Field Device Station Simulation for Pre-Commissioning Selection
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Solution Overview
Problem
Current methods for process plant control and regulation require complex interventions during operation and cannot select the optimal field devices before commissioning, leading to increased control and regulation effort.
Innovation Solution
A simulation environment is created to digitally map the process engineering system, allowing for the simulation of various field devices from a standard component kit, enabling the selection of the optimal field device based on simulated operating variables and design parameters before actual operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed simulation model is used to represent a specific process plant, then the plant's operation can be optimized, but field devices cannot be selected or tested before commissioning
Solution Approach 1:
The simulation model is transformed from a fixed, static representation to a dynamic, configurable system that can accommodate multiple field device variants. The model allows dynamic substitution of field devices from a standard component kit, enabling pre-commissioning testing of different device configurations without requiring physical installation.
Solution Approach 2:
Virtual copies of field devices are created and integrated into the simulation model. These digital representations allow comprehensive testing and evaluation of multiple field device options before actual commissioning, eliminating the need for physical trial installations while maintaining accurate performance characteristics.
2Productivity
If field devices are not selected before commissioning, then commissioning can proceed, but complex control interventions are necessary during operation
Solution Approach 1:
Field device selection and optimization are performed in advance during the simulation phase before actual commissioning. The simulation model enables comprehensive evaluation of different field device configurations, allowing the optimal device to be selected and configured prior to plant commissioning, thereby eliminating the need for complex control interventions during operation.
3Reliability
If multiple field devices are tested virtually before commissioning, then the optimal field device can be selected, but the design and simulation process becomes more complex
Solution Approach 1:
A universal simulation framework is created that can handle multiple field device types from a standard component kit using a common model structure. This multi-functional approach allows different field devices to be tested within the same simulation environment without requiring separate complex modeling procedures for each device type, thereby simplifying the overall simulation process while maintaining comprehensive testing capabilities.
Data Source
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AI summary
The invention relates to a method for designing a field device station, such as a control valve, a pump or the like, for a process plant, such as a chemical plant, a food-processing plant, a power plant or the like. The process plant with the field device station to be designed can be modeled in a simulation environment on the basis of operation-specific plant characteristics of the process plant, such as type of process medium, process fluid flow, number of field device stations, plant environment or the like. The method comprises the following steps: providing (603) a field device module for simulating at least a portion of the field device station in the simulation environment, the field device module being designed to simulate at least one field device from a group of field devices, whereby at least one operating variable, such as a controlled variable, for example, temperature, pressure, flow rate or the like, of the modeled process plant can be influenced; setting (605) the field device module to at least one field device to be simulated from the group of field devices and to at least one associated field-device-specific design parameter, such as a geometry parameter, a performance parameter, such as an actuating drive force, a pump rate, a Kv value or the like; simulating (607) the operation of the modeled process plant and of the field device station to be designed using the set field device module in order to determine, for the at least one field device to be simulated, at least one operating variable of the modeled process plant in accordance with the at least one associated field-device-specific design parameter; and selecting (609) a field device suitable for the field device station to be designed from the group of field devices on the basis of a comparison of the at least one determined operating variable with an evaluation operating variable.