ADVANCED PROCESS

CONTROL
KIL 4006
Prof. Ir. Dr. Mohd Azlan Bin Hussain
Introduction
• Studies have been shown that 40% of process loops are under
performing.
• Millions of dollars lost due to process variability and non
optimal control performance.
• Advanced control needed to reduce these variability and
increase quality and throughput.
• Advanced control needed to locate hidden variability and
under performing control loops.
• Advanced control needed to achieve more precise control
and reduce energy consumption and improve sustainability of
a process.
 Economical benefit with advanced
control techniques
Limit

Safety
Margin
= Profit

Target

APC Reduce Reduced variation allows

No APC
Variation operation closer to limit

Source from : Paul S. A., Zoltan K. N., Mircea V. C., Arpad I. L., Model Based
Control: Case Studies in Process Engineering, Wiley-VCH , 2006
 Typical operating regions with and
without Advanced Control (AC)
Optimal operating
region given
by AC
∆T
Typical operating ∆P
region (No AC)

Temperature
Pressure

Quality
Definition of Advanced control
• Earlier, advanced control defined as algorithm or strategy that
differed from the PID controller.
• Later, advanced control was associated with implementation
of computer based technologies.
• Definition of advanced differ from academic and industries at
times.
Comprehensive definition would be:
• “ Controller and/or control strategies different from the
conventional PID and/or conventional control strategy. ”
• Also can be further defined under ‘classical’ and ‘modern’
advanced control techniques.
• Classical refers to Cascade, Ratio, feed forward, time delay
compensator.
Main Categories of Advanced Control, (AC)

AC

Model Artificial
Adaptive Intelligence
PID based based
(linear & Non-linear) based
(linear & Non-linear)

E.g.: E.g.:
E.g.: Neural-
Autotuners GMC,MPC Network
Adaptive PID based
Controllers
Examples of Industrial Adaptive
PID (Autotuners)
1. Honeywell - UDC3200 controller

2. Emerson - Delta V adapt controller

3. Foxboro - Exact controller

4. Yokogawa - SLPC controller

5. Spirax Sarco – SX75 controller

Model based controllers
linear & Non-linear
Types of Model-Based controllers
• Model Predictive Controller (MPC)

• Globally Linearizing Controller (GLC)

• Generic Model Controller (GMC)

• Sliding Model controller

• Inverse Model Controller

Model Predictive Controller (MPC)
• Initiated at Shell Oil and other refineries during late 70s.
• The most applied advanced control technique in the process
industries.
• >5000 worldwide installations + unknown number of “in-
house” installations at present.
• Majority of applications (67%) are in refining and
petrochemicals. Chemical and pulp and paper are the next
areas.
• Models used are predominantly models developed through
plant testing.
• Technology is used not only for multivariable control but for
most economic operation within constraint boundaries.
 MPC General Framework
Theoretical Remove
Set-point optimization formulation
process Determine controlled
ill-conditioning process subsets

Dynamic optimization

MPC Output feedback

(State and disturbance
Theoretical formulation
; estimation)

I/O: Write MVs I/O: Read MVs, DVs, CVs

Lower level controllers

Plant
Operational Hierarchy : with MPC

Conventional

Advanced Control
Examples of MPC based controllers
DMC
1st generation: IDCom

• QDMC
2 generation:
nd

IDCom-M
3 generation:
rd
PFC

Process Perfector
4th generation:
DMC Plus
Delta V predict
3dMPC system
Profit Controller
Pavilion8
SMOC
 Summary of Linear MPC industrial
applications by area Refining
Petrochem
Others; 36.00% Chemicals
Automotive; 0.25; 0.25% Air & Gas
Furnace; 0.25; 0.25%
Refining; 45.00%
Food; 0.5; 0.50% Mining
Utility; 0.5; 0.50%
Polymer
Pulp & Paper; 0.5; 0.50%
Aerospace; 0.5; 0.50% Aerospace
Polymer; 0.5; 0.50% Petrochem; 12.00% Pulp & Paper
Mining; 0.5; 0.50%
Utility
Air & Gas; 0.5; 0.50%
Chemicals; 3.00% Food
Furnace
Automotive
Others
Source from : Paul S. A., Zoltan K. N., Mircea V. C., Arpad I. L., Model Based
Control: Case Studies in Process Engineering, Wiley-VCH , 2006
 Summary of Non-linear NMPC
applications by area
Others
Refining

Polymer; 23.00% Others ; 2.00% Chemicals

Refining ; 14.00%
Pulp &
Paper
Chemicals ; 23.00%
Food; 10.00%
Air & Gas
Utility; 8.00%
Pulp & Paper; 1.00%
Utility
Air & Gas; 19.00%
Food
Polymer

Source from : Paul S. A., Zoltan K. N., Mircea V. C., Arpad I. L., Model Based
Control: Case Studies in Process Engineering, Wiley-VCH , 2006
Types of Model-Based controllers
• Model Predictive Controller (MPC)

• Globally Linearizing Controller (GLC)

• Generic Model Controller (GMC)

• Sliding Model controller

• Inverse Model Controller

• Internal Model Control Strategy

Globally Linearizing Controller (GLC)

Linear Linearizing State Output

Process
Controller Feedback Map

Globally Linearizing Control Structure (GLC)

Types of Model-Based controllers
• Model Predictive Controller (MPC)

• Globally Linearizing Controller (GLC)

• Generic Model Controller (GMC)

• Sliding Model controller Other

Model-Based
• Inverse Model Controller Controller
Other Model-based controller formulation

•Generally, Nonlinear plant model:

• Control input u given as

• All the different nonlinear control strategy

differ in the formulation of the external input,
V
• Eg: in GMC, the external input is
Artificial-Intelligence based
Controllers
Artificial Intelligence based Controller
• Neural network based controller
– NNDIC
– NNIMC
– ANNIMC
• Fuzzy logic based control
– Conventional Fuzzy Logic Controller (FLC)
– Adaptive Fuzzy Logic Controller (AFLC)
• Genetic algorithm based controller