GENERAL ELECTRIC COMPANY

MVC Product Description

External/Internal Setpoint Control

Controller Optimization Algorithm

1999-2004 GENERAL ELECTRIC COMPANY

MVC Product Description

Controller Optimization Algorithm Infeasibility

The penalty function increases the farther away the

1999-2004 GENERAL ELECTRIC COMPANY

MVC Product Description

Nonlinear Optimization Algorithm

Economic Optimization Algorithm

1999-2004 GENERAL ELECTRIC COMPANY

MVC Product Description

Controller GCOMP Function

The setpoint trajectory for each defined setpoint variable.

Economic Optimizer GCOMP Function