MPC model monitoring and diagnosis for non-square systems

Many industrial model predictive control applications, called non-square systems, have more variables to be controlled than manipulated variables available. At these cases, the control objectives are related to keep the controlled ones within a range, instead in reference value (setpoint). Assessing the model quality of these controllers is fundamental, however, most available MPC assessment methods are setpoint dependent, providing misleading results when these are unavailable. The methods proposed by Botelho et al. (2015, 2016a, 2016b) allow the model assessment of linear MPCs independently from the setpoints. Even though such methodologies have this advantage, there is not a procedure to assess this kind of controller. Therefore, this paper presents a guideline to apply Botelho et al. (2015, 2016a, 2016b) methods in non-square MPCs. The Shell Heavy Oil Process is used as a case study. The results demonstrate that the procedure is capable of estimate the effect of modeling problems and indicate the associated controlled variable, as well as whether the problem is due to a model-plant mismatch or unmeasured disturbance in non-square controllers.