Daniel L. O'Connor

Lim C. Siang, Shams Elnawawi, Lee D. Rippon et al.

A significant portion of the effort involved in advanced process control, process analytics, and machine learning involves acquiring and preparing data. Literature often emphasizes increasingly complex modelling techniques with incremental performance improvements. However, when industrial case studies are published they often lack important details on data acquisition and preparation. Although data pre-processing is unfairly maligned as trivial and technically uninteresting, in practice it has an out-sized influence on the success of real-world artificial intelligence applications. This work describes best practices for acquiring and preparing operating data to pursue data-driven modelling and control opportunities in industrial processes. We present practical considerations for pre-processing industrial time series data to inform the efficient development of reliable soft sensors that provide valuable process insights.

Lim C. Siang, Daniel L. O'Connor

In the process industries, MPC (Model Predictive Control) is typically implemented as a two-stage controller with a Linear Program (LP) steady-state optimizer that generates economically optimal targets for the MPC algorithm. Abnormal behaviors in industrial LP optimizers are often difficult to rationalize, especially when a large number of manipulated variables (MVs) and controlled variables (CVs) are involved. We introduce a novel, post-hoc LP explainability method by recasting the role of shadow prices in the LP solution as an attribution mechanism for MV-CV relationships. The core idea is that the shadow price of a constrained CV is not just an intrinsic property of the LP solution, but can be split into contributions from individual unconstrained MVs and resolved into one-to-one MV-CV pairings using a linear sum assignment algorithm. The proposed MV-CV pairing framework serves as a practical explainability tool for online LP-MPC systems, enabling practitioners to diagnose suboptimal constraints and verify alignment of the controller's behavior with its original design.