Simulation-Based Process Parameter Tuning for Real-Time Plant Models
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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, which are essential for efficient operation and maintenance, as they often rely on historical data and are not adaptable to real-time changes, leading to delayed and potentially incorrect tuning.
Innovation Solution
A system that uses a first principle-based model with a tuning module to automatically determine and adjust process characteristic parameters in real-time by comparing predicted and measured process variables, ensuring that the model output matches actual plant operations, thereby enabling more accurate simulations and decision-making.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If historical data is used to determine process characteristic parameters, then the model can be initially configured, but the parameters become outdated and inaccurate over time as plant conditions change
Solution Approach 1:
The patent implements a feedback mechanism where the simulation model continuously compares its predicted process variables against actual measured values from the plant. The difference (error) between predicted and measured values is fed back to adjust the process characteristic parameters, ensuring they remain accurate and up-to-date as plant conditions change over time.
Solution Approach 2:
The simulation model automatically tunes its own process characteristic parameters by comparing its outputs with actual plant measurements and adjusting parameters to minimize errors. This self-service capability eliminates the need for manual parameter updates and keeps the model continuously aligned with actual plant conditions.
2Measurement precision
If manual tuning of process characteristic parameters is performed, then some accuracy can be achieved, but it is time-consuming and requires plant shutdown or special test conditions
Solution Approach 1:
The patent enables continuous automatic tuning of process characteristic parameters during normal plant operation without interruption. The simulation model runs continuously, comparing predicted versus actual values and adjusting parameters in real-time, eliminating the need for plant shutdowns or special test conditions required by manual tuning methods.
Solution Approach 2:
The system performs self-tuning automatically during normal operation, eliminating the need for operator intervention or special maintenance activities. The simulation model continuously adjusts its own parameters based on real-time plant data, maintaining accuracy without impacting productivity or requiring operational disruptions.
3Reliability
If first principle-based models are used, then physical understanding is improved, but the models require accurate process characteristic parameters that are difficult to obtain
Solution Approach 1:
The patent uses feedback from actual plant measurements to automatically determine and update process characteristic parameters in the first principle-based model. The simulation model compares its predictions with real plant data and adjusts parameters to minimize errors, providing an automated way to obtain accurate parameters without complex manual procedures.
Solution Approach 2:
The patent replaces complex manual parameter determination procedures with an automated computational approach. Instead of requiring operators to perform complex calculations or physical measurements to obtain process characteristic parameters, the system uses the simulation model with feedback control to automatically determine parameters through mathematical optimization based on real-time plant data.
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.