Real-time Synchronized Process Plant Simulation
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Solution Overview
Problem
Existing process control simulation systems in plants like power generation and industrial manufacturing are often not synchronized with the actual control network, leading to inaccurate and difficult-to-use simulations that diverge from the plant's operating conditions, making it hard to integrate with operator displays and control modules.
Innovation Solution
A real-time simulation system that synchronizes with the actual process control network, updating periodically to reflect changes and using the same user interface as the control system, allowing for easy initialization and operation without significant configuration, and alternating between tracking and prediction modes to maintain accuracy and usability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a simulation system is implemented separately from the control network, then it can operate independently, but it becomes desynchronized from actual plant conditions and requires significant configuration
Solution Approach 1:
The patent merges the simulation system with the control network by having the simulation application execute on the same workstation as the control application, sharing the same data highway and process control modules. This integration ensures automatic synchronization with actual plant conditions while reducing configuration complexity, as the simulation system inherits the control system's configuration and data structures.
2Measurement precision
If the simulation system updates frequently to track plant conditions, then accuracy improves, but system performance and responsiveness may deteriorate
Solution Approach 1:
The simulation system maintains continuous synchronization with the control network by periodically updating simulation inputs from the same data highway that the control system uses. This continuous data flow ensures the simulation remains accurate without requiring intensive processing, as it leverages the existing control system's data refresh cycle rather than implementing separate measurement and update mechanisms.
3Adaptability or versatility
If the simulation system uses a different user interface than the control system, then it can be optimized for simulation tasks, but it becomes harder to use and integrate
Solution Approach 1:
The simulation application utilizes the same user interface and data structures as the control system, allowing operators to interact with both control and simulation functions through a unified interface. This multi-functionality enables the system to serve both control and simulation purposes without requiring separate training or interfaces, while still providing simulation-specific capabilities through the shared interface framework.
Data Source
AI summary
A process control system simulation technique performs real-time simulation of an actual process control network as that network is running within a process plant in a manner that is synchronized with the operation of the actual process control network. This real-time, synchronized simulation system includes a simulation process control network and a process model which are automatically updated periodically during the operation of the actual process control network to reflect changes made to the process control network, as well as to account for changes in the plant itself, i.e., changes which require an updated process model. The simulation system provides for more readily accessible and usable simulation activities, as the process control network and the process models used within the simulation system are synchronized with and up-to-date with respect to the current process operating conditions.