ECONOMIC PLANTWIDE CONTROL

How to design the control system for a complete plant in a systematic manner Sigurd Skogestad
Department of Chemical Engineering Norwegian University of Science and Tecnology (NTNU) Trondheim, Norway

Brazil July 2011

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Plantwide control lectures. Sigurd Skogestad

Outline (6 lectures)
Control structure design (plantwide control) A procedure for control structure design
I Top Down Lecture 1 (49)

Step S1: Define operational objective (cost) and constraints Step S2: Identify degrees of freedom and optimize operation for disturbances Step S3: Implementation of optimal operation What to control ? (primary CVs) (self-optimizing control) Lecture 2 (71)+ Step S4: Where set the production rate? (Inventory control) Lecture 3 (36)

II Bottom Up
Step S5: Regulatory control: What more to control (secondary CVs) ? Lecture 4 (62)+ Distillation column control Step S6: Supervisory control Lecture 5 (19) Step S7: Real-time optimization

PID tuning (+ decentralized control if time)

Lecture 6 (54)

*Each lecture is 2 hours with a 10 min intermediate break after about 55 min (no. of slides) + means that it most likely will continue into the next lecture

Plantwide control intro course: Contents

Overview of plantwide control Top-down. Selection of primary controlled variables based on economic : The link between the optimization (RTO) and the control (MPC; PID) layers
- Degrees of freedom - Optimization - Self-optimizing control - Applications

Where to set the production rate and bottleneck Bottom-up. Design of the regulatory control layer ("what more should we control")
- stabilization - secondary controlled variables (measurements) - pairing with inputs

Design of supervisory control layer

- Decentralized versus centralized (MPC) - Pairing and RGA-analysis

Summary and case studies

Main references
The following paper summarizes the procedure:
S. Skogestad, ``Control structure design for complete chemical plants'', Computers and Chemical Engineering, 28 (1-2), 219-234 (2004).

There are many approaches to plantwide control as discussed in the following review paper:
T. Larsson and S. Skogestad, ``Plantwide control: A review and a new design procedure'' Modeling, Identification and Control, 21, 209-240 (2000).

The following paper updates the procedure:

S. Skogestad, ``Economic plantwide control, Book chapter in V. Kariwala and V.P. Rangaiah (Eds), Plant-Wide Control: Recent Developments and Applications, Wiley (late 2011). http://www.nt.ntnu.no/users/skoge/publications/2011/skogestad-plantwide-control-book-by-kariwala/

All papers available at: http://www.nt.ntnu.no/users/skoge/

S. Skogestad ``Plantwide control: the search for the self-optimizing control structure'', J. Proc. Control, 10, 487-507 (2000). S. Skogestad, ``Self-optimizing control: the missing link between steady-state optimization and control'', Comp.Chem.Engng., 24, 569575 (2000). I.J. Halvorsen, M. Serra and S. Skogestad, ``Evaluation of self-optimising control structures for an integrated Petlyuk distillation column'', Hung. J. of Ind.Chem., 28, 11-15 (2000). T. Larsson, K. Hestetun, E. Hovland, and S. Skogestad, ``Self-Optimizing Control of a Large-Scale Plant: The Tennessee Eastman Process'', Ind. Eng. Chem. Res., 40 (22), 4889-4901 (2001). K.L. Wu, C.C. Yu, W.L. Luyben and S. Skogestad, ``Reactor/separator processes with recycles-2. Design for composition control'', Comp. Chem. Engng., 27 (3), 401-421 (2003). T. Larsson, M.S. Govatsmark, S. Skogestad, and C.C. Yu, ``Control structure selection for reactor, separator and recycle processes'', Ind. Eng. Chem. Res., 42 (6), 1225-1234 (2003). A. Faanes and S. Skogestad, ``Buffer Tank Design for Acceptable Control Performance'', Ind. Eng. Chem. Res., 42 (10), 2198-2208 (2003). I.J. Halvorsen, S. Skogestad, J.C. Morud and V. Alstad, ``Optimal selection of controlled variables'', Ind. Eng. Chem. Res., 42 (14), 3273-3284 (2003). A. Faanes and S. Skogestad, ``pH-neutralization: integrated process and control design'', Computers and Chemical Engineering, 28 (8), 1475-1487 (2004). S. Skogestad, ``Near-optimal operation by self-optimizing control: From process control to marathon running and business systems'', Computers and Chemical Engineering, 29 (1), 127-137 (2004). E.S. Hori, S. Skogestad and V. Alstad, ``Perfect steady-state indirect control'', Ind.Eng.Chem.Res, 44 (4), 863-867 (2005). M.S. Govatsmark and S. Skogestad, ``Selection of controlled variables and robust setpoints'', Ind.Eng.Chem.Res, 44 (7), 2207-2217 (2005). V. Alstad and S. Skogestad, ``Null Space Method for Selecting Optimal Measurement Combinations as Controlled Variables'', Ind.Eng.Chem.Res, 46 (3), 846-853 (2007). S. Skogestad, ``The dos and don'ts of distillation columns control'', Chemical Engineering Research and Design (Trans IChemE, Part A), 85 (A1), 13-23 (2007). E.S. Hori and S. Skogestad, ``Selection of control structure and temperature location for two-product distillation columns'', Chemical Engineering Research and Design (Trans IChemE, Part A), 85 (A3), 293-306 (2007). A.C.B. Araujo, M. Govatsmark and S. Skogestad, ``Application of plantwide control to the HDA process. I Steady-state and selfoptimizing control'', Control Engineering Practice, 15, 1222-1237 (2007). A.C.B. Araujo, E.S. Hori and S. Skogestad, ``Application of plantwide control to the HDA process. Part II Regulatory control'', Ind.Eng.Chem.Res, 46 (15), 5159-5174 (2007). V. Lersbamrungsuk, T. Srinophakun, S. Narasimhan and S. Skogestad, ``Control structure design for optimal operation of heat exchanger networks'', AIChE J., 54 (1), 150-162 (2008). DOI 10.1002/aic.11366 990-999 (2008). T. Lid and S. Skogestad, ``Data reconciliation and optimal operation of a catalytic naphtha reformer'', Journal of Process Control, 18, 320-331 (2008). E.M.B. Aske, S. Strand and S. Skogestad, ``Coordinator MPC for maximizing plant throughput'', Computers and Chemical Engineering, 32, 195-204 (2008). A. Araujo and S. Skogestad, ``Control structure design for the ammonia synthesis process'', Computers and Chemical Engineering, 32 (12), 2920-2932 (2008). E.S. Hori and S. Skogestad, ``Selection of controlled variables: Maximum gain rule and combination of measurements'', Ind.Eng.Chem.Res, 47 (23), 9465-9471 (2008). V. Alstad, S. Skogestad and E.S. Hori, ``Optimal measurement combinations as controlled variables'', Journal of Process Control, 19, 138-148 (2009) E.M.B. Aske and S. Skogestad, ``Consistent inventory control'', Ind.Eng.Chem.Res, 48 (44), 10892-10902 (2009).

+ MORE

Idealized view of control (PhD control)

Practice: Tennessee Eastman challenge problem (Downs, 1991) (PID control)

How we design a control system for a complete chemical plant?

Where do we start? What should we control? and why? etc. etc.

Alan Foss (Critique of chemical process control theory, AIChE Journal,1973):

The central issue to be resolved ... is the determination of control system structure. Which variables should be measured, which inputs should be manipulated and which links should be made between the two sets? There is more than a suspicion that the work of a genius is needed here, for without it the control configuration problem will likely remain in a primitive, hazily stated and wholly unmanageable form. The gap is present indeed, but contrary to the views of many, it is the theoretician who must close it.

Carl Nett (1989):

Minimize control system complexity subject to the achievement of accuracy specifications in the face of uncertainty.

Control structure design

Not the tuning and behavior of each control loop, But rather the control philosophy of the overall plant with emphasis on the structural decisions:
Selection of controlled variables (outputs) Selection of manipulated variables (inputs) Selection of (extra) measurements Selection of control configuration (structure of overall controller that interconnects the controlled, manipulated and measured variables) Selection of controller type (LQG, H-infinity, PID, decoupler, MPC etc.).

That is: Control structure design includes all the decisions we need make to get from ``PID control to PhD control

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Process control:

Plantwide control = Control structure design for complete chemical plant

Large systems Each plant usually different modeling expensive Slow processes no problem with computation time Structural issues important
What to control? Extra measurements, Pairing of loops

Previous work on plantwide control:

Page Buckley (1964) - Chapter on Overall process control (still industrial practice) Greg Shinskey (1967) process control systems Alan Foss (1973) - control system structure Bill Luyben et al. (1975- ) case studies ; snowball effect George Stephanopoulos and Manfred Morari (1980) synthesis of control structures for chemical processes Ruel Shinnar (1981- ) - dominant variables Jim Downs (1991) - Tennessee Eastman challenge problem Larsson and Skogestad (2000): Review of plantwide control

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Control structure selection issues are identified as important also in other industries.
Professor Gary Balas (Minnesota) at ECC03 about flight control at Boeing:

The most important control issue has always been to select the right controlled variables --- no systematic tools used!

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Main objectives control system

1. Stabilization 2. Implementation of acceptable (near-optimal) operation ARE THESE OBJECTIVES CONFLICTING? Usually NOT
Different time scales
Stabilization fast time scale Reference value (setpoint) available for layer above But it uses up part of the time window (frequency range)

Stabilization doesnt use up any degrees of freedom

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Dealing with complexity

Main simplification: Hierarchical decomposition

Process control The controlled variables (CVs) interconnect the layers

OBJECTIVE
RTO

Min J (economics); MV=y1s cs = y1s Follow path (+ look after

other variables)

MPC

y2s
PID
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CV=y1

(+ u);

MV=y2s

Stabilize + avoid drift CV=y2; MV=u u (valves)

Hierarchical decomposition

Example: Bicycle riding

Note: design starts from the bottom

Regulatory control:
First need to learn to stabilize the bicycle
CV = y2 = tilt of bike MV = body position

Supervisory control:
Then need to follow the road.
CV = y1 = distance from right hand side MV=y2s

Usually a constant setpoint policy is OK, e.g. y1s=0.5 m

Optimization:
Which road should you follow? Temporary (discrete) changes in y1s

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Plantwide control decisions

No matter what procedure we choose to use, the following decisions must be made when designing a plantwide control strategy: Decision 1. Select economic (primary) controlled variables (CV1) for the supervisory control layer (the setpoints CV1s link the optimization layer with the control layers). Decision 2. Select stabilizing (secondary) controlled variables (CV2) for the regulatory control layer (the setpoints CV2s link the two control layers). Decision 3. Locate the throughput manipulator (TPM). Decision 4. Select pairings for the stabilizing layer, that is, pair inputs (valves) and controlled variables (CV2). By valves is here meant the original dynamic manipulated variables.

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Skogestad plantwide control structure design procedure

I Top Down
Step S1: Define operational objectives (optimal operation) Cost function J (to be minimized) Operational constraints Step S2 (optimization): (a) Identify degrees of freedom (MVs). (b) Optimize for expected disturbances and find regions of active constraints Step S3 (implementation): Select primary controlled variables c=y1 (CVs)

y1 y2
MVs Process

(Decision 1).

Step S4: Where set the production rate? (Inventory control) (Decision 3)

II Bottom Up
Step S5: Regulatory / stabilizing control (PID layer) What more to control (y2; local CVs)? y (Decision 2) Pairing of inputs and outputs y (Decision 4) Step S6: Supervisory control (MPC layer) Step S7: Real-time optimization (Do we need it?)

Understanding and using this procedure is the most important part of this course!!!!

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Comment: Luyben procedure

Step L1. Establish control objectives Step L2. Determine control degrees of freedom Step L3. Establish energy management system Step L4. Set the production rate (Decision 3) Step L5. Control product quality and handle safety, environmental and operational constraints Step L6. Fix a flow in every recycle loop and control inventories Step L7. Check component balances Step L8. Control individual unit operations Step L9. Optimize economics and improve dynamic controllability

Notes: Establish control objectives in step L1 does not lead directly to the choice of controlled variables (Decisions 1 and 2). Thus, in Luybens procedure, Decisions 1, 2 and 4 are not explicit, but are included implicitly in most of the steps. Even though the procedure is systematic, it is still heuristic and ad hoc in the sense that it is not clear how the authors arrived at the steps or their order. A major weakness is that the procedure does not include economics, except as an afterthought in step L9.
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Outline
Skogestad procedure for control structure design
I Top Down
Step S1: Define operational objective (cost) and constraints Step S2: Identify degrees of freedom and optimize operation for disturbances Step S3: Implementation of optimal operation What to control ? (primary CVs) (self-optimizing control) Step S4: Where set the production rate? (Inventory control)

II Bottom Up
Step S5: Regulatory control: What more to control (secondary CVs) ? Step S6: Supervisory control Step S7: Real-time optimization

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Step S1. Define optimal operation (economics)

What are we going to use our degrees of freedom u (MVs) for? Define scalar cost function J(u,x,d)
u: degrees of freedom (usually steady-state) d: disturbances x: states (internal variables) Typical cost function:

J = cost feed + cost energy value products

Optimize operation with respect to u for given d (usually steady-state):

minu J(u,x,d)
subject to: Model equations: Operational constraints: f(u,x,d) = 0 g(u,x,d) < 0

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Optimal operation distillation column

Distillation at steady state with given p and F: N=2 DOFs, e.g. L and V Cost to be minimized (economics)
cost energy (heating+ cooling)

J = - P where P= pD D + pB B pF F pV V value products

cost feed

Constraints Purity D: For example xD, impurity max Purity B: For example, xB, impurity max Flow constraints: min D, B, L etc. max Column capacity (flooding): V Vmax, etc. Pressure: 1) p given, 2) p free: pmin p pmax Feed: 1) F given 2) F free: F Fmax Optimal operation: Minimize J with respect to steady-state DOFs

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Optimal operation
minimize J = cost feed + cost energy value products

Two main cases (modes) depending on marked conditions:

Mode 1. Given feedrate
Amount of products is then usually indirectly given and J = cost energy. Optimal operation is then usually unconstrained:

maximize efficiency (energy)

Mode 2. Maximum production

Control: Operate at optimal trade-off (not obvious what to control to achieve this)

Products usually much more valuable than feed + energy costs small. With feedrate as a degree of freedom, optimal operation is then usually constrained by bottleneck. Control: Focus on tight control of
bottleneck (obvious what to control) 22

Outline
Skogestad procedure for control structure design
I Top Down
Step S1: Define operational objective (cost) and constraints Step S2: Identify degrees of freedom and optimize operation for disturbances Step S3: Implementation of optimal operation What to control ? (primary CVs) (self-optimizing control) Step S4: Where set the production rate? (Inventory control)

II Bottom Up
Step S5: Regulatory control: What more to control (secondary CVs) ? Step S6: Supervisory control Step S7: Real-time optimization

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Step S2 (Optimize operation): (a) Identify degrees of freedom (b) Optimize for expected disturbances
Need good steady-state model Goal: Identify regions of active constraints Time consuming!

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Example with Quiz: Optimal operation of two distillation columns in series

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QUIZ 1

Operation of Distillation columns in series

With given F (disturbance): 4 steady-state DOFs (e.g., L and V in each column)

N=41 AB=1.33

> 95% A pA=1 $/mol

N=41 BC=1.5

> 95% B pB=2 $/mol

F ~ 1.2mol/s pF=1 $/mol

< 4 mol/s

< 2.4 mol/s

> 95% C pC=1 $/mol Energy price: pV=0-0.2 $/mol (varies)

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DOF = Degree Of Freedom Ref.: M.G. Jacobsen and S. Skogestad (2011)

Cost (J) = - Profit = pF F + pV(V1+V2) pAD1 pBD2 pCB2 QUIZ: What are the expected active constraints? 1. Always. 2. For low energy prices.

SOLUTION QUIZ 1

Operation of Distillation columns in series

With given F (disturbance): 4 steady-state DOFs (e.g., L and V in each column)

N=41 AB=1.33

> 95% A pA=1 $/mol

N=41 BC=1.5

> 95% B pB=2 $/mol

F ~ 1.2mol/s pF=1 $/mol

1. xB = 95% B Spec. valuable product (B): Always active! Why? Avoid Hm.? product give-away
< 4 mol/s < 2.4 mol/s

Energy price: pV=0-0.2 $/mol (varies)

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DOF = Degree Of Freedom Ref.: M.G. Jacobsen and S. Skogestad (2011)

2. Cheap energy: V1=4 mol/s, V2=2.4 mol/s > 95% C Max. column capacity constraints active! pC=1 $/mol Why? Overpurify A & C to recover more B Cost (J) = - Profit = pF F + pV(V1+V2) pAD1 pBD2 pCB2 QUIZ: What are the expected active constraints? 1. Always. 2. For low energy prices.

SOLUTION QUIZ 1 (more details)

Active constraint regions for two distillation columns in series

Energy price
[$/mol]

BOTTLENECK
Higher F infeasible because all 5 constraints reached

[mol/s] 28
CV = Controlled Variable

QUIZ 2

Active constraint regions for two distillation columns in series

Energy price
[$/mol]

[mol/s] 29
CV = Controlled Variable

QUIZ. Assume low energy prices (pV=0.01 $/mol). How should we control the columns?

QUIZ 2

Control of Distillation columns in series

PC LC PC LC

Given

LC

LC

30 Red: Basic regulatory loops

QUIZ. Assume low energy prices (pV=0.01 $/mol). How should we control the columns?

Comment

Control of Distillation columns in series

PC LC PC LC

T1

TC

T1s

T2

TC

T2s

Given

LC

LC

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Comment: Should normally stabilize column profiles with temperature control, Should use reflux (L) in this case because boilup (V) may saturate. T1S and T2S would then replace L1 and L2 as DOFs but leave this out for now..
Red: Basic regulatory loops

Back to QUIZ 2

Control of Distillation columns in series

PC LC PC LC

Given

LC

LC

32 Red: Basic regulatory loops

QUIZ. Assume low energy prices (pV=0.01 $/mol). How should we control the columns?

SOLUTION QUIZ 2

Control of Distillation columns in series

PC LC xB CC 1 unconstrained DOF (L1): Hm. Use for what?? CV=? Not: CV=CONTROL xA in D1! (why? xA should CONSTRAINTS! vary with F!) HINT: ACTIVE xBS=95% PC LC

Given

MAX V2 MAX V1 General for remaining unconstrained DOFs: LOOK FOR SELF-OPTIMIZING CVs = Variables we can keep constant LC WILL GET BACK TO THIS! LC

Maybe: constant L1? (CV=L1) Better: CV= xA in B1? Self-optimizing?

33 Red: Basic regulatory loops

QUIZ. Assume low energy prices (pV=0.01 $/mol). How should we control the columns?

SOLUTION QUIZ 2 (more details)

Active constraint regions for two distillation columns in series

1
Energy price

1
[$/mol]

2 3 2 1
[mol/s]

Cheap energy: 1 remaining unconstrained DOF (L1) -> Need to find 1 additional CVs (self-optimizing) More expensive energy: 3 remaining unconstrained DOFs -> Need to find 3 additional CVs (self-optimizing)
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CV = Controlled Variable

Plans for next lectures

Step 2 (Find optimal operation using offline calculations):
Step 2a : DOF analysis (steady-state) (12 slides) Step 2b: Optimize for expected disturbances (1 slide)

Step 3 (Implementation of optimal operation) (Lecture 2)

Identify primary (economic) controlled variables (CVs): 1. Control active constraints. Backoff 2. Remaining unconstrained: Find self-optimizing CVs Will use a lot of time on this!

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Steady-state DOFs

Step S2a: Degrees of freedom (DOFs) for operation

NOT as simple as one may think! To find all operational (dynamic) degrees of freedom: Count valves! (Nvalves) Valves also includes adjustable compressor power, etc. Anything we can manipulate! BUT: not all these have a (steady-state) effect on the economics

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Steady-state DOFs

Steady-state degrees of freedom (DOFs)

IMPORTANT! DETERMINES THE NUMBER OF VARIABLES TO CONTROL! No. of primary CVs = No. of steady-state DOFs
Methods to obtain no. of steady-state degrees of freedom (Nss): 1. Equation-counting
Nss = no. of variables no. of equations/specifications Very difficult in practice Nss = Nvalves N0ss Nspecs N0ss = variables with no steady-state effect

2. Valve-counting (easier!) 3. Potential number for some units (useful for checking!) 4. Correct answer: Will eventually find it when we perform optimization

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CV = controlled variable (c)

Steady-state DOFs

Steady-state degrees of freedom (Nss): 2. Valve-counting

Nvalves = no. of dynamic (control) DOFs (valves) Nss = Nvalves N0ss Nspecs : no. of steady-state DOFs
N0ss = N0y + N0,valves : no. of variables with no steady-state effect N0,valves : no. purely dynamic control DOFs N0y : no. controlled variables (liquid levels) with no steady-state effect Nspecs: No of equality specifications (e.g., given pressure)

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Steady-state DOFs

Typical Distillation column

4 5 3

1 With given feed and pressure: NEED TO IDENTIFY 2 more CVs - Typical: Top and btm composition 6 2

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Nvalves = 6 , N0y = 2 , NDOF,SS = 6 -2 = 4 (including feed and pressure as DOFs)

N0y : no. controlled variables (liquid levels) with no steady-state effect

QUIZ 3

Steady-state DOFs

Heat-integrated distillation process

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Nvalves = 11 (w/feed), N0y = 4 (levels), Nss = 11 4 = 7 (with feed and 2 pressures) Need to find 7 CVs!

Steady-state DOFs

Heat exchanger with bypasses

CW

Nvalves = 3, N0valves = 2 (of 3),

Nss = 3 2 = 1

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Steady-state DOFs

Steady-state degrees of freedom (Nss): 3. Potential number for some process units
each external feedstream: 1 (feedrate) splitter: n-1 (split fractions) where n is the number of exit streams mixer: 0 compressor, turbine, pump: 1 (work/speed) adiabatic flash tank: 0* liquid phase reactor: 1 (holdup reactant) gas phase reactor: 0* heat exchanger: 1 (bypass or flow) column (e.g. distillation) excluding heat exchangers: 0* + no. of sidestreams pressure* : add 1DOF at each extra place you set pressure (using an extra valve, compressor or pump), e.g. in adiabatic flash tank, gas phase reactor or absorption column
*Pressure is normally assumed to be given by the surrounding process and is then not a degree of freedom Ref: Araujo, Govatsmark and Skogestad (2007) Extension to closed cycles: Jensen and Skogestad (2009) Real number may be less, for example, if there is no bypass valve

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Steady-state DOFs

Heat exchanger with bypasses

CW

Potential number heat exchanger

Nss = 1

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Steady-state DOFs

Distillation column (with feed and pressure as DOFs)

split

Potential number,
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Nss= 0 (distillation) + 1 (feed) + 2*1 (heat exchangers) + 1 (split) = 4 With given feed and pressure: Nss = 4 2 = 2

Steady-state DOFs

Heat-integrated distillation process

Potential number, Nss = 1 (feed) + 2*0 (columns) + 2*1 (splits) + 1 (sidestream) + 3 (hex) = 7
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QUIZ 4

Steady-state DOFs

HDA process
Purge (H2 + CH4)

Compressor

H2 + CH4 Toluene

Mixer

FEHE

Furnace

PFR

Quench

Separator
Toluene Benzene

Cooler

CH4

Toluene Column

Benzene Column

Stabilizer

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Diphenyl

QUIZ 4 solution

Steady-state DOFs

HDA process: steady-state degrees of freedom

8 7

feed:1.2

3 1 Hm.. Consider -Feeds 2 -Heat exchangers -Splitters -Compressors -Distillation columns 13 11

hex: 3, 4, 6 splitter 5, 7 compressor: 8

4 5 6

distillation: 2 each column

14

12

10

Conclusion: 14 steady-state DOFs

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Assume given column pressures

Steady-state DOFs

Check that there are enough manipulated variables (DOFs) - both dynamically and at steady-state (step 2) Otherwise: Need to add equipment
extra heat exchanger bypass surge tank

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Step S2b: Optimize with respects to DOFS (u) for expected disturbances (d) .. and identify regions of active constraints
minu J(u,x,d)
subject to: Model equations: Operational constraints: f(u,x,d) = 0 g(u,x,d) < 0
d2 = energy price

d1 = feedrate

Idea: Prepare operation for expected future disturbances, incl. price changes In principle: simple In practise: very time consuming
Commercial simulators (Aspen, Unisim/Hysys) are set up in design mode and often work poorly in operation (rating) mode.
Example Heat exchanger Easy (Design mode): Given streams (and temperatures), find UA Difficult (Operation mode): Given UA, find outlet temperatures We use Matlab or even Excel on top Heat exchanger: Let Matlab/Excel vary temperatures to match given UA

Optimization methods in commercial simulators often poor

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Focus on most important disturbances and range. Whole picture is complicated

Ref. Jacobsen and Skogestad, ESCAPE21, Greece, 2011