Method and apparatus for deploying industrial plant simulators using cloud computing technologies

• US 10,509,870 B2
• Filed: 12/15/2016
• Issued: 12/17/2019
• Est. Priority Date: 01/24/2012
• Status: Active Grant

• Current Assignee: Emerson Process Management Power & Water Solutions Incorporated (Emerson Electric Company)
• Original Assignee: Emerson Process Management Power & Water Solutions Incorporated (Emerson Electric Company)
• Inventors: Kephart, Richard W., Sanchez, Herman, Abruzere, Eugene
• Primary Examiner(s): Cook, Brian S
• Application Number:
  US15/379,736
• Publication Number:
  US 20170098022A1
• Time in Patent Office: 1,097 Days
• Field of Search: 703 18
• CPC Class Codes: G05B 17/02 electric
• CPC Class Codes: G05B 19/41885 characterised by modeling, simulation of the manufacturing system
• CPC Class Codes: G05B 2219/2609 Process control
• CPC Class Codes: G05B 2219/31124 Interface between communication network and process control, store, exchange data
• CPC Class Codes: G05B 2219/32345 Of interconnection of cells, subsystems, distributed simulation
• CPC Class Codes: G06F 2111/02 CAD in a network environment, e.g. collaborative CAD or distributed simulation
• CPC Class Codes: G06F 30/20 Design optimisation, verification or simulation optimisation, verification or simulation of circuit designs G06F30/30
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A system and method for operating a remote plant simulation system is disclosed. The system and method uses a light application at the plant to collect relevant data and communicate it to a remote plant simulation. The remote plant simulation uses the relevant data, including data from the actual process, to create a process simulation and communicate the display data to the light application operating at the plant where it is displayed to a user. The remote system offers the advantage of offering decreased cost and improved simulation as the equipment cost, operator cost and set up cost is shared by a plurality of users. Further, the data may be stored remotely and subject to data analytics which may identify additional areas for efficiency in the plant.

Claims

1. A network cloud based simulation system for simulating operation of a process control network as connected within a process plant, the simulation system comprising:

a local supervisor module configured to collect from the process plant a first state variable indicative of a configuration of the process control network and a second state variable indicative of a process operation;

a remote simulation module communicatively coupled to the local supervisor module via a network cloud system, the remote simulation module being configured to (i) use one or more simulated process variable signals to produce one or more simulated control signals to provide a simulated process control network that represents a simulation of the operation of the process control network as connected within the process plant, (ii) implement a process model that is communicatively coupled to the simulated process control network to produce the one or more simulated process variable signals using the one or more simulated control signals, (iii) periodically configure the simulated process control network with the first state variable, and (iv) periodically update the process model using the second state variable,

wherein the local supervisor module is further configured to function as a single consolidated access point to bridge communications between the process control network and the network cloud system, and

wherein the remote simulation module is further configured to store the first and second state variables as part of the network cloud system by communicating exclusively with the local supervisor module.

2. The system of claim 1, wherein the remote simulation module is further configured to store simulation data to facilitate the simulation of the operation of the process control network as connected within the process plant, the simulation data including data representative of the process model and the simulated process control network.

3. The system of claim 2, wherein the simulation data further includes a prediction of the first state variable and a prediction of the second state variable.

4. The system of claim 1, wherein the remote simulation module comprises:

a plurality of simulated process control networks.

5. The system of claim 1, wherein the remote simulation module comprises:

a plurality of process model versions.

6. The system of claim 1, wherein the one or more simulated control signals include the operation of the process control network and additional plant processes that are added while the network cloud based simulation system is operating.

7. A network cloud based simulation system for simulating operation of a process control network as connected within a process plant, the simulation system comprising:

a simulation system configured as part of a network cloud system, the simulation system providing a simulation of the operation of the process control network as connected within the process plant using a simulated process control network and a process model;

a supervisor module configured as part of the process plant that functions as a consolidated access point between the process control network and the network cloud system, the supervisor module being further configured to collect state variables from the process plant and to selectively transmit the collected state variables to the simulation system; and

an update module, configured as part of the network cloud system, the update module receiving the collected state variables exclusively from the supervisor module and storing the collected state variables as part of the network cloud system to update the simulation of the operation of the process control network.

8. The system of claim 7, wherein the state variables collected from the process plant include a first variable indicative of a configuration of the process control network and a second state variable indicative of a process operation.

9. The system of claim 8, wherein the update module is further configured to store simulation data to facilitate the simulation of the operation of the process control network as connected within the process plant, the simulation data including data representative of the process model and the simulated process control network.

10. The system of claim 9, wherein the simulation data further comprises:

a prediction of the first state variable and a prediction of the second state variable.

11. The system of claim 7, wherein the update module is further configured to store the collected state variables as part of the network cloud system to synchronize the simulation of the operation of the process control network to an actual operation of the process control network.

12. The system of claim 7, wherein the supervisor module is configured as a thin client application executed on a computing device.

13. The system of claim 7, wherein the supervisor module is further configured to transmit the collected state variables when a threshold amount of data has been collected.

14. The system of claim 7, wherein the supervisor module is further configured to transmit the collected state variables when a threshold amount of time has passed.

15. The system of claim 7, wherein the simulated process control network is further configured to generate one or more simulated control signals that are indicative of the operation of the process control network and additional plant processes that are added while the network cloud based simulation system is operating.

16. A method for simulating operation of a process control network as connected within a process plant, the method comprising:

generating, via a simulation system that is stored as part of a network cloud system, a simulated process control network that represents a simulation of the operation of the process control network as connected within the process plant;

collecting state variables from the process plant via a supervisor module that is part of the process plant and functions as a consolidated access point between the process control network and the network cloud system;

selectively transmitting, via the supervisor module, the collected state variables to the simulation system;

receiving, via an update module, the collected state variables exclusively from the supervisor module;

storing, via the update module, the collected state variables as part of the network cloud system; and

updating, via the simulation system, the simulation of the operation of the process control network based upon the stored collected state variables.

17. The method of claim 16, wherein the collected state variables include a first variable indicative of a configuration of the process control network and a second state variable indicative of a process operation.

18. The method of claim 17, further comprising:

storing, via the update module, simulation data in the network cloud system to facilitate the simulation of the operation of the process control network as connected within the process plant, the simulation data including data representative of the process model and the simulated process control network.

19. The method of claim 18, wherein the simulation data further comprises:

a prediction of the first state variable and a prediction of the second state variable.

20. The method of claim 16, wherein that act of updating the simulation of the operation of the process control network synchronizes the simulation of the operation of the process control network to an actual operation of the process control network.

21. The method of claim 16, wherein the act of selectively transmitting the collected state variables comprises:

transmitting the collected state variables when a threshold amount of data has been collected.

22. The method of claim 16, wherein the act of selectively transmitting the collected state variables comprises:

transmitting the collected state variables when a threshold amount of time has passed.

23. The method of claim 16, further comprising:

generating, by the simulation system, one or more simulated control signals that are indicative of the operation of the process control network and additional plant processes that are added while the network cloud based simulation system is operating.