Process Model Tuning for Real-Time Heat Transfer Coefficient Tracking
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Solution Overview
Problem
Current process simulation models in power plants and industrial manufacturing plants face challenges in accurately determining process characteristic parameters, such as heat transfer coefficients, due to unmeasurable factors like soot buildup, which affects model accuracy and requires time-consuming off-line calculations, leading to delayed and potentially incorrect tuning.
Innovation Solution
A process characteristic parameter determination system that uses a first principle-based model with a tuning module to automatically adjust process characteristic parameters in real-time, matching measured plant operations, enabling on-line determination and improved simulation accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If off-line calculations are used to determine process characteristic parameters, then model accuracy can be improved, but time consumption increases and tuning is delayed
Solution Approach 1:
The system performs preliminary actions by continuously running simulation models in parallel with the actual process, pre-calculating what the process variables should be under current conditions. This allows the tuning system to have accurate reference values ready when needed, eliminating the need for time-consuming off-line calculations while maintaining high accuracy.
Solution Approach 2:
The system implements feedback by continuously comparing simulated process variables with actual measured variables and using this difference to automatically adjust process characteristic parameters. This real-time feedback loop enables the system to maintain accurate models without delayed off-line tuning, resolving the contradiction between accuracy and time consumption.
2Measurement precision
If first principle-based models are used to simulate plant operation, then model accuracy is improved, but device complexity increases
Solution Approach 1:
The complex first principle-based model is segmented into multiple independent simulation modules, each handling a specific function or process aspect. This modular segmentation maintains the accuracy benefits of first principles while reducing overall system complexity by dividing it into manageable, independently configurable units that can be assembled according to specific plant requirements.
Solution Approach 2:
The simulation system is designed with universal, multi-functional components that can adapt to different plant configurations and processes. By creating reusable simulation modules that can serve multiple purposes across different applications, the system reduces the need for custom complex models for each specific case, thereby maintaining accuracy while managing complexity.
3Reliability
If process characteristic parameters are continuously tuned in real-time, then simulation accuracy is maintained, but computational load increases
Solution Approach 1:
The system applies partial action by selectively tuning only the most critical process characteristic parameters that have the greatest impact on simulation accuracy, rather than continuously adjusting all parameters. This approach maintains sufficient simulation reliability while significantly reducing the computational load compared to comprehensive real-time tuning of all parameters.
Solution Approach 2:
The system merges the simulation model execution with the parameter tuning process into a unified real-time operation. By combining these functions, the system efficiently shares computational resources and data between simulation and tuning tasks, reducing overall computational load while maintaining continuous accuracy through coordinated operation.
Data Source
AI summary
A process characteristic parameter determination system uses a process model and a tuning module to accurately determine a value for a process characteristic parameter within a plant without measuring the process characteristic parameter directly, and may operate on-line or while the process is running to automatically determine a correct value of the process characteristic parameter at any time during on-going operation of the process. The process characteristic parameter value, which may be a heat transfer coefficient value for a heat exchanger, can then be used to enable the determination of a more accurate simulation result and/or to make other on-line process decisions, such as process control decisions, process operational mode decisions, process maintenance decisions such as implementing a soot blowing operation, etc.