Abstract: A method for controlling a plant to achieve desired operating results. Select operating parameters of the plant are measured and input to a plurality of transforms that define select actions to be taken by an operator of the plant as a function of the measured select operating parameters. Each of the transforms is associated with a portion of the measured select operating parameters and is operable to determine if a predetermined and associated condition exists in the plant, which would warrant the associated action being taken. The measured select operating parameters are processed through the associated transforms to determine for each of the transforms if the associated condition is present. An indication that the condition associated with any of the transforms is present, and for which transform, is provided to a user. A suggestion of the action to be taken for the associated indication is then provided to the user.

Abstract: A method and apparatus for controlling a non-linear mill. A linear controller is provided having a linear gain k that is operable to receive inputs representing measured variables of the plant and predict on an output of the linear controller predicted control values for manipulatible variables that control the plant. A non-linear model of the plant is provided for storing a representation of the plant over a trained region of the operating input space and having a steady-state gain K associated therewith. The gain k of the linear model is adjusted with the gain K of the non-linear model in accordance with a predetermined relationship as the measured variables change the operating region of the input space at which the linear controller is predicting the values for the manipulatible variables. The predicted manipulatible variables are then output after the step of adjusting the gain k.

Abstract: A neural network system is provided that models the system in a system model (12) with the output thereof providing a predicted output. This predicted output is modified or controlled by an output control (14). Input data is processed in a data preprocess step (10) to reconcile the data for input to the system model (12). Additionally, the error resulted from the reconciliation is input to an uncertainty model to predict the uncertainty in the predicted output. This is input to a decision processor (20) which is utilized to control the output control (14). The output control (14) is controlled to either vary the predicted output or to inhibit the predicted output whenever the output of the uncertainty model (18) exceeds a predetermined decision threshold, input by a decision threshold block (22).

Abstract: An on-line optimizer is provided wherein a boiler (720) is optimized by measuring a select plurality of inputs to the boiler (720) and mapping them through a predetermined relationship that defines a single value representing a spacial relationship in the boiler that is a function of the select inputs. This single value is then optimized with the use of a plant optimizer (818) which provides an optimized value. This optimized value is then processed thought the inverse relationship of the single modified value to provide modified inputs to the plant that can be applied to the plant.

Abstract: A predictive network is disclosed for operating in a runtime mode and in a training mode. The network includes a preprocessor (34') for preprocessing input data in accordance with parameters stored in a storage device (14') for output as preprocessed data to a delay device (36'). The delay device (36') provides a predetermined amount of delay as defined by predetermined delay settings in a storage device (18). The delayed data is input to a system model (26') which is operable in a training mode or a runtime mode. In the training mode, training data is stored in a data file (10) and retrieved therefrom for preprocessing and delay and then input to the system model (26'). Model parameters are learned and then stored in the storage device (22). During the training mode, the preprocess parameters are defined and stored in a storage device (14) in a particular sequence and delay settings are determined in the storage device (18).

Abstract: A continuous emission monitoring system for a manufacturing plant (10) includes a control system (16) which has associated therewith a virtual sensor network (18). The network (18) is a predictive network that receives as inputs both control values to the plant (10) and also sensor values. The network (18) is then operable to map the inputs through a stored representation of the plant (10) to output a predicted pollutant sensor level. This predicted pollutant sensor level is essentially the prediction of an actual pollutant sensor level that can be measured by a pollutant sensor (14). The network (18) therefore is a substitute for the pollutant sensor (14), thus providing a virtual sensor. The sensor values from the plant (10) are first processed through a sensor validation system (22).