Process Plant Simulation Models from Flows and Control Logic
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Solution Overview
Problem
Existing methods for verifying and validating automation systems in industrial processes are manual, complex, and costly, lacking an automated process to generate simulation models for process sections, which complicates optimization and identification of unintended behavior.
Innovation Solution
A method is provided to automatically generate a simulation model of a process section by interpreting mechanical flows and control logic, integrating them, and simulating the process using a machine learning model, allowing early testing of control logics without manual development.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual methods are used for verification and validation of automation systems, then the systems can be tested, but the process becomes complex and costly with large amounts of manual work
Solution Approach 1:
The patent creates a virtual copy of the industrial process through automated generation of simulation models from process description data. This virtual model replicates the physical process behavior, allowing verification and validation to be performed on the digital twin rather than requiring complex manual testing of the actual automation system.
Solution Approach 2:
The patent performs verification and validation activities during the design phase by automatically generating simulation models before the automation system is fully implemented. This preliminary testing allows issues to be identified and resolved early, avoiding the need for extensive manual validation work after deployment.
2Productivity
If automated simulation model generation is implemented, then manual effort is reduced, but the automation extent needs to be increased
Solution Approach 1:
The patent replaces manual mechanical processes of model creation with automated computational processes. Machine learning models and algorithms automatically interpret process description data and generate simulation models, substituting the manual engineering work with intelligent automated systems.
Solution Approach 2:
The system performs self-service by automatically generating simulation models from process description data without requiring manual intervention. The automated generation process interprets the input data, creates the appropriate model structure, and produces the simulation model independently, reducing reliance on manual engineering effort.
3Loss of time
If simulation models are created early in development, then optimization is improved, but the automation capability must be enhanced
Solution Approach 1:
The patent enables simulation model generation during the early design phase by automating the interpretation of process description data. This preliminary creation of simulation models allows for early optimization and testing before the physical system is built, reducing overall development time through advance planning and virtual prototyping.
Data Source
AI summary
A method of simulating a process section of an industrial process is provided. The method comprises obtaining a model of mechanical flows within the process section and obtaining a state-based control logic describing interactions between equipment associated to the process section. The method further comprises providing a simulation model for the process section based on the model of mechanical flows and the control logic and simulating the process section based on the simulation model. Providing the simulation model comprises automatically interpreting the model of mechanical flows and the control logic; and automatically integrating interactions between the model of mechanical flows and the control logic.