Degradation modelling in process control applications

Degradation of industrial equipment is often influenced by how a system is operated, with certain operating points likely to accelerate degradation. The ability to mitigate degradation of an industrial system would result in improved performance and decreased costs of operation. The thesis aims to provide ways for managing degradation by adjusting the operating conditions of a system. The thesis provides original insights and a new classification of models of degradation to facilitate the integration of degradation models into process control applications. The thesis also develops an adaptive algorithm for degradation detection and prediction in turbomachinery, which is able to predict the expected future values of a degradation indicator and to quantify the uncertainty of the prediction. The thesis then proposes two frameworks for load-sharing in a compressor station in which the compressors are subject to degradation. One framework considers management of degradation and the other one focuses on power consumption of the whole station. These examples show how modelling of degradation can have an impact on the operation of an industrial system. The approaches have been evaluated with case studies developed in collaboration with industrial partners. As demonstrated in the case studies, the outcomes of the research presented in this thesis provide new ways to take account of degradation in process control applications. The thesis discusses steps and directions for future work to facilitate the technology transfer from academic to industrial implementation.Open Acces

Convergence of Laguerre Impulse Response Approximation for Noninteger Order Systems

One of the most important issues in application of noninteger order systems concerns their implementation. One of the possible approaches is the approximation of convolution operation with the impulse response of noninteger system. In this paper, new results on the Laguerre Impulse Response Approximation method are presented. Among the others, a new proof of convergence of approximation is given, allowing less strict assumptions. Additionally, more general results are given including one regarding functions that are in the joint part of and spaces. The method was also illustrated with examples of use: analysis of “fractional order lag” system, application to noninteger order filters design, and parametric optimization of fractional controllers

Influence of compressor degradation on optimal operation of a compressor station

Normal practice in a compressor station with compressors in parallel is to allocate the mass flows equally. However, this strategy is not optimal if the compressors are not identical. A common reason why compressors become non-identical is because their performance degrades over time. Degradation increases the power necessary to run the compressor station and changes the optimal allocation of mass flows. This paper presents a framework for optimal operation in a compressor station with degrading compressors. The optimisation framework proposed in this work explicitly includes a model of degradation in the optimisation problem and analyses how the optimal load-sharing changes when the compressors are degrading. The optimisation framework was applied in an industrial case study of a compressor station in which three parallel compressors are subject to degradation. The case study confirms that it is possible to minimise the extra power consumption due to degradation by adjusting the operating conditions of the compressor station. The analysis also gives insights into the impact of degradation on the optimal solution when compressors work at their limits

Load-sharing with degradation management in a compressor station

Management of compressor degradation is often considered from the perspective of maintenance of the compressor, but most frameworks for the operation of compressors do not take degradation into account. This paper proposes a method for operation of compressors that takes into account the current level of degradation in order to manage further degradation. The algorithm can be used in maintenance planning frameworks, in particular if the timings of maintenance activities are fixed. The algorithm can extend the lifetime of a compressor by mitigating its degradation, or, conversely, can intensify the degradation to reach the maximum level in time for planned maintenance. The performance of the algorithm has been demonstrated in a case study for five compressors. A comparison with equal load approach shows that the new algorithm improves the operation of the system by managing the degradation of selected compressors. Explicit management of degradation allows an extension of the lifetime of selected compressors before maintenance must be performed. Conversely, by ensuring that the desired level of degradation is attained before pre-planned maintenance actions, it contributes to increased efficacy of maintenance actions. Note to Practitioners —The paper presents a new framework for load-sharing in a compressor station with compressors subject to degradation. The main innovation of the framework is the use of relationships between custom degradation indicators to manage degradation of the compressors. The results in the paper prove that it is possible to manage degradation in an industrial setting by adjusting the load of each compressor. From a practical perspective, the framework allows more degraded compressors to follow the less degraded compressors (called leaders). The simplicity of the proposed framework enables an intuitive choice of leaders, in particular in compressor stations with more than two compressors. Focused directly on the load sharing, the framework al..

Automatic Scenario Generation for Robust Optimal Control Problems

Existing methods for nonlinear robust control often use scenario-based approaches to formulate the control problem as nonlinear optimization problems. Increasing the number of scenarios improves robustness while increasing the size of the optimization problems. Mitigating the size of the problem by reducing the number of scenarios requires knowledge about how the uncertainty affects the system. This paper draws from local reduction methods used in semi-infinite optimization to solve robust optimal control problems with parametric uncertainty. We show that nonlinear robust optimal control problems are equivalent to semi-infinite optimization problems and can be solved by local reduction. By iteratively adding interim globally worst-case scenarios to the problem, methods based on local reduction provide a way to manage the total number of scenarios. In particular, we show that local reduction methods find worst-case scenarios that are not on the boundary of the uncertainty set. The proposed approach is illustrated with a case study with both parametric and additive time-varying uncertainty. The number of scenarios obtained from local reduction is 101, smaller than in the case when all 2 14+3×192 boundary scenarios are considered. A validation with randomly-drawn scenarios shows that our proposed approach reduces the number of scenarios and ensures robustness even if local solvers are used

Automatic scenario generation for efficient solution of robust optimal control problems

Existing methods for nonlinear robust control often use scenario-based approaches to formulate the control problem as large nonlinear optimization problems. The optimization problems are challenging to solve due to their size, especially if the control problems include time-varying uncertainty. This paper draws from local reduction methods used in semi-infinite optimization to solve robust optimal control problems with parametric and time-varying uncertainty. By iteratively adding interim worst-case scenarios to the problem, methods based on local reduction provide a way to manage the total number of scenarios. We show that the local reduction method for optimal control problems consists of solving a series of simplified optimal control problems to find worst-case constraint violations. In particular, we present examples where local reduction methods find worst-case scenarios that are not on the boundary of the uncertainty set. We also provide bounds on the error if local solvers are used. The proposed approach is illustrated with two case studies with parametric and additive time-varying uncertainty. In the first case study, the number of scenarios obtained from local reduction is 101, smaller than in the case when all 2¹⁴⁺³×¹⁹² extreme scenarios are considered. In the second case study, the number of scenarios obtained from the local reduction is two compared to 512 extreme scenarios. Our approach was able to satisfy the constraints both for parametric uncertainty and time-varying disturbances, whereas approaches from literature either violated the constraints or became computationally expensive

Automatic scenario generation for efficient solution of robust optimal control problems

Existing methods for nonlinear robust control often use scenario-based approaches to formulate the control problem as large nonlinear optimization problems. The optimization problems are challenging to solve due to their size, especially if the control problems include time-varying uncertainty. This paper draws from local reduction methods used in semi-infinite optimization to solve robust optimal control problems with parametric and time-varying uncertainty. By iteratively adding interim worst-case scenarios to the problem, methods based on local reduction provide a way to manage the total number of scenarios. We show that the local reduction method for optimal control problems consists of solving a series of simplified optimal control problems to find worst-case constraint violations. In particular, we present examples where local reduction methods find worst-case scenarios that are not on the boundary of the uncertainty set. We also provide bounds on the error if local solvers are used. The proposed approach is illustrated with two case studies with parametric and additive time-varying uncertainty. In the first case study, the number of scenarios obtained from local reduction is 101, smaller than in the case when all 2¹⁴+³ₓ¹⁹² extreme scenarios are considered. In the second case study, the number of scenarios obtained from the local reduction is two compared to 512 extreme scenarios. Our approach was able to satisfy the constraints both for parametric uncertainty and time-varying disturbances, whereas approaches from literature either violated the constraints or became computationally expensive

Data-Driven Predictive Control With Improved Performance Using Segmented Trajectories

A class of data-driven control methods has recently emerged based on Willems’ fundamental lemma. Such methods can ease the modeling burden in control design but can be sensitive to disturbances acting on the system under control. In this article, we propose a restructuring of the problem to incorporate segmented prediction trajectories. The proposed segmentation leads to reduced tracking error for longer prediction horizons in the presence of unmeasured disturbance and noise when compared with an unsegmented formulation. The performance characteristics are illustrated in a set-point tracking case study in which the segmented formulation enables more consistent performance over a wide range of prediction horizons. The method is then applied to a building energy management problem using a detailed simulation environment. The case studies show that good tracking performance is achieved for a range of horizon choices, whereas performance degrades with longer horizons without segmentation

Automatic scenario generation for efficient solution of robust optimal control problems

Existing methods for nonlinear robust control often use scenario-based approaches to formulate the control problem as large nonlinear optimization problems. The optimization problems are challenging to solve due to their size, especially if the control problems include time-varying uncertainty. This paper draws from local reduction methods used in semi-infinite optimization to solve robust optimal control problems with parametric and time-varying uncertainty. By iteratively adding interim worst-case scenarios to the problem, methods based on local reduction provide a way to manage the total number of scenarios. We show that the local reduction method for optimal control problems consists of solving a series of simplified optimal control problems to find worst-case constraint violations. In particular, we present examples where local reduction methods find worst-case scenarios that are not on the boundary of the uncertainty set. We also provide bounds on the error if local solvers are used. The proposed approach is illustrated with two case studies with parametric and additive time-varying uncertainty. In the first case study, the number of scenarios obtained from local reduction is 101, smaller than in the case when all $2^{14+3\times192}$ extreme scenarios are considered. In the second case study, the number of scenarios obtained from the local reduction is two compared to 512 extreme scenarios. Our approach was able to satisfy the constraints both for parametric uncertainty and time-varying disturbances, whereas approaches from literature either violated the constraints or became computationally expensive.Comment: arXiv admin note: substantial text overlap with arXiv:2204.14145 (IFAC conference submission

Application of gaussian processes to online approximation of compressor maps for load-sharing in a compressor station

Devising optimal operating strategies for a compressor station relies on the knowledge of compressor characteristics. As the compressor characteristics change with time and use, it is necessary to provide accurate models of the characteristics that can be used in optimization of the operating strategy. This paper proposes a new algorithm for online learning of the characteristics of the compressors using Gaussian Processes. The performance of the new approximation is shown in a case study with three compressors. The case study shows that Gaussian Processes accurately capture the characteristics of compressors even if no knowledge about the characteristics is initially available. The results show that the flexible nature of Gaussian Processes allows them to adapt to the data online making them amenable for use in real-time optimization problems