MPC Operating Limits Based on Real Asset Capability
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Solution Overview
Problem
Industrial processes often operate inefficiently due to fixed limits that are inaccurately configured, leading to disruptions and undesirable operations in industrial facilities, where concatenated processes can negatively impact other processes, resulting in inefficiencies and suboptimal performance.
Innovation Solution
A system and method that utilize asset modeling data from performance management systems to adjust real-time operating limits and transmit control signals for industrial processes, enabling dynamic optimization and minimizing disruptions through model predictive control and industrial process optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fixed limits of operation are used for industrial assets, then operational simplicity is maintained, but operational efficiency deteriorates due to inaccurate configuration and inability to adapt to dynamic conditions
Solution Approach 1:
The patent transforms fixed static operating limits into dynamic real-time operating limits that continuously adapt to changing asset capabilities and process conditions. The system calculates and updates operating limits dynamically based on real-time asset performance data, process conditions, and predictive models, enabling the control system to respond to dynamic conditions while maintaining operational simplicity through automated limit adjustment.
Solution Approach 2:
The patent implements a feedback mechanism where asset performance data and process conditions are continuously monitored, and this information feeds back into the operating limit calculation system. The system uses this feedback to continuously refine and adjust real-time operating limits, ensuring they remain accurate and optimized for current conditions while automatically correcting for any configuration inaccuracies.
2Stability of the object's composition
If fixed operating limits are configured based on equipment specifications, then operational stability is maintained, but adaptability to actual asset capabilities deteriorates
Solution Approach 1:
The patent enables the system to self-adjust operating limits by automatically calculating them based on real-time asset performance data and process conditions. Rather than relying on pre-configured fixed limits, the system serves itself by continuously determining optimal limits through predictive models and real-time data analysis, adapting to actual asset capabilities without external intervention while maintaining operational stability through controlled adjustment mechanisms.
Solution Approach 2:
The patent changes the operating parameters from fixed static values to dynamic calculated values that reflect actual asset capabilities. The system continuously updates operating limits by changing key parameters such as throughput rates, operational constraints, and performance thresholds based on real-time asset condition data, enabling adaptability while maintaining stability through gradual, controlled parameter transitions.
3Device complexity
If concatenated industrial processes are operated independently with fixed limits, then process control simplicity is maintained, but overall facility efficiency deteriorates due to process disruptions
Solution Approach 1:
The patent merges the control of concatenated industrial processes by implementing a unified real-time operating limit calculation system that considers the interdependencies between connected processes. Rather than controlling each process independently with separate fixed limits, the system integrates data from multiple processes and calculates coordinated operating limits that account for process interactions, disruptions, and cascading effects, improving facility efficiency while maintaining control simplicity through centralized automated management.
Data Source
AI summary
Various embodiments described herein relate to calculating asset capability using model predictive control and/or industrial process optimization. In this regard, an optimization request to optimize an industrial process that produces an industrial process product is received. In response to the optimization request, asset modeling data is obtained from one or more asset performance management systems for an asset associated with the industrial process. Also in response to the optimization request, one or more real-time operating limits for the industrial process are adjusted based at least in part on the asset modeling data obtained from the one or more asset performance management systems. Furthermore, a control signal configured based at least in part on the one or more real-time operating limits is transmitted to a controller configured for optimization associated with the industrial process that produces the industrial process product.