Apparatus and method for predicting windup and improving process control in an industrial process control system

1. A method comprising:

receiving at an upstream controller an output (OP) value used to implement a manipulated variable, the manipulated variable associated with an industrial process, the OP value comprising an output of a downstream controller;

identifying, by the upstream controller, one of multiple regions in a range where the OP value is located;

calculating, by the upstream controller, an achievable manipulated variable (MV) limit for the manipulated variable based on the region in which the OP value is located;

calculating, by the upstream controller, a setpoint for the manipulated variable based on the region in which the OP value is located;

sending the setpoint to the downstream controller;

receiving the setpoint at the downstream controller; and

using the downstream controller, generating a control signal that adjusts operation of an actuator in order to change a value of a process variable associated with the industrial process so that the process variable follows the setpoint;

wherein calculating the achievable MV limit comprises:

when the OP value is located in a first of the regions, causing the achievable MV limit to match a user-specified MV limit;

when the OP value is located in a second of the regions, causing the achievable MV limit to track the value of the process variable with a gap between the achievable MV limit and the value of the process variable, the process variable affected by the manipulated variable; and

when the OP value is located in a third of the regions between the first and second regions, causing the achievable MV limit to move from the user-specified MV limit toward the value of the process variable.

2. The method of claim 1 , further comprising receiving at least one of:

values defining boundaries between the regions;

a gain defining how the process variable responds to changes in the OP value within at least one of the regions; and

information identifying coefficients for a polynomial curve or piecewise linear segments defining a relationship between the OP value and the value of the process variable.

3. The method of claim 1 , further comprising:

using the achievable MV limit to predict the value of the process variable.

4. The method of claim 1 , further comprising:

using the achievable MV limit to identify an optimization solution for controlling the manipulated variable and one or more related manipulated variables;

wherein use of the achievable MV limit to identify the optimization solution prevents the optimization solution from repeatedly jumping back and forth.

5. The method of claim 1 , further comprising:

using the actuator and in response to the control signal, causing a change to the value of the process variable so that the process variable follows the setpoint.

6. The method of claim 5 , wherein:

the industrial process is implemented using one or more pieces of industrial equipment; and

the actuator adjusts at least one of the one or more pieces of industrial equipment to cause the change to the value of the process variable.

7. The method of claim 1 , wherein:

the upstream controller comprises a model predictive control (MPC) controller; and

the downstream controller comprises a proportional-integral-derivative (PID) controller.

8. A system comprising:

a first industrial process controller and a second industrial process controller;

wherein the first controller comprises at least one processing unit configured to:

receive an output (OP) value used to implement a manipulated variable, the manipulated variable associated with an industrial process, the OP value comprising an output of the second controller;

identify one of multiple regions in a range where the OP value is located;

calculate an achievable manipulated variable (MV) limit for the manipulated variable based on the region in which the OP value is located;

calculate a setpoint for the manipulated variable based on the region in which the OP value is located; and

send the setpoint to the second controller; and

wherein the second controller is configured to:

receive the setpoint from the first controller; and

generate and output a control signal that adjusts operation of an actuator in order to change a value of a process variable associated with the industrial process so that the process variable follows the setpoint; and

wherein, to calculate the achievable MV limit, the at least one processing unit is configured to:

when the OP value is located in a first of the regions, cause the achievable MV limit to match a user-specified MV limit;

when the OP value is located in a second of the regions, cause the achievable MV limit to track the value of the process variable with a gap between the achievable MV limit and the value of the process variable, the process variable affected by the manipulated variable; and

when the OP value is located in a third of the regions between the first and second regions, cause the achievable MV limit to move from the user-specified MV limit toward the value of the process variable.

9. The system of claim 8 , wherein the at least one processing unit is configured to receive at least one of:

values defining boundaries between the regions;

a gain defining how the process variable responds to changes in the OP value within at least one of the regions; and

information identifying coefficients for a polynomial curve or piecewise linear segments defining a relationship between the OP value and the value of the process variable.

10. The system of claim 8 , further comprising:

at least one interface configured to provide the setpoint to the second controller; wherein the at least one processing unit is configured to identify and adjust the achievable MV limit and the setpoint for the manipulated variable while the second controller is in windup.

11. The system of claim 8 , wherein the actuator is configured, in response to the control signal, to cause a change to the value of the process variable so that the process variable follows the setpoint.

12. The system of claim 11 , wherein:

the industrial process is implemented using one or more pieces of industrial equipment; and

the actuator is configured to adjust at least one of the one or more pieces of industrial equipment to cause the change to the value of the process variable.

13. The system of claim 8 , wherein:

the first controller is further configured to use the achievable MV limit to identify an optimization solution for controlling the manipulated variable and one or more related manipulated variables; and

use of the achievable MV limit to identify the optimization solution prevents the optimization solution from repeatedly jumping back and forth.

14. The system of claim 8 , wherein:

the first controller comprises a model predictive control (MPC) controller; and

the second controller comprises a proportional-integral-derivative (PID) controller.

15. A system comprising:

an upstream first controller configured to control an industrial process;

a downstream second controller configured to generate an output (OP) value used to implement a manipulated variable associated with the industrial process; and

an actuator configured to alter the industrial process;

wherein the first controller is configured to:

receive the OP value;

identify one of multiple regions in a range where the OP value is located;

calculate an achievable manipulated variable (MV) limit for the manipulated variable based on the region in which the OP value is located;

calculate a setpoint for the manipulated variable based on the region in which the OP value is located; and

send the setpoint to the downstream second controller;

wherein the second controller is configured to:

receive the setpoint from the first controller; and

generate and output a control signal; and

wherein the control signal adjusts operation of the actuator in order to change a value of a process variable associated with the industrial process so that the process variable follows the setpoint; and

wherein, to calculate the achievable MV limit, the first controller is configured to:

when the OP value is located in a first of the regions, cause the achievable MV limit to match a user-specified MV limit;

when the OP value is located in a second of the regions, cause the achievable MV limit to track the value of the process variable with a gap between the achievable MV limit and the value of the process variable, the process variable affected by the manipulated variable; and

when the OP value is located in a third of the regions between the first and second regions, cause the achievable MV limit to move from the user-specified MV limit toward the value of the process variable.

16. The system of claim 15 , wherein:

the first controller comprises a model predictive control (MPC) controller; and.

the second controller comprises a proportional-integral-derivative (PID) controller.

17. The system of claim 15 , wherein the first controller is further configured to receive at least one of:

values defining boundaries between the regions;

a gain defining how the process variable responds to changes in the OP value within at least one of the regions; and

information identifying coefficients for a polynomial curve or piecewise linear segments defining a relationship between the OP value and the value of the process variable.

18. The system of claim 15 , wherein the first controller is further configured to use the achievable MV limit to predict the value of the process variable.

19. The system of claim 15 , wherein:

the first controller is further configured to use the achievable MV limit to identify an optimization solution for controlling the manipulated variable and one or more related manipulated variables; and

use of the achievable MV limit to identify the optimization solution prevents the optimization solution from repeatedly jumping back and forth.

20. The system of claim 15 , wherein the actuator is configured, in response to the control signal, to cause a change to the value of the process variable so that the process variable follows the setpoint.