Production Site Simulation Calibration for Integrated Process Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems for managing and controlling large-scale production sites, such as refineries, operate independently across different departments, leading to inefficiencies in site control and optimization.
Innovation Solution
A system that integrates planning, simulation, monitoring, calibration, and control functions to generate and execute production plans, simulate operations, monitor actual performance, calibrate simulation models, and adjust site controls based on calibrated simulation results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If independent systems are used for enterprise resource planning, manufacturing execution, and process control in different departments, then each department can operate autonomously, but the overall production site control efficiency deteriorates due to lack of integration
Solution Approach 1:
The patent integrates multiple independent departmental systems (enterprise resource planning, manufacturing execution, process control) into a unified production site control system. This merging allows data and control functions to flow seamlessly across departments, resolving the contradiction by maintaining departmental operational capabilities while achieving overall site-wide coordination and efficiency improvement.
Solution Approach 2:
The control system is designed with universal functionality that serves multiple departments and purposes simultaneously. It can perform enterprise resource planning, manufacturing execution, and process control functions within a single integrated platform, allowing the system to adapt to various departmental needs while maintaining overall integration and efficiency.
2Measurement precision
If simulation models are not calibrated with actual operation data, then the modeling process is simpler and faster, but the accuracy of simulation results deteriorates
Solution Approach 1:
The system implements a feedback mechanism where actual operation data from the production site is continuously fed back to calibrate and update the simulation models. This feedback loop ensures that models remain accurate by comparing simulated results with actual measurements and adjusting model parameters accordingly, resolving the contradiction between accuracy and calibration time through iterative improvement.
Solution Approach 2:
The system performs preliminary calibration of simulation models using available data before full-scale operation, and maintains calibrated models through periodic updates. This preliminary action ensures models are ready for accurate simulation without requiring extensive calibration each time, balancing accuracy requirements with time constraints.
3Measurement precision
If simulation models are calibrated frequently to maintain accuracy, then model precision improves, but the complexity and time required for calibration increases
Solution Approach 1:
The system employs periodic calibration of simulation models at scheduled intervals rather than continuous calibration. This periodic action maintains model precision by updating models with fresh operational data at appropriate frequencies, while avoiding the excessive complexity and time consumption of continuous calibration processes.
Solution Approach 2:
The calibration process focuses on adjusting key model parameters based on actual operational data rather than recalibrating entire models. This parameter-based approach maintains precision by updating critical variables while minimizing the complexity and computational burden of full model recalibration.
Data Source
AI summary
Provided is a system including a planning section that generates a production plan for a production site, using a planning model; a simulating section that simulates operation of at least a portion of the 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 a control section that controls the at least a portion of the production site, based on a simulation result obtained by simulating the operation of the at least a portion of the production site in accordance with the production plan, using the simulation model that has been calibrated.