Data Driven Temperature Control of Heat Exchangers
The following poster presents a couple of approaches for temperature control at heat exchanger’s exit. One of the approaches is based on using n-step ahead neural network while the other approach utilizes a combination of control + learning module for temperature control. Designing robust controllers for typical heat exchangers is very challenging primarily because of complexities associated with the synthesis of dynamics of industrial heat exchangers. Even if a dynamics model is synthesized, the accuracy of it would be called into question as there can be lot of unmodeled system dynamics and random noise in input parameters. In many situations, the degree of uncertainty in the model of system being controlled limits the utility of optimal control design. Controller can be manually tuned on the field but it is very difficult to determine manual adjustments that result in overall improvement. These practical challenges call for learning based approaches for temperature control that would result in optimal heat exchanger performance. We utilize the existing mathematical model for air-water system synthesized by Underwood and Crawford for testing our algorithms. Underwood and Crawford developed a model of heating coil by fitting a second-order non-linear equations to measurements of air and water temperature and flow rates obtained from the actual coil. The uncertainties in the model include air and water inlet temperatures and air-flow rate. These uncertainties are modeled as random variables that are sampled from a uniform distribution. The control variable is the water flow rate which is controlled for regulating the air-outlet temperature. Neural networks are frequently used in various literatures for learning time-series. We propose a modified version of neural networks known as n-step ahead neural network that take the state variables and output at time t as input to successfully predict output at time t+n. The variable n is a hyper-parameter which can be optimized based on performance constraints. The n-step ahead neural network was then trained on training data generated from experimental model to high training accuracies. This trained model performed appreciably in its objective to regulate outlet temperature of a heat exchanger. The second approach uses a combination of control and learning module for temperature regulation. The control module used is a proportional controller while the learning module used is steady state neural network. The steady state neural network is used to learn the controller output as a function of random variables and temperature set-point. The proportional controller is then used to compensate for transient behavior of linearized system around various operating points. The algorithm works effectively for temperature regulation as neural network captures the non-linear input-output behavior of closed loop system leaving proportional controller to compensate for steady state errors of a linearized plant. The proposed algorithm’s performances were evaluated against the performance of a PI controller. Further, the robustness of the algorithms were also studied in great detail under small perturbations around tuned parameters of the proposed algorithms.