Modular Subflowsheet Architecture for Industrial Process Modeling
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Solution Overview
Problem
Current process modeling systems lack modularity and hierarchy, making it difficult to efficiently develop, deploy, and maintain large-scale industrial process models, particularly in complex manufacturing facilities with repetitive and parallel constructs.
Innovation Solution
A system and method that allow for the collection and combination of flowsheets with corresponding unit models, enabling the automatic execution of macros across hierarchical levels, resolving conflicts, and facilitating scripting within merged subflowsheets to create a comprehensive and modular process model.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If process modeling systems use traditional non-modular structures to represent complex real-world systems, then they can model large-scale systems, but the development, deployment and maintenance become increasingly difficult and time-consuming
Solution Approach 1:
The patent divides a complex process model into multiple subflowsheets that can be independently developed, maintained, and executed. Each subflowsheet represents a modular segment of the overall process, allowing parallel development by different users and reducing the complexity of managing large-scale models as a single monolithic structure.
Solution Approach 2:
The patent implements a hierarchical structure where subflowsheets can contain nested subflowsheets within them, creating a multi-level modular architecture. This nesting allows complex processes to be broken down into manageable layers, where each layer can be developed and maintained independently while still functioning as part of the larger system.
2Ease of repair
If process models are developed as single integrated units, then they can represent complete processes, but any modifications require analyzing the entire model which reduces maintainability
Solution Approach 1:
By segmenting the process model into independent subflowsheets, the patent enables maintainers to modify only the specific subflowsheet that needs changes rather than analyzing the entire model. This segmentation isolates modifications to manageable segments, significantly reducing the time and effort required for model maintenance.
3Productivity
If manual development of large-scale flowsheets is used, then detailed control is possible, but the effort required increases significantly with system size and complexity
Solution Approach 1:
The nested subflowsheet structure allows users to create templates at higher hierarchical levels that can be automatically instantiated and reused across multiple lower-level subflowsheets. This reduces the amount of repetitive work required for modeling large-scale facilities with similar process units, as changes at the parent level automatically propagate to child levels.
Solution Approach 2:
The patent enables copying and reusing of subflowsheet templates across multiple instances. Once a subflowsheet is created, it can be copied and instantiated multiple times throughout the larger process model, significantly reducing the effort required to model repetitive process units while maintaining detailed control over each instance.
4Productivity
If modular subflowsheet structure is implemented, then development and maintenance efficiency improve, but conflicts between merged subflowsheets need to be resolved
Solution Approach 1:
The patent implements an automatic conflict detection and resolution mechanism that provides feedback when merging subflowsheets. The system identifies conflicts between merged subflowsheets and automatically resolves them using predefined rules, reducing the manual effort and complexity associated with conflict resolution while maintaining the benefits of modular development.
Data Source
AI summary
A system and method for modeling industrial processes is described. One embodiment includes collecting a plurality of flowsheets, which include corresponding groups of unit models and combining the plurality of flowsheets to create a combined model. In addition, a first macro associated with a first flowsheet is initiated and other macros by the same name as the first macro are automatically executed. In variations, the other macros are executed from a lowest hierarchical level flowsheet relative to the first flowsheet to a higher hierarchical level until the first macro is run.