Method and apparatus for intelligent control and monitoring in a process control system
First Claim
1. An adaptive process control loop controller within a process control environment comprising:
- a control module to control operation of the process control loop including one or more process control loop devices within the process control loop in response to control data from the control module;
a plug-in module operatively coupled to the control module as a non-layered, integrated extension thereof, the plug-in module comprising a process model identification control routine to examine the control data to detect a change therein, and a collection routine to collect the control data and operating condition data in connection with a condition of the process in response to the detected change; and
a model identification engine operatively coupled to the plug-in module to receive the collected control data and the collected operating condition data, the model identification engine comprising a model identification routine to execute a plurality of model parameter identification cycles, wherein each cycle comprises;
a plurality of simulations of the process based on one or more simulation parameters, each simulation having different simulation parameter values and each simulation using the collected control data as an input,an estimation error calculation for each simulation based on simulated operation condition data in connection with an output of the simulation and based on the collected operating condition data, anda model parameter calculation of a model parameter value based on at least two of the estimation errors and based on simulation parameter values used in the simulation corresponding to each of the at least two estimation errors.
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Abstract
A controller includes a control module to control operation of a process in response to control data, a plug-in module coupled to the control module as a non-layered, integrated extension thereof, and a model identification engine. The plug-in detects a change in the control data, and a collects the control data and data in connection with a condition of the process in response to the detected change. The model identification engine executes a plurality of model parameter identification cycles. Each cycle includes simulations of the process each having different simulation parameter values and each using the control data as an input, an estimation error calculation for each simulation based on an output of the simulation and based on the operating condition data, and a calculation of a model parameter value based on the estimation errors and simulation parameter values used in the simulation corresponding to each of the estimation errors.
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Citations
30 Claims
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1. An adaptive process control loop controller within a process control environment comprising:
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a control module to control operation of the process control loop including one or more process control loop devices within the process control loop in response to control data from the control module; a plug-in module operatively coupled to the control module as a non-layered, integrated extension thereof, the plug-in module comprising a process model identification control routine to examine the control data to detect a change therein, and a collection routine to collect the control data and operating condition data in connection with a condition of the process in response to the detected change; and a model identification engine operatively coupled to the plug-in module to receive the collected control data and the collected operating condition data, the model identification engine comprising a model identification routine to execute a plurality of model parameter identification cycles, wherein each cycle comprises; a plurality of simulations of the process based on one or more simulation parameters, each simulation having different simulation parameter values and each simulation using the collected control data as an input, an estimation error calculation for each simulation based on simulated operation condition data in connection with an output of the simulation and based on the collected operating condition data, and a model parameter calculation of a model parameter value based on at least two of the estimation errors and based on simulation parameter values used in the simulation corresponding to each of the at least two estimation errors. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A process control system comprising:
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an adaptive process controller comprising a control module to control operation of a process using control data, a plug-in module to detect changes in the control data and to collect operation condition data in connection with a condition of the process in response to detecting a change in the control data, and a model identification engine to determine one or more model parameter values based on simulation outputs of the process using the control data as simulation inputs and based on the collected operation condition data, wherein a model of the process comprises the one or more model parameter values to model the process; and a workstation operatively coupled to the adaptive process controller, the workstation comprising a server to fetch and store the model of the process from the adaptive process controller, and an operator interface application to enable a user to view, analyze and edit the stored model of the process; wherein the adaptive process controller comprises the model identification engine to retrieve the model of the process from the server in response to a signal from the plug-in module indicating a detected operating state of the process corresponding to the model of the process, and wherein the plug-in module utilizes the model of the process to tune the adaptive process controller. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
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26. A method of controlling a process control system having a plurality of control routines, the method comprising:
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controlling the operation of a process control loop including one or more process control loop devices within the process control loop in response to control data from a control module; examining the control data to detect an event indicative of a process change in connection with a control routine of the plurality of control routines associated with the process change; collecting control data used by the control routine associated with the process change in response to the detected event; collecting operating condition data in connection with a condition of the process in response to the detected event; receiving the collected control data and the collected operating condition data; identifying a process model for the control routine associated with the process change, wherein identifying a process model comprises executing a plurality of model parameter identification cycles, wherein each cycle comprises; executing a plurality of simulations of the process based on one or more simulation parameters, each simulation having different simulation parameter values and each simulation using the collected control data as an input, calculating an estimation error for each simulation based on simulated operation condition data in connection with an output of the simulation and based on the collected operating condition data, calculating a model parameter value based on at least two of the estimation errors and based on simulation parameter values used in the simulation corresponding to each of the at least two estimation errors, and generating a process model from the model parameter values. - View Dependent Claims (27, 28, 29, 30)
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Specification