On-line dynamic advisor from MPC models

A method for creating an on-line operator advisor for use in process simulation and for training simulators for a process having a plurality of independently controllable, manipulated variables and at least one controlled variable dependent upon said independently controllable, manipulated variables;

• said process operating under a defined regulatory control scheme of proportional-integral-derivative (PID) controllers;
• comprising the steps of:
• gathering data about said process by separately introducing a test disturbance in each of said manipulated variables and measuring the effect of the disturbances on said controlled variable;
• using said effects of the disturbances on said controlled variable to generate a first linearized dynamic model relating said at least one controlled variable to said independently controllable, manipulated variables;
• interchanging selected final control element position controlled variables with their corresponding selected independently controllable, manipulated proportional-integral-derivative (PID) controller set point variables in said first linearized dynamic model using matrix row elimination mathematics to generate a second linearized dynamic model that has a new set of independently controllable, manipulated variables, said second linearized dynamic model having the dynamics of said selected independently controllable, manipulated proportional-integral-derivative (PID) controller set point variables removed from said second linearized dynamic model and replaced with final control element positions;
• and
• externally emulating the regulatory control scheme via mathematical emulators to emulate proportional-integral-derivative (PID) controllers in manual, cascade, or automatic modes to obtain a completed on-line operator advisor of said process.