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Experimental Design
Not just
process
control
Plant Experimentation
Determine Model Structure
Parameter Estimation
Diagnostic Evaluation
Alternative
data
Model Verification
Complete
Experimental Design
Plant Experimentation
Determine Model Structure
Parameter Estimation
Diagnostic Evaluation
T
A
Model Verification
Complete
Safely
Small effect on product quality
Small effect of profit
We will stick with linear.
What order, dead time, etc?
Parameter Estimation
Diagnostic Evaluation
Model Verification
Complete
45
15
S = maximum slope
35
11
25
K p /
15
/S
shown in figure
-1
-5
-5
0
10
20
time (min)
30
40
o u tp u t va ri a b l e i n d e vi a ti o n (K )
i n p u t va ri a b l e i n d e vi a ti o n (% o p e n )
45
15
K p /
35
11
0.63
t 63%
25
0.28
15
-1
t28%
-5
0
10
t63%
-5
20
time (min)
30
40
o u tp u t va ri a b l e i n d e vi a ti o n (K )
i n p u t va ri a b l e i n d e vi a ti o n (% o p e n )
55
47
43
55
39
45
0
10
20
time
30
40
51
Method II
Developed first
Developed in 1960s
Prone to errors
because of evaluation
of maximum slope
Simple calculations
Recommended
Experimental Design
Plant Experimentation
Determine Model Structure
45
15
35
11
25
15
-1
Parameter Estimation
-5
-5
0
10
20
time (min)
30
Diagnostic Evaluation
Model Verification
Complete
40
o u tp u t va ri a b l e i n d e vi a ti o n (K )
Start
i n p u t va ri a b l e i n d e vi a ti o n (% o p e n )
Experimental Design
Plant Experimentation
Determine Model Structure
45
15
35
11
25
15
-1
Parameter Estimation
-5
-5
0
10
20
time (min)
30
40
Diagnostic Evaluation
Model Verification
Complete
o u tp u t va ri a b l e i n d e vi a ti o n (K )
Start
i n p u t va ri a b l e i n d e vi a ti o n (% o p e n )
i n p u t va ri a b l e , % o p e n
Start
35
11
25
15
Parameter Estimation
-1
Diagnostic Evaluation
-5
-5
0
10
20
time
30
Model Verification
Complete
40
o u tp u t va ri a b l e , d e g re e s C
15
Start
Experimental Design
Plant Experimentation
Determine Model Structure
Parameter Estimation
i n p u t va ri a b l e , % o p e n
15
35
11
25
15
-1
-5
-5
0
10
20
time
30
Diagnostic Evaluation
Model Verification
Complete
40
o u tp u t va ri a b l e , d e g re e s C
45
10
35
25
15
-2
-6
Plant Experimentation
Determine Model Structure
Parameter Estimation
i n p u t va ri a b l e , % o p e n
Experimental Design
Diagnostic Evaluation
-5
Model Verification
Complete
-10
0
20
40
time
60
80
45
Plant Experimentation
Determine Model Structure
Parameter Estimation
i n p u t va ri a b l e , % o p e n
Experimental Design
35
25
15
-2
-6
Diagnostic Evaluation
-5
Model Verification
Complete
-10
0
20
40
time
60
80
Experimental Design
i n p u t va ri a b l e , % o p e n
Plant Experimentation
15
measured
35
11
25
15
predicted
-1
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-5
0
10
20
time
30
40
o u tp u t va ri a b l e , d e g re e s C
45
dY (t )
Y (t ) K p X (t )
dt
Y (s) K pe
X (s) s 1
'
Yi 1 predicted
a Yi
'
measured
a e t /
b K p (1 e t / )
/ t
'
X i measured
min
Y
'
predicted
Yi
'
measured
Y
'
predicted
Yi
'
measured
EMPIRICAL MODEL
BUILDING
PROCEDURE
The model parameters
are evaluated at
numerous values of the
dead time, = /t,
and the result giving
the lowest sum of error
squared is taken as the
best estimate of all
parameters.
Always compare with
data.
15
35
11
25
15
Plant Experimentation
Determine Model
Structure
Parameter Estimation
Diagnostic Evaluation
i n p u t va ri a b l e , % o p e n
Experimental Design
-1
-5
-5
Model Verification
0
Complete
10
20
time
30
40
o u tp u t va ri a b l e , d e g re e s C
Start
Y
'
m e a su re d o u tp u t - p re d i c ti o n , d e g re e s
Start
'
Y
i
predicted
measured
Random?
1.5
0.5
-0.5
-1
Model Verification
-1.5
0
Complete
10
20
time
30
40
F
CA0
CA
A B
rA kCA
dC' A
V
F(C' A0 C' A ) Vk C'A
dt
dC A'
C A' KC A' 0
dt
V
F
with
and K
F kV
F kV
Feature
Input magnitude
Experiment duration
Input change shape
Model structure
Accuracy with
unmeasured
disturbances
Diagnostics
Calculations
Statistical method
Can be much smaller
Steady state not required
Arbitrary, sufficient information
required
General linear dynamic model
Poor with significant disturbance
Plot residuals
Requires spreadsheet or other
computer program
output
0
0
10
15
20
25
30
m3
% open
T1 ( s )
G tank1 ( s )
F0 ( s )
3
m
1.2 K /
250 s 1
Gsensor ( s )
Gtank2 ( s )
T2 ( s ) 1.0 K / K
T1 ( s )
300 s 1
Tmeasured ( s )
T2 ( s )
1 .0 K / K
10 s 1
(Time in seconds)
Fresh
feed
flow is
constant
Pure
product
Reactor
Mostly
unreacted
feed
Software Laboratory
- S_LOOP program to simulate experimental step
data, with noise if desired