Process Plant Order Synchronization for Batch-Continuous Control
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Solution Overview
Problem
Industrial process control systems face challenges in managing disruptions caused by batch operations, asset downtime, and unsynchronized orders, leading to inefficient operations and performance in processing facilities.
Innovation Solution
A system and method for managing industrial processes using a virtual content tracker and asynchronous update scheme to monitor and optimize batch operations, ensuring seamless synchronization with continuous processes, minimizing disruptions, and optimizing performance and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If batch process section is concatenated to continuous process section, then refined products can be produced utilizing blending components, but batch operations disrupt continuous process operations
Solution Approach 1:
The system segments the batch process monitoring into discrete, manageable components including virtual content trackers for individual batch operations, separate flag mechanisms for different batch statuses, and modular notification systems. This segmentation allows continuous processes to remain stable while batch operations are independently tracked and managed without mutual disruption
Solution Approach 2:
The patent introduces an intermediary batch management system that acts as a mediator between batch and continuous processes. This intermediary monitors batch operations through virtual content trackers, manages synchronization through control signals, and coordinates between the two process types, preventing direct disruption while maintaining production flexibility
2Ease of repair
If asset downtime or maintenance operations occur, then equipment can be serviced and repaired, but industrial process operations are disrupted
Solution Approach 1:
The system performs preliminary actions by pre-tracking batch operation statuses and maintaining virtual content records before maintenance occurs. When maintenance is needed, the pre-established tracking system and flag mechanisms are already in place, allowing rapid coordination of process adjustments and faster recovery, minimizing overall disruption to productivity
Solution Approach 2:
The patent implements feedback mechanisms through notifications and control signals that continuously monitor batch operation status. When maintenance operations begin, the system provides real-time feedback about affected batch operations, enabling operators to make informed decisions about process adjustments and recovery timing, thereby maintaining productivity
3Adaptability or versatility
If ad hoc orders or requests to produce refined products are processed, then customer demand can be met, but scheduled operations are disrupted
Solution Approach 1:
The system employs dynamic tracking where virtual content trackers and notification mechanisms adapt in real-time to changing order requirements. When ad hoc orders arrive, the system dynamically updates batch operation status tracking and generates appropriate notifications without requiring complete rescheduling of all operations, thus managing complexity while maintaining demand responsiveness
Solution Approach 2:
The patent utilizes parameter changes in the form of status flags and notification levels that can be adjusted based on order priority and type. Rather than fundamentally changing the scheduling system, the patent modifies operational parameters such as tracking intensity and notification frequency to handle ad hoc orders, reducing overall system complexity
Data Source
AI summary
Various embodiments described herein relate to management of an industrial process in a process plant. In this regard, a status of an order of one or more orders is determined based at least on component spent characteristics. The one or more orders are associated with production of an industrial process product by the industrial process. A flag is set to a first value if the status of the order is a first status. Upon receiving an optimization request to optimize the industrial process with respect to another order, first notification(s) are rendered on a display. Then, the flag is set to a second value if the status of the order is a second status. Further, second notifications are rendered on the display, demand data associated with the orders is updated, and control signal is transmitted to a controller to optimize the industrial process with respect to another order.