System and Method for Process Predictive Simulation

• US 20120095808A1
• Filed: 10/15/2010
• Published: 04/19/2012
• Est. Priority Date: 10/15/2010
• Status: Abandoned Application

• Current Assignee: Schneider Electric Software, LLC (Schneider Electric SE)
• Original Assignee: Invensys Systems Incorporated (Invensys PLC)
• Inventors: Bluck, David, Kattapuram, James
• Application Number:
  US12/906,070
• Publication Number:
  US 20120095808A1
• Time in Patent Office: Days
• US Class Current: 705/7.37
• CPC Class Codes: G05B 19/41885 characterised by modeling, simulation of the manufacturing system
• CPC Class Codes: G06Q 10/06375 Prediction of business process outcome or impact based on a proposed change
• 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 for process control is provided. The system comprises a computer system, a data store comprising a plurality of data sets, each data set associated with operating conditions of a plant at a particular time, a first application, and a second application, the first and second applications executed by the computer system. The first application simulates operation of the plant in accordance with first principles and based on one of the data sets. The second application receives plant simulation data from the first application, aggregates plant historical data about the plant from a plurality of sources, associates the plant simulation data and the plant historical data to components of the plant, analyzes the plant simulation data and the plant historical data, and visually presents an information produced by the analysis of the plant simulation data and the plant historical data.

Claims

1. A system for process control, comprising:

a computer system;

a data store comprising a plurality of data sets, each data set associated with operating conditions of a plant at a particular time,

a first application that, when executed by the computer system, simulates operation of the plant based at least in part on one of the data sets, wherein the application simulates operation of the plant based on first principles,

a second application that, when executed by the computer system,

receives plant simulation data from the first application,

aggregates plant historical data about the plant from a plurality of sources,

associates the plant simulation data and the plant historical data to components of the plant,

analyzes the plant simulation data and the plant historical data, and

visually presents an information produced by the analysis of the plant simulation data and the plant historical data.

2. The system of claim 1, wherein the second application is an enterprise manufacturing intelligence (EMI) application.

3. The system of claim 1, wherein the plant is one of an oil refinery, a steam powered electrical generation plant, a brewery, and a food processing plant.

4. The system of claim 1, wherein the first application simulates operation of the plant based further on at least one change parameter, where the change parameter is substituted in first principles calculations by the first application in the place of a parameter from one of the data sets.

5. The system of claim 1, wherein the second application visually presents a parameter that is simulated by the first application, wherein the parameter is not directly measured by a sensor of the plant.

6. The system of claim 1, wherein the second application determines the economic value of replacing a component of the plant based on the plant simulation data.

7. The system of claim 1, wherein the second application determines a sensitivity of the analysis based on the plant simulation data.

8. A system for process control, comprising:

a computer system;

a data store comprising a plurality of data sets, each data set associated with a plant at a particular time;

an enterprise manufacturing intelligence (EMI) application that, when executed by the computer system,

aggregates a plurality of historic data from a plurality of sources, at least some of the historic data stored in the data store,

contextualizes the historic data by associating at least some of the historic data to components of the plant,

analyzes at least some of the historic data and a plurality of simulation data to determine the economic value of a change of the plant from a current actual state of the plant represented by the simulated data, and

presents the economic value of the change; and

a first principles plant simulation application that, when executed by the computer system, produces the simulation data based at least in part on the change of the plant from a current actual state of the plant.

9. The system of claim 8, wherein the EMI application contextualizes the historic data further by associating a unit of measure with at least some of the historic data.

10. The system of claim 8, wherein the first principles plant simulation application produces the simulation data based at least in part on calculating thermodynamic properties using at least one equation of state.

11. The system of claim 10, wherein the first principles plant simulation application calculates the thermodynamic properties further using at least one phase equilibrium calculation.

12. The system of claim 8, wherein the change of the plant comprises replacing a component of the plant and wherein determining the economic value of the change is based in part on a cost of the replacement cost of the component.

13. The system of claim 8, wherein the historic data analyzed by the EMI application comprises a data set selected from the data store based on a criteria selected from one of a market price for a precursor material consumed by the plant, a market price for a product produced by the plant, and a seasonal constraint.

14. A method of operating a plant, comprising:

storing a first historical data set in a data store, the first historical data set representing at least in part an operating state of the plant;

aggregating historical data from a plurality of sources, the sources comprising the data store;

providing a context for the historical data by associating at least some of the historical data with one of components in the plant or units of measurement;

simulating the plant to produce a simulated data set representing at least in part a simulated operating state of the plant, the simulating based on at least some of the historical data and based on changing an at least one operating parameter of the plant;

analyzing some of the historical data and the simulated data set to determine a result of changing the at least one operating parameter; and

presenting the result of changing the at least one operating parameter.

15. The method of claim 14, further comprising storing a second historical data set in the data store, the second historical data set representing at least in part an operating state of a second plant.

16. The method of claim 15, wherein changing the at least one operating parameter of the plant is based on the second historical data set.

17. The method of claim 14, wherein the operating parameter is an operational set point of the plant.

18. The method of claim 14, wherein the operating parameter is associated with replacing a component of the plant.

19. The method of claim 14, wherein the plant is one of an oil refinery, a steam cycle electrical power generation plant, a brewery, and a food processing plant.

20. The method of claim 14, wherein the at least one operating condition is one of a market price of a raw material processed by the plant, a market price of a product produced by the plant, and a seasonal parameter.