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9th
International
Symposium
on
Advanced Control
of
Chemical Processes
9th
International
Symposium
on
Control
of
9th
International
Symposium
on Advanced
Advanced
Control
of Chemical
Chemical Processes
Processes
June
7-10,
2015.
Whistler,
British
Columbia,
Canada
June
7-10,
2015.
Whistler,
British
Columbia,
Canada
June 7-10, 2015. Whistler, British Columbia, Canada
9th International Symposium on Advanced Control of Chemical Processes
June 7-10, 2015. Whistler, British Columbia, Canada
ScienceDirect
Model
Model Predictive
Predictive Control
Control in
in Industry:
Industry:
Challenges
and
Opportunities
Challenges
and
Opportunities
Model
Predictive
Control
in Industry:
Challenges
and Opportunities
Michael G. Forbes* Rohit
S. Patwardhan**
Hamza Hamadah** R. Bhushan Gopaluni***
Michael
Michael G.
G. Forbes*
Forbes* Rohit
Rohit S.
S. Patwardhan**
Patwardhan** Hamza
Hamza Hamadah**
Hamadah** R.
R. Bhushan
Bhushan Gopaluni***
Gopaluni***
*Honeywell
Process
Solutions,
North
Vancouver,
BC
V7J
3S4,
Canada
Process
Solutions,
North
Vancouver,
BC
V7J
3S4,
Canada
Michael G. *Honeywell
Forbes*
Rohit
S.
Patwardhan**
Hamza
Hamadah**
R.
Bhushan
Gopaluni***
*Honeywell Process Solutions, North Vancouver, BC V7J 3S4, Canada
**Process
**Process &
& Control
Control Systems
Systems Department,
Department, Saudi
Saudi Aramco,
Aramco, Dhahran,
Dhahran, 31311,
31311, Saudi
Saudi Arabia
Arabia
**Process
&
Control
Systems
Department,
Saudi
Aramco,
Dhahran,
31311,
Saudi
Arabia
*Honeywell
Process
Solutions, North
Vancouver,
BCColumbia,
V7J 3S4, Canada
***
Chemical
and
Biological
Engineering,
University
of
British
Vancouver,
BC
*** Department
Department of
of
Chemical
and
Biological
Engineering,
University
of
British
Columbia,
Vancouver,
BC V6T
V6T 1Z3,
1Z3, Canada
Canada
***
Department
of
Chemical
and
Biological
Engineering,
University
of
British
Columbia,
Vancouver,
BC
V6T
1Z3,
Canada
**Process & Control Systems Department, Saudi Aramco, Dhahran, 31311, Saudi Arabia
*** Department of Chemical and Biological Engineering, University of British Columbia, Vancouver, BC V6T 1Z3, Canada
Abstract: With
With decades of
of successful application
application of model
model predictive control
control (MPC) to
to industrial
Abstract:
Abstract: With decades
decades of successful
successful application of
of model predictive
predictive control (MPC)
(MPC) to industrial
industrial
processes,
practitioners
are
now
focused
on
ease
of
commissioning,
monitoring,
and
automation
of
processes,
practitioners
are
now
focused
on
ease
of
commissioning,
monitoring,
and
automation
of
processes,
practitioners
are
now
focused
on
ease
of
commissioning,
monitoring,
and
automation
of
Abstract: With
decades
of successful
application
ofbetter
model
predictive
control
(MPC) tousability
industrial
maintenance.
Many
industries
do
not
necessarily
need
algorithms,
but
rather
improved
of
maintenance.
Many
industries
do
not
necessarily
need
better
algorithms,
but
rather
improved
usability
of
maintenance.
Many
industries
do
not
necessarily
need
better
algorithms,
but
rather
improved
usability
of
processes,
practitioners
are
now
focusedworkforce
on ease of
of varying
commissioning,
monitoring,
and automation
of
existing
technologies
to
allow
aa limited
expertise
to
easily commission,
use,
and
existing
technologies
to
workforce
of
varying
expertise
to
commission,
use,
existing
technologies
to allow
allow do
a limited
limited
workforce
of better
varying
expertise but
to easily
easily
commission,
use, and
and
maintenance.
Many
industries
not necessarily
need
algorithms,
rather
improved usability
of
maintain
these
valued
applications.
Continuous
performance
monitoring,
and
automated
model
remaintain
these
Continuous
performance
monitoring,
and
model
remaintain technologies
these valued
valuedto applications.
applications.
Continuous
performance
monitoring,
and automated
automated
model
reexisting
allowasavendors
limited
workforce
of varying
expertise
to easily
commission,
use, and
identification
are
being
used
work
to
deliver
automated
adaptive
MPC.
This
paper
examines
identification
are
being
used
as
vendors
work
to
deliver
automated
adaptive
MPC.
This
paper
examines
identification
arevalued
being used
as vendors
work to deliver
automated
adaptive MPC.
This papermodel
examines
maintain
these
applications.
Continuous
performance
monitoring,
and
automated
reindustrial
practice and
emerging research
trends
towards providing
sustained MPC
performance.
industrial
and
research
trends
industrial practice
practice
and emerging
emerging
research work
trendstotowards
towards
providing
sustained
MPC
performance.
identification
are being
used as vendors
deliver providing
automatedsustained
adaptiveMPC
MPC.performance.
This paper examines
Keywords:
industrial
control,
process
control,
model-based
control,by
predictive
control,
adaptive
control,
2015, IFAC
(International
Federation
of Automatic
Control)
Hosting
Elsevier
Ltd.
All rights
reserved.
Keywords:
industrial
process
control,
control,
predictive
control,
adaptive
control,
industrial
practice
andcontrol,
emerging
research
trendsmodel-based
towards
providing
MPC
performance.
Keywords:
industrial
control,
process
control,
model-based
control,sustained
predictive
control,
adaptive
control,
performance
monitoring,
control
applications,
human
factors.
performance
monitoring,
control
applications,
factors.
performance
monitoring,
control
applications,
human
factors.control, predictive control, adaptive control,
Keywords: industrial
control,
process
control, human
model-based
performance monitoring, control applications, human factors.
1. INTRODUCTION
1.
2.1
MPC
Structure
1. INTRODUCTION
INTRODUCTION
2.1 MPC
MPC Structure
Structure
2.1
Model
predictive
control
(MPC)
is
an
industry
accepted
1.
INTRODUCTION
Model predictive
predictive control
control (MPC)
(MPC) is
is an
an industry
industry accepted
accepted One
Model
2.1 MPC
Structure
benefit
of
MPC
is
that
it
determines
the
optimal
actions
technology for
for advanced
advanced control
control of
of many
many processes.
processes. Recall
Recall One
One benefit
benefit of
of MPC
MPC is
is that
that it
it determines
determines the
the optimal
optimal actions
actions
technology
technology
for
advanced
control
of
many
processes.
Recall
to
take
for
large
multi-input,
multi-output
(MIMO)
systems.
Model
predictive
control
(MPC)
is was
an introduced
industry accepted
that
DMC
(dynamic
matrix
control)
around
to
take
for
large
multi-input,
multi-output
(MIMO)
systems.
to
take
for large
multi-input,
multi-output
(MIMO)
systems.
that
DMC (dynamic
(dynamic
matrix
control)
was introduced
introduced
around
One
benefit
of MPC
isadjusts
that itall
determines
the
optimal
actions
that
DMC
matrix
control)
was
around
MPC
simultaneously
inputs
to
control
all
outputs
technology
advanced
control
of many
processes.
Recall
1980
(Cutlerforand
and
Ramaker,
1980);
by 1997
1997
a number
number
of MPC
MPC
simultaneously
adjusts all
all
inputs to
to control
control
allsystems.
outputs
simultaneously
adjusts
inputs
all
1980
(Cutler
Ramaker,
1980);
by
a
of
to
take
for
large
multi-input,
multi-output
(MIMO)
1980
(Cutler
and Ramaker,
1980); by
1997
a number
of while accounting for all process interactions. As a outputs
result,
that
DMC
(dynamic
matrix
control)
was
introduced
around
commercial MPC
MPC software
software packages
packages were
were available
available (see,
(see, for
for while
while
accounting for
for adjusts
all process
process
interactions.
Asallaa outputs
result,
accounting
all
interactions.
As
result,
commercial
MPC
simultaneously
all improve
inputs
to plant
controlperformance
commercial
MPC
software
packages
were
available
(see, for
MPC
often
takes
actions
that
1980
(Cutler
and
Ramaker,
1980);
by
1997
a
number
of
example,
Qin
and
Badgwell
(1997)).
Industrial
expectations
MPC
often
takes
actions
that
improve
plant
performance
MPC
often
takes for
actions
that improve
plant performance
example, Qin
QinMPC
and software
Badgwellpackages
(1997)). were
Industrial
expectations
while
accounting
all experienced
process
interactions.
As achieve.
a result,
example,
and
Badgwell
(1997)).
Industrial
expectations
beyond
what
a skilled
and
operator
can
commercial
available
(see, for
for MPC
MPC have
have
increased from
from providing
providing superior
superior
control
for beyond
beyond
what takes
skilled
and experienced
experienced
operator
can
achieve.
what
aa skilled
and
operator
can
achieve.
for
increased
control
for
MPC
often
actions
that
improve
plant
performance
for
MPC
have
increased
from
providing
superior
control
for
example, Qin systems
and Badgwell
Industrial
expectations
multivariable
to doing
doing(1997)).
so with
minimum
set-up effort
effort However, there are also drawbacks to the use of a single
multivariable
systems
to
so
with minimum
minimum
set-up
beyond
what
a skilled
and drawbacks
experiencedto
multivariable
systems
to
doing
so
with
set-up
effort
However,
there
are also
also
drawbacks
tooperator
the use
usecan
ofachieve.
single
for
MPC
have
increased
from
providing
superior
control
for However,
there
are
the
of
aa single
and ease
ease of
of maintenance.
maintenance. In
In todays
todays process
process industries,
industries,
MPC
MPC
to
control
an
entire
MIMO
system,
which
may
inhibit
and
MPC
and
ease
of
maintenance.
In
todays
process
industries,
MPC
MPC
to
control
an
entire
MIMO
system,
which
may
inhibit
multivariable
systems
to doingsolution
so with minimum
set-up effort MPC
to control
an
MIMO system,
which
may
However,
there
areentire
also drawbacks
to
the
usealternative
of a inhibit
single
is
often considered
considered
a required
required
for many
many applications.
applications.
the
success
of
an
application.
One
obvious
to
is
often
solution
for
is
aa required
solution
for
many
applications.
the success
success of
of an
an application.
application. One
One obvious
obvious alternative
alternative to
to
the
andoften
easeconsidered
of maintenance.
In todays
process
industries,
MPC
MPC
to
control
an
entire
MIMO
system,
which
may
inhibit
At
the
same
time,
resources
of
expert
practitioners
to
putting
all
variables
into
a
single
MPC
is
to
break
up
the
At
the
same
time,
resources
of
expert
practitioners
to
At
the considered
same time,
resources
of expert
practitioners
to putting
putting
all
variables
into
a
single
MPC
is
to
break
up
the
all
variables
into
a
single
MPC
is
to
break
up
the
is
often
a
required
solution
for
many
applications.
success
of
an application.
One
obvious
alternative
to
commission, monitor,
monitor, and
and maintain
maintain MPC
MPC are
are increasingly
increasingly the
problem
into
a number
of
smaller
systems
which
have
limited
commission,
commission,
monitor,
and maintain
MPC are
increasingly
problem
intovariables
numberinto
of smaller
smaller
systems
which
have limited
limited
into
aa number
of
systems
which
have
At
the same
time,
resources
of expert
practitioners
to problem
putting
all
a
single
MPC
is
to
break
up
the
limited.
For
this
reason,
both
vendors
and
customers
are
In
the
following
points,
some
of
the
potential
limited.
For this
this
reason,
both
vendors
andarecustomers
customers
are interactions.
limited.
For
reason,
vendors
and
are
interactions.
In
the following
following
points,
some
of the
the
potential
In
the
points,
some
of
potential
commission,
monitor,
andboth
maintain
MPC
increasingly
problem into
aincluding
number
of
smaller
systems
which
have
limited
looking for
for ways
ways
to sustain
sustain
MPC
performance
with
minimum interactions.
drawbacks
to
all
process
variables
in
a
single
MPC
looking
to
MPC
performance
with
minimum
looking
for
ways
to
sustain
MPC
performance
with
minimum
drawbacks
to
including
all
process
variables
in
a
single
MPC
drawbacks
to
including
all
process
variables
in
a
single
MPC
limited.
For
this
reason,
both
vendors
and
customers
are
interactions.
In
the
following
points,
some
of
the
potential
manual
intervention.
In
this
paper,
some
established
and
are
listed,
along
with
the
comparative
advantage
possible
if
manual
intervention.
In
this
paper,
some
established
and
manual
intervention.
In
this
paper,
some
established
and
are
listed,
along
with
the
comparative
advantage
possible
if
are
listed,
along
with
the
comparative
advantage
possible
if
looking
for
ways
to
sustain
MPC
performance
with
minimum
drawbacks
to
including
all
process
variables
in
a
single
MPC
emerging
trends
in
the
industrial
application
of
MPC
for
the
MPC
is
broken
into
several
smaller
systems:
emerging
trends
in
the
industrial
application
of
MPC
for
emerging
trends
in
the
industrial
application
of
MPC
for
the
MPC
is
broken
into
several
smaller
systems:
manual
this discussed.
paper, someSection
establishedgives
and the MPC is broken into several smaller systems:
sustainedintervention.
performanceIn are
are
sustained
performance
discussed. Section
Section 222 gives
gives are listed, along with the comparative advantage possible if
sustained
performance
are discussed.
emerging
trends
in the industrial
application
of MPC
for the
single
MPC
can
optimize
an
entire
process,
but
it
may
is broken
intooptimize
several smaller
systems:
considerations
in
commissioning
MPC
for
long
term
success.
A
AMPC
single
MPC can
can
optimize
an entire
entire
process, but
but it
it may
may
considerations
in commissioning
commissioning
MPC for
for long
long
term 2success.
success.
single
MPC
an
process,
considerations
in
MPC
term
sustained
performance
areoperation
discussed.
Section
gives A
also
be
difficult
to
understand
and
monitor
performance
of
Section
3
examines
ease
of
as
a
contributing
factor
also
be
difficult
to
understand
and
monitor
performance
of
Section
3
examines
ease
of
operation
as
a
contributing
factor
also
be
difficult
to
understand
and
monitor
performance
of
Section
3 examines
ease of operation
a contributing
factor aA large
singleapplication
MPC can due
optimize
an
entire
process,
but it may
considerations
in
commissioning
MPCas
for
long termindustrial
success.
to
the
large
number
of
interactions
to
successful
applications.
Section
4
discusses
a
large
application
due
to
the
large
number
of
interactions
to
successful
applications.
Section
4
discusses
industrial
a
large
application
due
to
the
large
number
of
interactions
to
successful
applications.
Section as
4 adiscusses
industrial
also
be difficult
to understand
and
monitor
performance
of
Section
3 examines
ease
of operation
contributing
factor
between
variables.
Splitting
the
MPC
into
smaller
systems,
MPC
maintenance
practice,
with aa focus
focus
on performance
performance
between
variables. Splitting
Splitting
thelarge
MPCnumber
into smaller
smaller
systems,
MPC
maintenance
practice,
with
on
between
variables.
the
MPC
into
systems,
MPC
maintenance
practice,
with
a focus
on
performance
amay
large
application
duejudge
to the
of
interactions
to
successful
applications.
Section
4
discusses
industrial
make
it
easier
to
the
behaviour
of
each
MPC.
monitoring and
and adaptive
adaptive control.
control. Section
Section 55 reviews
reviews emerging
emerging
may
make
it easier
easier Splitting
to judge
judge the
the
behaviour
of
each MPC.
MPC.
monitoring
may
make
it
to
each
monitoring
and adaptive
control.
5 reviews
emerging
between
variables.
the behaviour
MPC into of
smaller
systems,
MPC
maintenance
practice,
withSection
a focus
on performance
research
trends
for
industrial
MPC.
research
trends
for
industrial
MPC.
When
a large
large
application
performs
poorly
due to
to
model
research
trends
industrial
MPC.
may make
it easier
to judgeperforms
the behaviour
of each
MPC.
When
application
performs
poorly
due
model
monitoring
and for
adaptive
control.
Section 5 reviews emerging When
aa large
application
poorly
due
to
model
mismatch,
it
may
be
difficult
to
determine
which
2.
COMMISSIONING
AN
MPC
APPLICATION
mismatch,
it application
may be
be difficult
difficult
to
determine
which
research
trends for industrial MPC.
2. COMMISSIONING
COMMISSIONING
AN MPC
MPC APPLICATION
APPLICATION
it
may
to
determine
which
2.
AN
mismatch,
When
a large
performs
poorly
due to model
submodel(s)
need
updating.
Often,
plant
experimentation
submodel(s)
need
updating.
Often, plant
plantdetermine
experimentation
submodel(s)
Often,
experimentation
Sustained
performance of
of an
an MPC
MPC depends
depends on
on many
many
mismatch,
itneed
mayupdating.
which
2. COMMISSIONING
Sustained
performance
and
identification
forbeall
all difficult
models is
istotime
time consuming,
consuming,
or
Sustained
performance
of AN
an MPC
MPCAPPLICATION
depends on
many
and
identification
for
models
or
and
identification
for
all
models
is
time
consuming, or
important decisions
decisions made
made during
during commissioning.
commissioning. An
An MPC
MPC
submodel(s)
need updating.
Often, plant
experimentation
important
introduces
unnecessary
variability
to
the
process.
With
important
decisions
made
during
commissioning.
An
MPC
introduces
unnecessary
variability
to
the
process.
With
Sustained
an MPC
depends has
on a many
introduces
unnecessary
to the consuming,
process. With
that
is easy
easyperformance
to configure,
configure, ofoperate,
operate,
and maintain
maintain
good
and
identification
for when
allvariability
models
or
that
is
to
and
has
good
multiple
small MPCs,
MPCs,
one of
of isthetime
small MPCs
MPCs is
is not
not
that
is
easydecisions
to
configure,
and
maintain has
good
multiple
one
small
important
made operate,
during
commissioning.
Anaa in
MPC
small
MPCs, when
when
one of the
the
smallprocess.
MPCs isWith
not
multiple small
chance
of
long
term
success.
While
examples
are
given
the
introduces
unnecessary
variability
to
the
chance
of
long
term
success.
While
examples
are
given
in
the
performing,
there
are
fewer
models
to
evaluate.
chance
of long
success.
While and
examples
are given
the
performing,
there
are
that
is easy
to term
configure,
operate,
maintain
has are:
a in
good
performing,
there
are fewer
fewer
models
to
evaluate.
following
subsections,
the main
main
themes of
of
this section
section
multiple
small
MPCs,
whenmodels
one of to
theevaluate.
small MPCs is not
following
subsections,
the
themes
this
are:
following
the
main
themes
of this
section
chance
of subsections,
long term success.
While
examples
are
givenare:
in the If
the
controller
cannot
be
used
for
some
reason (a
(a set-up
performing,
there
are
fewer
models
to
evaluate.
If
If the
the controller
controller cannot
cannot be
be used
used for
for some
some reason
reason (a set-up
set-up
MPC structure
structure
and use
use
of
features
affect
maintainability,
subsections,
theof
main
themes
of this
section are:
MPC
MPC
and
of
features
affect
maintainability,
error
for
example),
then
no
controlled
variables
(CVs)
are
following
structure
and
use
features
affect
maintainability,
error
for
example),
then
no
controlled
variables
(CVs)
are
error
for
example),
then
no
controlled
variables
(CVs)
are
controlled.
If the controller
cannot
besmall
used systems,
for someone
reason
(a can
set-up
With
multiple
MPC
be
Difficult
Difficult
MPC
set-up
may
cause
less
robust
tuning
and
controlled.
With
multiple
small
systems,
one
MPC
can
be
MPC
structure
and
use
of
features
affect
maintainability,
controlled.
With
multiple
small
systems,
one
MPC
can
be
MPC
set-up
may
cause
less
robust
tuning
and
Difficult MPC set-up may cause less robust tuning and
error for
then no
variables
(CVs)most
are
turned
offexample),
independently
of controlled
the other
other MPCs,
MPCs,
leaving
model
mismatch
due
to
software
use
errors.
Chances
of
turned
off
independently
of
the
leaving
most
turned
off
independently
of
the
other
MPCs,
leaving
most
model
mismatch
due
to
software
use
errors.
Chances
of
mismatch
due to
software
Chances
of
controlled.
multiple
small
systems, one
MPC can
be
model
Difficult
MPC
set-up
may
cause use
less errors.
robust
tuning and
CVs under
underWith
control.
Some
commercial
packages
have
sustainable
performance
are
immediately
reduced.
CVs
control.
commercial
packages
have
CVs under
control. Some
Some
commercial
packages
have
sustainable
performance
are
immediately
reduced.
sustainable
performance
immediately
reduced.
turned
off independently
of the
other MPCs,
leaving most
model mismatch
due to are
software
use errors.
Chances of
CVsbyunder
Somereserved.
commercial packages have
2405-8963
2015,
IFAC (International
Federation reduced.
of Automatic Control) Hosting
Elseviercontrol.
Ltd. All rights
sustainable
performance
are immediately
533
SP
q = 0.1
220
CV
q =1
2
215
q = 10
2
210
q = 100
205
q = 1000
200
0
2
2
10
Time (min)
15
20
150
q = 0.1
2
140
MV
532
IFAC ADCHEM 2015
June 7-10, 2015. Whistler, BC, Canada
q =1
2
q = 10
130
q = 100
2
120
q = 1000
2
110
100
0
10
Time (min)
15
20
534
Of course, the MPC has to work well, but even a highperforming MPC could fall victim to the above scenarios if
the operators do not understand and trust the application.
Size Press Moisture (%)
4
2
0
0
10
15
Time (min)
20
The operator may turn off the MPC each time he/she does
not understand the control actions, possibly leaving it off
for the rest of the shift,
25
30
8
7
6
5
0
10
15
Time (min)
20
180
Dryer Section 4
Steam Pressure (psi)
533
25
30
160
140
120
100
0
10
15
Time (min)
20
80
25
30
Dryer Section 5
Steam Pressure (psi)
70
60
50
40
30
0
10
15
Time (min)
20
25
30
Level
of
Complexity
Emphasis
Frequency
Management
Low
Application Use;
Financial Impact
Quarterlybiannually
Engineering
High
Core Technology
MonthlyQuarterly
Operations
Medium
Service
factors,
Base-layer control
Dailyweekly
Plant
B
Plant
C
KPI 1
Plant A
535
Target
KPI 2
536
537
538
IFAC ADCHEM 2015
June 7-10, 2015. Whistler, BC, Canada