Production Site Model Calibration for Accurate Planning Updates
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Solution Overview
Problem
In large-scale petroleum refineries, existing systems operate independently for enterprise resource planning, manufacturing execution, and process control, leading to inaccurate models and lack of integration, which hampers efficient production planning and site management.
Innovation Solution
A system that integrates simulation, monitoring, calibration, and updating of models to align simulated operations with actual site conditions, using a linear programming model to generate production plans and adjust coefficients based on differences, ensuring accurate modeling and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If independent systems are used for enterprise resource planning, manufacturing execution, and process control, then each system can be managed separately, but the models become inaccurate and integration is lost
Solution Approach 1:
The patent merges previously independent systems (enterprise resource planning, manufacturing execution, and process control) into an integrated system where a simulation model serves as a common platform. This integration allows data and models to be shared across all functional areas, improving model accuracy while maintaining operational independence through modular architecture.
Solution Approach 2:
The simulation model is designed to serve multiple functions simultaneously - it supports enterprise resource planning, manufacturing execution, and process control operations. This universal model acts as a common foundation for all planning and control activities, ensuring consistency and accuracy across different operational levels.
2Adaptability or versatility
If independent systems are used for different departments, then departmental autonomy is maintained, but production planning efficiency deteriorates
Solution Approach 1:
The integrated system is segmented into modular components that can be independently configured for different departments while sharing a common simulation model. This allows departmental autonomy in terms of customization and operation, while the shared model ensures efficient production planning across the entire organization.
Solution Approach 2:
The system implements feedback mechanisms where simulation results from the common model are used to optimize production plans that affect multiple departments. This feedback loop enables efficient coordination and resource allocation while respecting departmental specificities and autonomy.
3Device complexity
If the simulation model is not continuously calibrated, then system simplicity is maintained, but the difference between simulated and actual operation increases
Solution Approach 1:
The system implements self-service calibration where the simulation model automatically adjusts itself using actual operational data from the production site. This self-calibration mechanism maintains high simulation accuracy without requiring complex external intervention, balancing system simplicity with measurement precision.
Solution Approach 2:
A feedback mechanism continuously compares simulation results with actual operational data and uses this information to calibrate and update the simulation model. This automated feedback loop maintains high accuracy while keeping the system relatively simple by using standard data processing and model adjustment techniques.
4Stability of the object's composition
If the planning model is not updated based on simulation calibration, then model structure stability is maintained, but production plan accuracy deteriorates
Solution Approach 1:
The planning model is designed to be dynamic, automatically updating its parameters and coefficients based on calibration results from the simulation model. This dynamic update mechanism ensures the production plan remains accurate with changing conditions while maintaining overall model structure stability through systematic update procedures.
Data Source
AI summary
When operating a production site, it is preferable to maintain accurate models continuously. Provided is a system including a simulating section that simulates operation of at least a portion of a production site, based on a simulation model of the at least a portion of the production site; a monitoring section that monitors actual operation of the at least a portion of the production site; a calibrating section that calibrates the simulation model, based on a difference between the simulated operation and the actual operation; and an updating section that updates a planning model used to generate a production plan for the production site, according to the calibration of the simulation model.