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Special Section on Industrial

Systems Control
Editors Note: The Guest Editor of this spe- invited sessions each year at two meetings: vited session at the 1987 American Control
cia1 section of the Magazine is Eugene King the American Control Conference and the Conference and then served as Guest Editor,
of Alcoa who is Chair of the IEEE Control IEEE Conference on Decision and Control. evaluating these candidate papers and others
Systems Society Technical Committee on Selected papers from the invited sessions can included here. We thank Gene for his efforts
Industrial Systems Control. Part of the tech- serve as the nucleus for a special edition of and look forward to additional special sec-
nical committee activities is to help organize the Magazine. Gene helped organize an in- tions proposed by technical committees.

Application of Modern Control


to a Continuous Anneal Line
Christopher D. Kelly, Dhani Watanapongse,
and Kenneth M. Gaskey

ABSTRACT: This paper presents the devel- steels, particularly in the automotive indus- even before the confirming measurement is
opment of a state-variable design approach try. Studies were conducted to develop the made. Further, the multiple-input/multiple-
to control strip temperature in a continuous steel compositions and to establish the pro- output variables typically associated with a
anneal process producing a variety of high- cess for producing these high-strength steels. heat-treating process are systematically co-
strength low-alloy steels. In this process, a It was determined that the ability to manip- ordinated based on linear quadratic control
steel strip passes continuously through five ulate and control the heating and cooling of design so as to yield the best possible control
consecutive heat-treating operations to a steel strip is an effective way of achieving performance.
achieve desired metallurgical properties for a wide range of high-strength products with In this paper, the CAL process is de-
the automotive market. Each operation is unique properties from a limited number of scribed, the design of the strip temperature
controlled by an individual controller de- compositions. This effort culminated in Sep- control system as applied to a furnace section
signed to maintain the tight strip tempera- tember 1983, when a state-of-the-art contin- of the CAL is presented, and performance
tures required for the product mix. To uous anneal line (CAL) was brought on of the control system is discussed.
achieve this goal, linear quadratic Gaussian stream at Inland [l].
control techniques were used to develop the The decision to apply modem control to
the CAL was based on a belief that superior
Process Description
control system.
strip temperature control performance could The CAL process is designed to produce
Introduction be achieved. For a typical heating furnace steel strips with thicknesses ranging from
control [2], when measurements deviate from 0.48 to 2.16 mm and widths from 610 to
In the late 1970s, the Inland Steel Com- the desired value, new steady-state set points 1525 mm. The maximum line speed is 137
pany recognized the increasing need in the are calculated from an implicit heat-transfer m/min and the maximum furnace capacity is
marketplace for high-quality, high-strength model using an iterative procedure. The con- 65 metric tons/h, with a yearly production
trol systems response is inherently very slow rating of 363,000 metric tons. The line is
Presented at the Special Seminar of the Associa- due to a transport delay in strip temperature designed to produce a diverse range of prod-
tion of Iron and Steel Engineers and the IEEE measurement and the need to wait for a new ucts with tensile strengths ranging from 275
Control Systems Society on The Application of steady state to be reached before taking the to 1380 MPa.
Modem Control in the Metals Industry, February next control actions. Using modern control, The strip heat-treating units of CAL are
26, 1987, Pittsburgh, Pennsylvania, and at the
explicit linear equations represent the dy- the annealing furnace, water quench, and the
1987 American Control Conference, Minneapolis,
namics of the heating process, with a Kal- aging furnace, as shown in Fig. 1. The an-
Minnesota, June 11, 1987. Christopher D. Kelly,
Dhani Watanapongse, and Kenneth M. Gaskey are man filter to predict strip temperatures in the nealing furnace has a preheat, heat, soak,
with Inland Steel Company Research Laborato- furnace. This allows strip temperature de- and gas-jet cool section. The three sections
ries, 3001 E. Columbus Drive, East Chicago, IN viations anywhere in the furnace to be pre- of the aging furnace are reheat, overage, and
46312. dicted in real time and control actions taken fast cool. Strip temperature is measured by

0272-1 70818810400-0032 $01 00 0 1988 IEEE


J
,
! IE Controi Systems Magazine
ANNEALING AGING changes in furnace performance and strip
ENTRY FURNACE FURNACE EXIT surface condition. The transition strategy
LOOP LOOP contains the logic that determines the timing
TOWER I I TOWER
for and adjustments to the line speed and
furnace operating conditions required to
minimize strip temperature variation during
product size and product cycle changes. In-
dividual section controllers, developed using
modem control, establish the adjustments to
the operating conditions to correct for pro-
cess variations so that a tight control of strip
temperature can be accomplished.
The individual section controllers are the
DEL IV E R Y elements of the strip temperature control sys-
ENTRY QUENCH
END END tem that utilize modem control. In order to
PROCESSING P R O C E S S IN G
provide an in-depth discussion of the theory,
1-OVERALL LENGTH 2 0 91-nr this paper will focus on the derivation and
development of the heat section controller.
Fig. 1. Schematic of Inland No. 3 CAL.
The same methodology applies to the other
section controllers.
infrared radiation pyrometers located at the perature is an input for a second control that
exit of each section. Typical strip measure- uses a thermocouple reading of zone tem- Process Model
ment cycles for the processing of high- perature and the zone temperature set point The physical layout of the heat section is
strength and ultrahigh-strength products to control fuel flow and airflow to obtain the shown in Fig. 4. The steel strip travels a
through the furnace sections are shown sche- desired zone temperature.) In addition, the distance of 210 m, stays in the section 2-5
matically in Fig. 2 . Included in this figure transitions from coil to coil are controlled min, depending on line speed, and is heated
are the design exit strip temperature toler- precisely to ensure that each coil is within to 600-800C. The heat section has IO fur-
ances, which must be maintained to achieve its metallurgical aims. These functions are nace temperature control zones, with the
quality CAL products. performed by the strip temperature control temperature in each zone labeled TZn ( n =
The objective of the process control sys- system (Fig. 3) using setup models, adaptive I , 10). The strip travels within a control zone
tem is to achieve and maintain the desired update models, transition strategy, and in- and between adjacent control zones. The strip
exit strip temperature of the heat, soak, gas- dividual section controllers. The setup is, therefore, affected by a given zone more
jet cool, reheat, and overage sections during models are heat-transfer equations that de- than once during its travel in the heat section
both steady-state and transient conditions. To termine the steady-state operating conditions by traveling between heating tubes of the
accomplish this objective, the control system needed to achieve the desired exit strip tem- same zone or between the heating tubes of
adjusts the zone temperatures of each section peratures for each product. The adaptive up- two different heating zones.
and the line speed on a continuous basis to date heat-transfer models use process mea- The thermal process in the heat section can
assure that the strip is heated or cooled to surements to establish update coefficients that be represented by a nonlinear heat-transfer
the desired strip temperatures. (Zone tem- correct the setup models to account for equation describing the dynamic response of

A
ANNEALING

U L T R A HIGH
STRENGTH , m F *
-r,
FURNACE./

*--eA

'
T; '\\
bAGING FURNACE4
COIL

DESCRIPTION
SETUP
AND
UPDATE MODELS -
e LINE SPEED

WELD TRACKING

?23% -'lOC '9


TRANSITION

STRATEGY

ws
PREHEAT HEAT SOAK JET REHEAT OVERAGE
CWL

DISTANCE ~~

Fig. 2. Product thermal cycle with temperature tolerances. Fig. 3. Schematic of process control system.

April 1988 33
of a predictor, Kalman filter, and linear con-
troller. The predictor calculates the strip
temperature along the entire length of the
strip. The Kalman filter then ensures that the
calculated strip temperatures are correct by
using the exit strip temperature measure-
ment. The linear controller then adjusts the
U + control set points to minimize any differ-
TZIO TZ8
ences between the calculated and desired
strip temperatures along the length of the
strip.

.~-....~.....
~ ...
.
Strip Temperature Predictor
The predictor is a linearized model that
calculates strip temperature changes caused
by process perturbations around a nominal
TZ9 TZ7
operation condition. The predictor calculates
the strip temperatures in real time. To de-
velop the predictor, the transport term in Eq.
( I ) is linearized by dividing the strip length
EXIT STRP
into segments or nodes using the following
ENTRY STRP
TEMPERkTURE TEMPERATURE difference approximation for the partial dif-
PYROMETER PYROMETER
ference, with L being the length between
-
V
- temperature measurements and 73,- I being
the previous nodes strip temperature.
Fig. 4. Schematic diagram of the physical CAL heat section. dTS,ldt = (TS, - TS,- 1)lL (2)
The radiation term in Eq. (1) is linearized
strip temperature so that the temporal change view factor, U the Stefan-Boltzmann con- around a nominal operating condition using
in heat energy at a particular location is equal stant, e the emissivity of the steel, and TZ the Taylor series expansion. In addition, the
to the transport heat energy plus the radiation the zone temperature. radiation from the zones on each side of the
heat energy, where c,, is the specific heat of strip is accounted for by separately consid-
steel, p the density of steel, U the strip ve-
dTSldt = -udTSldL + K(TZ4 - TS4) ering the left and right zone temperatures.
locity, TS the strip temperature, t the time, (1) Substituting the linearized transport and ra-
Vthe volume element (width X gage x node where K = (AFue)/(cpVp). diation expressions into the nonlinear equa-
length), L the node length, A the radiation The heat section controller is shown sche- tion yields the following linear state-variable
surface area (width x node length), F the matically in Fig. 5 . The controller consists form, where ATS, ATL, and ATR represent
the deviation from nominal of the strip tem-
perature, left control zone temperature af-
fecting the strip, and right control zone tem-
AIM STRIP FEED-FORWARD
TEMPERATURE CONTROL perature, respectively, and TS,, TL,, and
PROFILE SET POINTS TR, are the nominal operation point condi-
tions.
dATS/d? = -(u/L)(ATS, - A T S , _ l )
-
LINEAR OUADRATIC
TYPICAL + 4K(TL:ATL + TR:ATR
SECTION
CONTROLLER
PROCESS
MEASURED EXIT - TS;ATS,) (3)

CONTROL SET POINTS I STRIP


TEMPERATURE This equation represents the response of
one strip temperature node along the length
of the strip. Twenty nodes were chosen to
WIDTH -
- STRIP FILTER
provide a good approximation of strip tem-

- perature in the heat section.


and
GAGE ____z TEMPERATURE
COIL SPEC
INCOMING STRIP
PREDICTOR TEMPERATURE The predictor matrix equation has 20 strip
TEMPERATURE
ESTIMATED STRIP temperature nodes developed using Eq. (3)
TEMPERATURE and their physical relationship to the other
strip temperature nodes and the control zone.
The 20 nodes were chosen according to the
CORRECTEDlFlLTERED 20 distinct heat-transfer regions a strip would
STRIP TEMPERATURES
pass as it traveled upward through each zone
Fig. 5 . Schematic diagram of the individual section controller. and between adjacent zones as it traveled

34 IEEE Control S y s t r m s Alogozrne


down to the next zone. In addition, an entry ways possible. The final solution was to at- ment factors need to be calculated. This is
node is included to allow for variation in the tempt to add an integral-type compensation accomplished by using a proprietary detailed
entry strip temperature. This node is mod- with the estimator, thereby allowing the Kal- heat-transfer model and running it at differ-
eled as an exponential decay. The complete man filter to properly compensate for the dif- ent nominal operating conditions. For each
predictor then has 2 1 strip temperature states ferences in the two steady states. strip temperature node, deviations in strip
and 10 zone temperature inputs. The Kalman filter that was finally imple- temperature from nominal were noted for
The zone temperature could be directly mented does not directly update the strip variations in gage, width, or furnace zone
measured with sufficient accuracy using this temperature as in the traditional Kalman fil- temperatures. Then, each strip temperature
process. Therefore, zone temperature was ter approach. To achieve the integral type of node was normalized to the exit strip tem-
used as an input and was not modeled as part control desired, a two-step approach was perature node. These translation adjustment
of the strip temperature predictor. The zone used. A Kalman filter was developed to es- factors were then added to translate the exit
temperature response will have to be added timate only the bias, or difference, between strip temperature error to the other strip tem-
later to develop a control system. the models exit strip temperature and the perature nodes for improved strip tempera-
A proprietary detailed heat-transfer model measured strip temperature. Therefore, the ture estimates.
of the heat section was used to generate the Kalman filter does not directly update the
nonzero elements in the matrix for a number strip temperature measurements. This pre-
of nominal operating conditions that would diction of a bias adjustment becomes the in- Controller
satisfy the thermal requirements of Inlands tegral-type action needed to provide accurate The controller was developed by expand-
product mix, i.e., strip width, gage, line estimates of strip temperatures. In the second ing the state-variable matrix to include zone
speed, and thermal cycle. The values for step, the bias adjustment is then translated temperature response and integral gain to
each of the nonzero elements are updated for to each of the strip temperature estimates provide a controller matrix model. After de-
each new operating condition, such as a new along the strip length. The bias was trans- fining the values of the weighting matrices
coil entering the line. The detailed heat- lated to each node using a table created from in the quadratic cost function, the Riccati
transfer model was also used to obtain the an off-line model to relate how much error equation [4] was solved to calculate the con-
coefficients in the development of the Kal- at the exit translated into at each strip node. trol gains. The gains were suboptimized for
man filter and controller. This is not an ideal way of accomplishing the on-line controller.
the required task, however, this simplified
design was used and has worked for this pro- Zone Temperature Response
Kalman Filter cess. This design closely followed the design The zone temperature response model is a
The Kalman filter adjusts for predictive er- of a Slab Mill Reheat Furnace Control Sys-
first-order exponential equation where TZ is
rors in the predictor due to factors that were tem in which the problems are more apparent the zone temperature, 7 the response time
not modeled, coefficients in the predictor [3]. The following discusses the develop-
constant of the given zone, and TZsp is the
matrix that may not be exact, or unforeseen ment of the bias and translation adjustment. zone temperature set point.
furnace operating problems such as zone
Bias Adjustment
temperature measurement errors. Without the d TZldt = (1/7)( -TZ + TZsp) (4)
Kalman filter, the calculated strip tempera- The bias adjustment model is a discrete
tures could consistently be in error. Kalman filter model. It was modeled to have In this equation, each zone temperature is
The developed Kalman filter was different a bias value estimate that would slowly vary modeled to act independently, i.e., without
from traditional Kalman filter applications. over time using random noise. In other being affected by the adjacent zones. This is
The traditional discrete Kalman filter with a words, the bias value was assumed to change not entirely correct, but is considered ade-
continuous estimator configuration can be from sample to sample because of zero-mean quate for control purposes.
separated into a three-step sequence: contin- random process noise. The process noise
Integral Gain
uously predict, obtain a measurement at a covariance did change to account for in-
given instant, and update for an instant at creased uncertainty of the process when coil- Integral gain was included in the last five
measurement. In this Kalman filter, the es- to-coil transitions occurred by increasing the zones by adding integral states and inputs to
timated strip temperature had a sawtooth re- process noise covariance. the matrix model. This approach was nec-
sponse during steady-state operation. This ef- Using the standard Kalman filter equa- essary to reduce the size of the control sys-
fect was found to occur when the models tions, the resulting bias adjustment equation tem matrix. The equation for integral con-
prediction of steady state differed from the is a one-dimensional Kalman filter that de- trol, where ITZ is the integral control action
true steady state. The strip temperature, after termines the bias or provides an integral cor- of the controller, ITZ,, is the control input
being updated by the Kalman filter, would rection beyond a straight proportional cor- to the integrator.
(one end of the sawtooth), over time, drift rection. This is done by multiplying the
back to the models prediction (opposite end Kalman gain times the difference between dITZldt = ITZsp (5)
of the sawtooth). This is understandable, as the actual measurement and the predicted
the models process dynamics would cause measurement. The Kalman gain was calcu- d TZldt = (117) (- TZ + TZSp + I T Z )
the estimates to drift back or settle back to lated on-line based on the time since the last (6)
the models prediction regardless of any up- measurement, regardless of the number of
date. predictions that occurred during this time. The input to the integrator was a rate of
Thus, useful information gained from the zone temperature change input control. The
Translation Adjustment Factor
Kalman filter was lost. A possible solution output of the integrator was then added to
would have been to obtain process measure- To translate the bias adjustment to each the zone temperature in the controller matrix
ments more often; however, this was not al- strip temperature node, translation adjust- model.

Am1 1988 35
Controller Matrix Model was accomplished using the MIT Control ature estimates and the desired strip temper-
Design Package [6]. ature profile derived from the product ther-
The final controller matrix model has 36
The control gains were suboptimized for mal cycle requirements. To accomplish this
states and 15 inputs. The 36 states are de-
the following reasons. First, since any feed- function, the controller is implemented on-
fined by the 21 strip temperature nodes, the
back that attempts to correct the integral con- line using a set of algebraic equations.
10 zone temperatures, and the five rate of
trol action is unnecessary, the gains relating To allow the controller to operate over the
zone temperature changes (integral). The 15
the feedback of the integral control action to entire operating range, a gain set was cal-
inputs are defined by 10 zone temperature
the control set points were zeroed. Second, culated off-line for each of the nominal op-
set points and the five control inputs to the
off-line simulations showed that when the erating conditions. Then, as a new coil en-
integrators.
desired zone temperatures did not provide ters the line (new operating condition), the
Cost-Weighting Matrices the required strip temperatures, the control appropriate gain set for this condition is used
system tried to achieve the required strip by the controller.
Given the control model defined, the cost- temperatures while maintaining the incorrect
weighting values must be determined. The
desired zone temperatures. Therefore, even
design decision was made that relates the though the zone temperature feedback pro- Performance Evaluation
balance between the magnitude of the con- vided a derivative-type feedback, the gains The control system has been in routine op-
trol action (matrix R) and the magnitude of relating the feedback for zone temperature eration since July 1984. It is currently on-
error in the strip temperature (matrix Q) of were reluctantly zeroed. control 90 percent of the time. The 10 per-
the cost-function equation, where J is the Figure 6 shows detailed controller gains cent off-control is due primarily to nonrou-
scalar cost value, x the strip and zone tem- for a typical zone, Zone 5 , based on all 2 1 tine operations, such as stop and go line op-
perature states, and U the zone temperature
strip temperature node errors. The strip nodes eration, and improper transitions resulting in
set points. that Zone 5 directly affects are shown above unrealistic control requirements.
the bottom axis. It can be seen that Zone 5 The following analysis of the control sys-
J = S'x'Qx + uTRu dt (7) responds to each strip temperature node error tem performance will focus on the control
systematically, i.e., the gains are largest action for the heat section over a 12-h time
Both Q and R were chosen to be diagonal around Zone 5 and trail off on both sides of period. This analysis also includes a gage
matrices. To calculate the Q and R matrices, the zone. This behavior is not unexpected, change transition.
a design decision is required to define the since the strip should be most responsive to Figure 7 shows the Kalman filter bias ad-
maximum allowable error for each zone and the zone that it is in and should anticipate justment, the error between the measured and
strip temperature and the maximum allow- the strip temperature errors that will enter the desired exit strip temperature, and the con-
able control for the integral and proportional zone. trol action of the last zone temperature con-
action of the zone temperature set points. The controller completes the feedback loop troller. (Due to labeling convention, the last
The cost-weighting matrices are chosen so of the control system. It is driven by the zone is Zone 9 and not Zone IO.) The top
that Q is the inverse of the square of the difference of the Kalman filter strip temper- plot shows the Kalman filter bias adjustment
maximum allowable error and R is the in-
verse of the square of the maximum allow-
able control [ 5 ] .
The elements in the Q matrix were chosen
so that a high-cost penalty was placed on * .
strip temperature errors and a no-cost penalty
was placed on zone temperature errors and
integral control action errors. This allows the
controller to react to strip temperature errors
Zone 5
and to be nonresponsive to zone or integral
errors. The elements in the R matrix must be Gain
nonzero and were chosen to balance the al-
lowable control action with an acceptable
strip temperature error. The actual values
were tuned using off-line simulation of a
heat-transfer model of the heat section and
the controller to check if the balance of con-
trol action and strip temperature error did not
produce poor transient response. This pro-
cedure provided good response when the
control system was finally used on-line with
very little fine-tuning of the gains required.
t STRIP TRAVEL

Control Gains
The control gains were calculated from the
t==l * * * * *
0 1 2 3 4 6 0 7 8 91011121314161017181920

controller matrix model and the cost-weight-


Strip Temperature Node
ing function. The Riccati equation was used
for solving the control gains. This solution Fig. 6. Proportional control gains for Zone 5.

36 I Control Systems Mogozine


4 caeo. Indiana. His interest of studv is Dmcess
30 -
Y , < 1

HEAT modeling, and application of modem control to


KALMAN FILTER
BIAS ADJUSTMENT
(DEG. C)
: M e - .. __ --- -- - ..- industrial processes.

30
HEAT 0 Gage Change
IC, +in
EXIT STRIP
TEMP ERROR
(DEG. C)

I Dhani Watanapongse
ZONE 9 received the B.S.I.E. de-
(DEG. C) gree from Chulalongkoon
University in Thailand
and the Ph.D. degree
in industrial engineering
ELAPSED TIME (MINUTES) from Purdue University in
Fig. 7. Extended time control system performance. 1969. He is currently Sec-
tion Manager of Process
Modeling, Inland Steel
References Research Laboratories,
as applied to the exit strip temperature node
East Chicago, Indiana. He
of the predictor. It shows that a corrective
[I] K. M. Gaskey, V. R. Hoffman, and D. G. is active as a committee
ability such as a Kalman filter was needed Crosby, Design of Inlands New Continu- member of AISE, ISS-PTD, and AISI. He cur-
to improve the predicted strip temperatures. ous Anneal Line, AISE Annual Conven- rently serves as AISE Director on the American
The middle plot shows that the exit strip tion, Oct. 15, 1984. Automatic Control Council Board of Directors.
temperature is maintained to within the [2] J. A. Kilpatrick and E. J . Seeman, Com- His research interests are in rolling deformation
k 10C well within the required product tol- puter Control of a Continuous Anneal Line, pmessing, application of estimation and control
erance of k23C. This shows that the over- AISE Rolling Mill Conference, Mar. 25, theories, and on-line sensor technology. He has
all control was able to achieve the desired 1985. authored technical papers, presented talks, and or-
[3] T. A. Veslocki, C. C. Smith, and C. D. ganized technical sessions in modeling and control
objective. The bottom plot shows the last
Kelly, Automatic Slab Heat Control at In- in rolling, and co-organized a seminar on Appli-
heat zone temperatures. This curve indicates
lands 80-in. Hot Strip Mill, AISE Iron and cation of Modem Control Theory in the Metals
that the control action did occur in a reason- Steel Engineer, p. 47, Dec. 1986. Industry.
able fashion to control the strip temperature [4] M. Athans, Modern Control Theov-Study
along the length of the strip. Guide, MIT, 1974.
In addition, the bullet at 540 min shows a [5] A. E. Bryson and Y. C. Ho, Applied Optimal
satisfactory system response at a gage change Control, Waltham, MA: Blaisdell, 1969.
transition. [6] N . R. Sandell and M. Athans, Manual of
Fortran Computer Subroutines for Linear,
Quadratic, Gaussian Designs, MIT, 1974.
Acknowledgments
The development and implementation of
this continuous anneal line control system Kenneth M. Gaskey re-
was done with the contributions and support Christopher D. Kelly re- ceived the B.S.M.E. de-
of many Inland people. The authors wish to ceived the B S.E.E de- gree in 1961 and the
acknowledge the following for their signifi- gree from Michigan State M.S.M.E. degree in 1963
cant contributions to the control system de- University in 1979 and the from Purdue University.
M.S.E.E. degree from the He currently works as a
sign: Mitch Lapman, Lewis (Skip) Kim-
Illinois Institute of Tech- Scientist at Inland Steel
berly, Phil Papesh, and Dave Lueck of the
nology (Chicago) in 1984. Research, East Chicago,
Process Automation Department; Jim Cun- Currently, he is Senior Indiana. He has authored
diff and each of the operators in the Oper- Research Engineer, Steel papers and presented talks
ating Department; and Cliff Smith, Dick Products Division, Pro- on various topics dealing
Pelc, John Sinclair, Bob Gray, Karey Pie- cess Modeling Section at with heat transfer and
ters, Ron Kordys, and Dennis Namovice of Inland Steel Research control in continuous pro-
the Research Department. Laboratories. East Chi- cesses.

37

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