DESALINATION

ELSEVIER

Desalination 152 (2002) 175-184

www.el sevier.com/locate/desal

Application of hybrid modeling and control techniques to

desalination plants
A. Gambier*, E. Badreddin
Automation Laboratory, University of Mannheim, 68131 Mannheim, Germany
Tel. +49 (621) 181-2740," Fax +49 (621) 181-2739; emails: gambier@,ti.uni-mannheim.de,
badreddin@ti, uni-mannheim,de

Received 30 March 2002; accepted 15 April 2002

Abstract

One of the most recent and most intense efforts in control theory deals with handling systems whose behavior of
interest is determined by interacting continuous and discrete dynamics. This approach can be applied not only to
intrinsic hybrid processes but also to other systems as for example continuous processes with supervisory logic,
multi-model control systems, switching control, etc. In this paper, hybrid systems are briefly introduced and possible
applications to desalination plants are given by means of illustrative examples.
Keywords: Hybrid systems; Hybrid control; Dynamic modeling; Desalination plants

1. Introduction

Many physical systems are hybrid in the sense

that they have barriers or limitations. Inside the
limitations they are modeled with differential
equations. A natural way to model these systems
is to use a mixture of differential equations and
inequalities. Other systems have switches and
*Corresponding author.

relays that can be naturally modeled as hybrid

systems. These hybrid models appear in many
areas. Typical examples are flight control, air traffic
control, missile guidance, process control, robotics
etc. Although modes can be strictly speaking not
discrete, it can be advantageous to model systems
in that way. An example o f this is when a nonlinear
system is modeled with a set o f linear models each
one covering a part of the state space. Desalination

Presented at the EuroMed 2002 conference on Desalination Strategies in South Mediterranean Countries:
Cooperation between Mediterranean Countries of Europe and the Southern Rim of the Mediterranean.
Sponsored by the European Desalination Society and Alexandria University Desalination Studies and Technology
Center, Sharm El Sheikh, Egypt, May 4-6, 2002.

0011-9164/02/$- See front matter 2002 Elsevier Science B.V. All rights reserved
PII: S 0 0 1 1 - 9 1 6 4 ( 0 2 ) 0 1 0 6 0 - 3

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A. Gambier, E. Badreddin / Desalination 152 (2002) 175-184

plants are also examples of complex large-scale

systems that fit more than one of the above-described
characteristics. Therefore, the application of hybrid
modeling and control can be an interesting approach
to improve plant performance, efficiency, safety
and reliability.
The first attempt to obtain a dynamical model
of an MSF-process has already been reported
in [1]. A second effort [2] applies empirical corrections for the evaporation rates. Simulations
realized with this model by [3] showed significant
deviations in the cooling water rate. Advanced
models for MSF plants can be found in [4-9].
The most common approaches for controlling
MSF plants are based on decentralized PID control
loops. A survey on control of desalination plants
can be found in [10]. Another approach was proposed by [11]. It consists in a parameter scheduling
PID adaptive control for a subsystem defined by
the most important six inputs and six outputs.
Because brine temperature at the first-stage input
is the most important variable in the plant, several
efforts have been carried out to improve the control
performance at this point by using advanced
techniques. For example, in [12] fuzzy conti'ol
was successfully applied, and [13] implemented
an evolutionary PID fuzzy controller for the same
purposes.
Regarding reverse osmosis plants (RO), mass
transfer models were reviewed by [14]. Moreover,
[15] reported a simplified dynamic model for an
industrial plant. In [16], an overview of process
control of desalination plants is given and [17]
presented advanced control techniques for RO
plants. In [18], an approach based on DMC
(Dynamic Matrix Control) was compared with
standard PID control.
Even though hybrid modeling and design
techniques have developed in the last 10 years
with good results particularly in the area of
supervisory control, applications in the area of
desalination have still not been reported in the
literature. This paper gives a brief introduction
to hybrid systems and examples how they can be
applied to desalination plants.

2. Modeling hybrid systems

There are many approaches to model hybrid
systems. A common characteristic consists in that
the state space S has both discrete and continuous
variables, e.g. S c R" Z ~. The equations can be
linear or nonlinear and in general the discrete parts
cannot be separated from the continuous parts.
The models proposed by various researchers differ
in definition of and restrictions on dynamic behavior.
The difference between the models are on aspects
as generality, allowance o f state jumps, dynamic
restrictions, etc. Many models do not allow fast
switching or sliding.
A hybrid model, like all models, should be
sufficiently complex to capture the rich behavior
of the systems. However, it should also be easy
enough to be analyzed, and formulated in such a
way that simulation is possible. Different areas
of control science have their proper model structures and there is no unified approach or any
agreement on what is the most fruitful compromise
between model generality and expressibility (for
a review of different approaches see for example
[19]. The most used approaches to model hybrid
systems are hybrid automata [20] and Petri nets
[21,22]. In this article, hybrid automata are used.

2.1. Hybrid automaton

The hybrid automaton is an extension of the

traditional finite state machine. It can be defined
by a three-couple (N, F, L). The network N is also
called finite state machine or finite automaton. It
is a directed graph characterized by the ordered
pair (V,A). Visa set of vertices andA c Vx Visa
set ofdir~ted arcs between vertices. Fig. 1 illusWates
a network with three vertices V= {v~,v2,v3} and
the arcs A = {(Vl,V2), (v2,v3), (v3,vl) }. A marked
network is defined by N = (V,A,kt),where I~: Vg{0,1 }.
~t (vl) = 1 means that the vertex vj is marked, i.e.
v t is the current state, kt can be described by a
vector Ix, where the value of the i-th component
is the marked vertex and the other components
are equal to zero. The value that this vector takes

A. Gambler, E. Badreddin / Desalination 152 (2002) 175-184

at time t is denoted by I,t (t). Thus, kt represents

the discrete state of the hybrid system.
F is a finite Lipschitz continuous vector field.
(1)

F={J],f2,...,f,}

where f : R" ---) R for i = 1, ... n. E a c h f maps the

continuous state space R" back into itself and
represents a continuous dynamical system. It
generates state trajectories x: R ---) R" through the
differential equation

xCt) = Z

u(t))

(2)
(3)

x ( t o) = x o

The four-triple y = (Jc, x, x0, to) characterizes

the continuous state of the hybrid system.
L is the interface between N and F. It is
represented as a mapping from the network's
vertices and arcs of N in a prepositional logic P.
The equations used for the labeling are of the form:
Invariant equations: e . g . f (x(t), u(t)) = 0
Guard equations: they have the form g (x) > 0,
where g: R" ~ R is a function defined over the
continuous-state space R".
The logical propositions labeling the network
vertices and arcs can be defined in a variety of
ways. In this contribution, it is assumed that
networks arcs are labeled with guard equations
and vertices with invariant equations This is
shown in Fig. 1.

xE+x_~>0~(x,u)_~

Fig. 1. Example of a very simple hybrid automaton.

3. Example 1: brine heater model of a MSF

plant

The brine heater is one of the most important

subsystems in a MSF plant. It is the physical

177

decoupling interface between the electrical power

subsystem and the desalination units. Damages
in the tube bundle will produce damages in eleclrical
unit (return of saline steam condensate). Fouled
tubes introduce important changes in the plant
performance. In [23], it was pointed out that the
control of Top Brine Temperature (TBT) is decisive
to reach the overall stability and economy of plant
operation. The system also presents non-linear
characteristics.
For the brine heater, it is possible to define
22 variables and 19 equations, so that the degree
of freedom is 3. Thus, tree control loops can be
introduced in order to obtain an exactly specified
equation system. A very important controlled and
measured variable is the TBT on the heater output
shown here as Tb. The TBT depends on the steam
temperature ( T ) , the brine temperature (To), the
brine flow rate (Fb) and the steam flow rate (F~),
all at the heater input. T, depends on the temperature of the incoming steam, which is assumed
constant, and on the water spray flow (Fd) (its
control variable) from the desuperheater. F j is
defined as control variable for Tb. Tb, is the temperature gained in the heat recovery section and
therefore it is an output variable for this section
and cannot be directly manipulated at this point.
On the other hand, a minimum water level in the
sump must be guaranteed in order to maintain the
load of the condensate extraction pump constant.
Hence, there is an additional controlled variable:
the condensate level (/) in the sump, the control
variable is Fco. Moreover, mass of steam (m),
mass of brine (mb), specific enthalpy of steam (h)
and condensate level (lc) can be selected as state
variables. The equations for the brine heater are
obtained from salt, mass and energy balance as
well as from the thermodynamic properties of
steam (IAPWS-IF97, [24] and the properties
correlations for saltwater [25].
The model can be summarized as follows (see
[26] for details):
dm~ =Fs,(t)_Fci(t)

dt

(4)

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A. Gambier, E. Badreddin / Desalination 152 (2002) 175-184

1--~-[F~.,(t)[h,,(t)-h,(t)]+ F~,(t)[h~(t)-h~(t)]-Q~(,)]

if m~ > 0

ms

1--L[F~,(t)[h,(t)-h~(t)l-Q,(t)]

dt

if m~ > O a n d P > P ~ x

d~_
dt

if m,=O

1 [F~;(t)-F~(t)]

(8)

PcAo

F~; (t) ITs,(t) - Tc(t)]

pcAol~

d~_
dt

if 0 < l c <lm~x

l---!---[F~,(t)[T~,(t)T~
Qw(t)
~,~
(t)]- 1---C

if l~>lm~

peA& L

(9-12)

[Fc;(t)[T~,(t) - T~(t)]- Faom(t)ATm]

if 0</~ and Fb~-F b * 0

if /~=0

if Fb, (t) = F b(t)

dC~ = I 0

dt

dt

(5-7)

m s

1---~[Fd.,.Cb(t)-[F~;(t)+ Fd.,.(t)~7"~(t)]

if Fb, (t) F b(t)

(pcAolc

= & , ( t ) - F~(t)

(13,14)

(15)

if mb > 0

d~_
dt

(0]]

Ira,,LR~,(,)[r~,(,)- r~(ol+ ~----[O.c.(') + Oc

if lc >/max

if m b = 0

(16-18)

A. Gambier, E. Badreddin / Desalination 152 (2002) 175-184

Q(t)

(19)

= % (t)Ah, AT,n

AT., =[rb,-

Tl,]/ln/Tsa' - T---b~

(20)

rso,-g,)

Fc(t ) =
[ As2,mpA2i,
P c ~ ' A ~ : 2 i , ~2[glc -(Pp,,,p - Psa,)/ Oc]

(21)

In order to simulate this model, a hybrid

automaton can be implemented. That is, the model
is driven by a finite state machine, which launches
the correct equation when the corresponding conditions are satisfied. Table 1 shows some possible
discrete states for the hybrid model.
This hybrid automaton is shown in Fig. 2,
where guards, jumps and states are shown. Note
that the automaton also brings information for a
higher supervision level, which can be used for
fault handling purposes.

179

Table 1
Possible discrete states to define a hybrid model
Discrete state

Mnemonic Equations

Normal operation
NO
High pressure
HP
No condensate
NC
No brine
NB
No steam
NS
No condensate--no brine N C N B
No brine---no steam
NBNS
Salt in condensate
SC
High condensate level
HCL

1,2,5,6,10,12,13
1,3,5,6,10,12,13
1,2,5,9,10,12,13
1,2,5,6,10,12,15
1,4,5,9,10,12,13
1,2,5,9,10,12,15
1,4,5,9,10,12,15
1,2,5,8,11,12,13
1,2,5,7,10,12,14

4. Example 2: top brine temperature supervisory

control of a MSF plant
Traditional control strategies for MSF plants
arc based on fixed PID controllers. However, it
can be shown that fixed PID controllers cannot
bring satisfactory control performance for wide
operating conditions. Therefore, in [ 12] a parameter
scheduling adaptive scheme for six operating

Alarm signal:

Venting system is not

working correctly

P~>P~x and

To5

'ondensate

To Salt in Condensa

e is brocken

Fig. 2. Automaton for the treatment of discrete events for the brine heater.

180

A. Gambier, E Badreddin / Desalination 152 (2002) 175-184

points was proposed. Such strategy presents in

general some difficulties as for example: detection
of the operating point changes, controller switching
method (or parameter switching for the same controller) bumpless parameter change and stability
issues due to switching control. Here, these problems
will be treated by introducing a hybrid automaton
in the control system according to Fig. 3.
reference

.~Ctmtro|lers~

Su~r

4.2. The supervisor

The supervisor is responsible for detecting
operating point changes and producing a bumpless
switching when the parameters are changed. Its
structure is schemed in Fig. 4. The first task is
implemented by using the Min-switching strategy
and the second one by using standard procedures
for bumpless transfer [28].

4.3. Detection of operating point change: Minswitching strategy

H)brld

ContinuousModel~

Fig. 3. General hybrid control strategy.

4.1. Control law

As control laws, the PID controller is used:
u(t) =

g e K,,r(t) - y ( t ) + 1 fe('c)dr
"l;g

with anti-windup mechanism (integration stop).

The parameters for the PID controller can be tuned
according to the Ziegler-Nichols rules.

- Tep(t)

The problem is to find a stable closed-loop

control system for a continuous time process, several
controllers and a logic system that commands the
switches between these controllers. Malmborg
[27] proposed a solution based on a set of controllers
coupled to a set of Lyapunov functions. The key
idea is to associate each linear model with a
separated Lyapunov function and construct the
logic-switching device in such a way that the
composite system is stable. The switching strategy
selects the controller corresponding to the Lyapunov
function with the smallest value. This is known
as the Min-switching strategy and it has been shown
to be stable (see [28] for details of implementation).

Stateof nonlinearsystem

vj

[&2:l Hybrid
Automaton

V3.1

r,)

&tl

s.p.)

Fig. 4. General scheme for the supervisor.

181

A, Gambier, E. Badreddin / Desalination 152 (2002) 175-184

4.4. Bumpless transfer

Because the controller is a dynamic system, a

change in its parameters will result in changes of
the control signal even if the input is kept constant.
Methods to introduce bumpless switching differ
in the form that they set e(t) and d(t) to zero.
One important point here consists in deciding
when the p a r a m e t e r s w i t c h i n g should be
undertaken. One possibility is to do this when the
new set point is reached. Another one consists in
doing this when the trajectory crosses the
switching surfaces. The fist case has the advantage
that the switching is carried out when the steady
state is reached (i.e. e(t) and ~(t) equal to zero)
satisfying the condition for bumpless transfer. The
drawback is the retard introduced between the
change detection and the parameter switching.
Fig. 5 shows the hybrid automaton for the
supervisor.

Reverse osmosis desalination plants require

that the feed seawater should be pretreated to
minimize deposition of fine particles, mud and
scaling compounds. This activity is normally carried
out in tanks like it is shown in Fig. 6. The pump
at the tank output is also very important in order
to maintain the feed pressure at levels specified
by the membrane manufacturer. Thus, a control
level in the tank is necessary to avoid drainage and
overflow, and to compensate flow rate variations
due to changes in the chemical additives. The tank
model comprises three different states corresponding to normal, empty and full operating conditions with the dynamic mass balance equation
tacking a different form in each of them. The pump
model has two states corresponding to operational
(p = 1) and non-operational (p = 0) modes. The

Sj2>
_ 0 and $41 > 0

$12< 0 and S41 > 0

e = 0 and &=

5. Example 3: level control of the pretreatment

stage in a RO plant

e= 0 and k=0

S~z> 0 and $23 < 0

Sn2_<0 and $23 <

Oand ~=0
S12< 0 TM

,,=0 and ~=0

and S41 <~

e = 0 and
S41 >and S~

$34 > 0 and $4~< 0

e = 0 and e = 0

e= 0 and e 0

Set CPi = Set Controller parameter set number i

Fig. 5. Hybrid automatonfor the supervisor.

~k~$23< 0 and
~ 534<0

34-<0 and
541 < 0

Sl2> 0 and
\&3_>O

$34> 0 and S~ > 0

e= 0 and ~=0

$23>-"Oand $34< 0

Set Cond. = Set conditions for e = 0 and e = 0

182

A. Gambler; E. Badreddin / Desalination 152 (2002) 175-184

s.p.

pretreatment
chemical

automated functions o f the plant. The introduction

of hybrid modeling and control leads to more complex computer controlled systems and therefore
to more complicated analysis and design tools,
which are still being developed. The studies are
just in an initial state and much effort should be
undertaken in order to implement such systems.

seawat~

, to the
~embrane
unit
LP pump
Fig. 6. Schematic diagram for the pre-treatment stage of a
RO plant.
transition depends on the control signal sent to
the pump. The valve comprises one state for the
normal operation and some states to describe the
malfunctioning. Models for the system components
are shown in Fig. 7.
6. S u m m a r y

In this contribution, the main idea o f hybrid

systems has been presented. General properties
and advantages o f hybrid modeling were highlighted and possible applications to desalination
plants were illustrated be mean of simple examples.
Simulation results showed that hybrid modeling
and control can be promisingly for the desalination
industry in order to extend and to improve the

2__d <o

IT

\_k

Fig. 7. Models for (a) the tank, (b) the pump and (c) the valve.

Symbols

A
An,
cx,
C
C
F
h
l
m
P
T
t

--------------

--

Cross area, m e
Heat transfer area, m 2
Heat transfer coefficient, W / ( m 2 C )
Salt concentration, g/kg
Heat capacity, kJ/(kg.C)
Mass flow rate, kg/s
Specific enthalpy, kJ/kg
Level, m
Mass, kg
Pressure, MPa
Heat flor rate, W
Temperature, C
Time, s
Density, kg/m 3

Subsripts

b
c
i
s
sat

- - Brine
- - Condensate
- - Input (e.g. Fbj is mass flow rate for brine
input)
- - Steam
- - Saturated steam

A. Gambler, E. Badreddin / Desalination 152 (2002) 175-184

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