OPTIMIZATION SYSTEM USING AN ITERATIVELY COUPLED EXPERT ENGINE

• US 20120010758A1
• Filed: 05/20/2011
• Published: 01/12/2012
• Est. Priority Date: 07/09/2010
• 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: Francino, Peter N., Huff, Frederick C., Foster, David G.
• Granted Patent: US 8,880,202 B2
• Time in Patent Office: Days
• US Class Current: 700/291
• CPC Class Codes: F01K 13/02 Controlling, e.g. stopping or starting
• CPC Class Codes: G05B 17/02 electric
• CPC Class Codes: Y02P 80/10 Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

An energy management system uses an expert engine and a numerical solver to determine an optimal manner of using and controlling the various energy consumption, producing and storage equipment in a plant/communities in order to for example reduce energy costs within the plant, and is especially applicable to plants that require or that are capable of using and/or producing different types of energy at different times. The energy management system operates the various energy manufacturing and energy usage components of the plant to minimize the cost of energy over time, or at various different times, while still meeting certain constraints or requirements within the operational system, such as producing a certain amount of heat or cooling, a certain power level, a certain level of production, etc. In some cases, the energy management system may cause the operational equipment of the plant to produce unneeded energy that can be stored until a later time and then used, or that can be sold back to a public utility, for example, so as to reduce the overall cost of energy within the plant.

Claims

1. A configuration system for use in configuring the operation of a plant having a set of interconnected plant equipment, wherein the plant equipment includes multiple sets of energy production units that can be run separately or together to produce energy, the configuration system comprising:

a computer readable memory that stores a plurality of equipment models that model the operation of the plant equipment and an objective function defining optimal operation of the interconnected plant equipment;

a numerical solver that operates on a computer processing device using the objective function, the plurality of equipment models and a set of plant configuration input criteria to determine an optimal operating configuration of the set of interconnected plant equipment by determining an operational configuration of the set of interconnected plant equipment that minimizes or maximizes the objective function; and

an expert engine that operates on a computer processing device to determine one or more operating values for use in running the plant equipment, wherein the expert engine calls the numerical solver a plurality of times to determine the one or more operating values for use in running the plant equipment, and wherein the expert engine provides the numerical solver a different set of plant configuration input criteria during each of the calls.

2. The configuration system of claim 1, wherein the objective function determines an economic cost of running the energy production units to produce a needed amount of energy.

3. The configuration system of claim 1, wherein the computer readable memory stores first and second different equipment models for one or more of the energy production units, wherein the numerical solver uses the first equipment model for the one or more of the energy production units during a first call from the expert engine and uses the second equipment model for the one or more energy production units during a second call from the expert engine.

4. The configuration system of claim 3, wherein the first equipment model for the one or more energy production units is less accurate but less computationally expensive than the second equipment model for the one or more energy production units.

5. The configuration system of claim 3, wherein the first equipment model for the one or more energy production units is less constrained than the second equipment model for the one or more energy production units.

6. The configuration system of claim 1, wherein the expert engine provides a first set of operational constraints to the numerical solver as the plant configuration input criteria for one or more pieces of the plant equipment during the first call to the numerical solver and provides a second set of operational constraints to the numerical solver as the plant configuration input criteria during the second call to the numerical solver, wherein the second set of operational constraints are less relaxed than the first set of operational constraints.

7. The configuration system of claim 1, wherein the expert engine provides a set of ambient conditions, plant equipment operating costs, energy demands and equipment constraints to the numerical solver as the plant configuration input criteria during each of a first call and a second call to the numerical solver.

8. The configuration system of claim 7, wherein the expert engine provides the same set of ambient conditions, plant equipment operating costs, and energy demands as the plant configuration input criteria during each of the first call and the second call to the numerical solver but provides a different set of equipment constraints to the numerical solver during the first call and the second call to the numerical solver.

9. The configuration system of claim 7, wherein the expert engine provides the same set of ambient conditions, plant equipment operating costs, and energy demands as the plant configuration input criteria during each of the first call and the second call to the numerical solver but provides a subset of equipment to use as constraints to the numerical solver during the second call to the numerical solver.

10. The configuration system of claim 1, wherein the numerical solver uses the objective function to determine an optimal set of plant equipment to use during a first call to the numerical solver, and wherein the expert engine provides the optimal set of plant equipment to the numerical solver in a second call to the numerical solver and wherein the numerical solver uses the objective function to determine an optimal set of equipment operational parameters for the optimal set of plant equipment during the second call to the numerical solver.

11. The configuration system of claim 10, wherein the numerical solver uses a first set of equipment models during the first call from the expert engine and uses a second and different set of equipment models during the second call from the expert engine, wherein the second set of equipment models are more accurate than the first set of equipment models.

12. The configuration system of claim 10, wherein the numerical solver uses a first set of operational constraints in response to the first call from the expert engine and uses a second and different set of operational constraints during the second call from the expert engine, wherein the second set of operational constraints are less relaxed than the first set of operational constraints.

13. The configuration system of claim 1, wherein the expert engine provides ambient conditions, plant operating costs, and plant demands as the plant configuration input criteria during a first call to the numerical solver, wherein the numeral solver determines an optimal set of the plant equipment to use to meet the plant demands based on the objective function during the first call to the numerical solver, and wherein the expert engine provides ambient conditions, plant operating costs, and plant demands and an indication of the optimal set of plant equipment to use to meet the plant demands during a second call of the numerical solver, and wherein the numerical solver determines a set of optimal operational settings for the optimal set of plant equipment during the second call to the numerical solver.

14. The configuration system of claim 13, wherein the numerical solver uses different equipment models for the same plant equipment during the first and second calls to the numerical solver.

15. The configuration system of claim 13, wherein the numerical solver uses different sets of equipment operational constraints during the first and second calls to the numerical solver.

16. The configuration system of claim 1, wherein the objective function has parameters that consider costs of energy creation and usage of the plurality of energy production units associated with operational configurations of the energy production units.

17. The configuration system of claim 1, wherein the expert engine uses an output of numerical solver from a first call to the numerical solver to determine one or more of the plant configuration input criteria for use in a second call to the numerical solver.

18. The energy management system of claim 1, wherein the numerical solver receives a set of constraints associated with operating limits of plant equipment including each of the energy production units, and wherein the numerical solver determines different operational configurations of the energy production units as plant operating points that do not violate any of the set of constraints.

19. An energy management system for use in operating a plant having a plurality of energy producing units coupled to one or more loads, the energy management system comprising:

an expert engine that operates on a computer processing device to determine different sets of input plant operating configuration criteria for operating the energy producing units, wherein the expert engine uses the different sets of input plant operating configuration criteria to determined a final optimal operating configuration of the plurality of energy producing units; and

a numerical solver coupled to the expert engine, the numerical solver including an objective function and a set of equipment models for the energy producing units, wherein the numerical solver operates on a computer processing device to determine an optimal plant operating configuration by modeling the plant operation at a number of different operating configurations based on a particular set of input plant operating configuration criteria and determining one of the number of different operating configurations that best meets the objective function, wherein the objective function considers costs of energy creation and usage of the plurality of energy producing units;

wherein the expert engine calls the numerical solver multiple times, provides the numerical solver with a different set of input plant operating configuration criteria during each call of the numerical solver and determines the final optimal operating configuration of the plurality of energy producing units based on the optimal plant operating configurations determined by the numerical solver during the calls.

20. The energy management system of claim 19, further including a control system having one or more controllers that control the operation of the plurality of energy producing units, wherein the expert engine provides signals based on the final optimal operating configuration to the control system to use in controlling the operation of the plurality of energy producing units.

21. The energy management system of claim 19, further including a user interface device and wherein the expert engine provides signals indicative of the final optimal operating configuration to a user via the user interface device.

22. The energy management system of claim 19, wherein the numerical solver uses the equipment models to predict the operation of the plant at each of the different operating configurations based on a particular set of input plant operating configuration criteria.

23. The energy management system of claim 19, wherein the numerical solver receives a set of constraints associated with operating limits of plant equipment including each of the plurality of energy producing units, and wherein the numerical solver determines the optimal plant operating configuration as a plant operating point that does not violate any of the set of constraints.

24. The energy management system of claim 19, wherein the expert engine determines the different sets of input plant operating configuration criteria based on rules within the expert engine and provides the determined different sets of input plant operating configuration criteria to the numerical solver.

25. The energy management system of claim 19, wherein the numerical solver receives a set of constraints associated with operating limits of plant equipment, a set of environmental conditions associated with operation of the plant equipment and a load requirement of the plant, and wherein the numerical solver determines the optimal plant operating configuration as a plant operating point at which the plant operates at the environmental conditions to produce the load requirement without violating any of the set of constraints.

26. The energy management system of claim 19, wherein the objective function specifies a manner of evaluating a plant operating point as a point that minimizes the economic costs of energy creation and usage of the plurality of energy producing units in the plant.

27. The energy management system of claim 19, wherein the objective function specifies a manner of evaluating a plant operating point as a point that minimizes the economic costs of energy creation and usage of the plurality of energy producing units in the plant over a specific period of time.

28. The energy management system of claim 19, wherein the numerical solver includes first and second different equipment models for one or more of the energy producing units, wherein the numerical solver uses the first equipment model for the one or more of the energy producing units during a first call from the expert engine and uses the second equipment model for the one or more of the energy producing units during a second call from the expert engine.

29. The energy management system of claim 28, wherein the first equipment model for the one or more of the energy producing units is less accurate but is less computationally expensive than the second equipment model for the one or more energy producing units.

30. The energy management system of claim 28, wherein the first equipment model for the one or more of the energy producing units is less constrained than the second equipment model for the one or more of the energy producing units.

31. The energy management system of claim 19, wherein the expert engine provides a first set of operational constraints to the numerical solver as a set of input plant operating configuration criteria for one or more pieces of the plant equipment during the first call to the numerical solver and provides a second set of operational constraints to the numerical solver as a set of input plant operating configuration criteria during the second call to the numerical solver, wherein the second set of operational constraints are less relaxed than the first set of operational constraints.

32. The energy management system of claim 19, wherein the expert engine provides the same set of ambient conditions, plant equipment operating costs, and energy demands as the set of input plant operating configuration criteria during each of the first call and the second call to the numerical solver but provides a different set of equipment constraints to the numerical solver during the first call and the second call to the numerical solver.

33. The energy management system of claim 19, wherein the expert engine provides the same set of ambient conditions, plant equipment operating costs, and energy demands as the set of input plant operating configuration criteria during each of the first call and the second call to the numerical solver but provides a subset of equipment to use as constraints to the numerical solver during the second call to the numerical solver.

34. The energy management system of claim 19, wherein during a first call to the numerical solver, the numerical solver uses the objective function to determine an optimal set of plant equipment to use and wherein during a second call to the numerical solver the expert engine provides the optimal set of plant equipment to the numerical solver and the numerical solver uses the objective function to determine an optimal set of equipment operational parameters for the optimal set of plant equipment.

35. The energy management system of claim 34, wherein the numerical solver uses a first set of equipment models during the first call from the expert engine and uses a second and different set of equipment models during the second call from the expert engine, wherein the second set of equipment models are more accurate than the first set of equipment models.

36. The energy management system of claim 34, wherein the numerical solver uses a first set of operational constraints in response to the first call from the expert engine and uses a second and different set of operational constraints during the second call from the expert engine, wherein the second set of operational constraints are less relaxed than the first set of operational constraints.

37. The energy management system of claim 34, wherein the numerical solver uses different equipment models for the same plant equipment during the first and second calls to the numerical solver.

38. The energy management system of claim 34, wherein the numerical solver uses different sets of equipment operational constraints during the first and second calls to the numerical solver.

39. The energy management system of claim 34, wherein the expert engine uses an output of numerical solver from a first call to the numerical solver to determine one or more of the set of input plant operating configuration criteria for use in a second call to the numerical solver.

40. A method of configuring the operation of a plant having a set of interconnected plant equipment, wherein the plant equipment includes multiple sets of energy production units that can be run separately or together to produce energy, the method comprising:

storing on a computer device a plurality of equipment models that model the operation of the plant equipment and an objective function defining optimal operation of the interconnected plant equipment;

determining one or more operating values for use in running the plant equipment by calling via a computer device a numerical solver a plurality of times to determine one or more operating values for use in running the plant equipment, including providing the numerical solver different plant configuration input criteria during each of the calls; and

during each of the calls, using the objective function, the plurality of equipment models and a set of plant configuration input criteria to determine an optimal operating configuration of the set of interconnected plant equipment by determining an operational configuration of the set of interconnected plant equipment that minimizes or maximizes the objective function.

41. The method of configuring the operation of a plant of claim 40, wherein using the objective function includes using an objective function that determines an economic cost of running the energy production units to produce a needed amount of energy.

42. The method of configuring the operation of a plant of claim 40, wherein storing includes storing first and second different equipment models for one of the energy production units, and wherein determining an operational configuration of the set of interconnected plant equipment in the numerical solver includes using the first equipment model for the one of the energy production units during a first call of the numerical solver and using the second equipment model for the one of the energy production units during a second call of the numerical solver.

43. The method of configuring the operation of a plant of claim 42, wherein the first equipment model for the one of the energy production units is less accurate but less computationally expensive than the second equipment model for the one of the energy production units.

44. The method of configuring the operation of a plant of claim 42, wherein the first equipment model for the one of the energy production units is less constrained than the second equipment model for the one of the energy production units.

45. The method of configuring the operation of a plant of claim 40, wherein providing the numerical solver different plant configuration input criteria during each of the calls includes providing a first set of operational constraints to the numerical solver as the plant configuration input criteria for one or more pieces of the plant equipment during a first call to the numerical solver and providing a second set of operational constraints to the numerical solver as the plant configuration input criteria during a second call to the numerical solver, wherein the second set of operational constraints are less relaxed than the first set of operational constraints.

46. The method of configuring the operation of a plant of claim 40, wherein providing the numerical solver different plant configuration input criteria during each of the calls includes providing a set of ambient conditions, plant equipment operating costs, energy demands and equipment constraints to the numerical solver as the plant configuration input criteria during each of a first call and a second call to the numerical solver.

47. The method of configuring the operation of a plant of claim 46, wherein providing the numerical solver different plant configuration input criteria during each of the calls includes providing the same set of ambient conditions, plant equipment operating costs, and energy demands as the plant configuration input criteria during each of the first call and the second call to the numerical solver but providing a different set of equipment constraints to the numerical solver during the first call and the second call to the numerical solver.

48. The method of configuring the operation of a plant of claim 46, wherein providing the numerical solver different plant configuration input criteria during each of the calls includes providing the same set of ambient conditions, plant equipment operating costs, and energy demands as the plant configuration input criteria during each of the first call and the second call to the numerical solver but providing a subset of equipment to use as constraints to the numerical solver during the second call to the numerical solver.

49. The method of configuring the operation of a plant of claim 40, wherein determining an operational configuration of the set of interconnected plant equipment that minimizes or maximizes the objective function in a first call to the numerical solver includes using the objective function to determine an optimal set of plant equipment to use, and wherein determining an operational configuration of the set of interconnected plant equipment that minimizes or maximizes the objective function in a second call to the numerical solver includes using the objective function to determine an optimal set of equipment operational parameters for the optimal set of plant equipment.

50. The method of configuring the operation of a plant of claim 40, wherein determining an operational configuration of the set of interconnected plant equipment that minimizes or maximizes the objective function includes using different equipment models for the same plant equipment during first and second calls to the numerical solver.

51. The method of configuring the operation of a plant of claim 40, wherein determining an operational configuration of the set of interconnected plant equipment that minimizes or maximizes the objective function includes using different sets of equipment operational constraints during the first and second calls to the numerical solver.

52. The method of configuring the operation of a plant of claim 40, including using an output of the numerical solver from a first call to the numerical solver to determine one or more of the plant configuration input criteria for use in a second call to the numerical solver.