Plant Facility Evaluation Using Parameter-Matched Simulation
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Solution Overview
Problem
Existing evaluation methods for facility performance in process plants are inaccurate due to differences between design/test conditions and actual operating conditions, leading to late detection of abnormalities and performance deterioration.
Innovation Solution
An evaluation apparatus and system that adjusts model parameters based on real-time measurements to match simulation values with actual values, enabling early detection of abnormalities and accurate performance evaluation under actual operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If simulation is performed using model created based on value provided by manufacturer, then simulation can be executed, but accuracy of simulation is lowered and performance of facility cannot be properly evaluated
Solution Approach 1:
The patent changes the parameters used in simulation from manufacturer-provided design values to actual operating values obtained from sensors installed on the facility. This includes using real measurements of flow rate, pressure, temperature, and power consumption under actual operating conditions to create an accurate model that reflects true facility performance
Solution Approach 2:
The patent implements feedback by continuously monitoring actual facility operation through sensors and comparing measured values with simulation results. This feedback loop allows for validation and refinement of the simulation model to improve accuracy over time
2Difficulty of detecting and measuring
If various sensors are installed in target facility to detect abnormality, then detection capability is improved, but abnormality is detected only after deterioration has significantly progressed
Solution Approach 1:
The patent performs preliminary action by creating a simulation model that predicts facility behavior and performance degradation trends before actual abnormalities occur. By comparing simulated performance with actual measurements, the system can detect early signs of deterioration that have not yet manifested as obvious abnormalities
Solution Approach 2:
The patent replaces traditional mechanical sensor-based detection systems with a simulation-based prediction system. Instead of relying solely on physical sensors to detect abnormalities after they occur, the system uses computational modeling to predict and detect early signs of performance degradation
Data Source
AI summary
An evaluation apparatus includes a storage unit that stores a model modeling a state of a facility provided in a plant, a simulator that adjusts a parameter that is set in the model so that a difference between an actual measurement value based on a process value of the facility in a first state and a first simulate value calculated by using the model is equal to or less than a threshold, and an estimation unit that estimates a first estimated operating point that indicates an operation state of the facility in the first state based on the adjusted parameter.