Valve Positioner Self-Assessment for Realistic Digital Twin Control
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Solution Overview
Problem
Existing positioner technologies for process plants face challenges in achieving optimized operation due to discrepancies between simulated and real plant conditions, leading to potential misidentification of field device defects and high computational efforts for optimization, which can result in suboptimal performance and increased computing resources.
Innovation Solution
A positioner with integrated positioner electronics that includes a computing device capable of determining simulation parameters characterizing signal responses to control variables, using a grey-box model to adapt simulation parameters based on real signal responses, thereby providing realistic simulation data for improved design and control of process plants with reduced computational and data transmission efforts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If simulation parameters are based on idealized assumptions or reference data, then design simulation can be performed, but the simulation results do not match real plant conditions leading to misidentification of defects
Solution Approach 1:
The patent applies parameter changes by continuously adapting simulation parameters to match real plant conditions. The positioner determines simulation parameters characterizing its actual signal response and uses these updated parameters in the digital twin, ensuring the simulation accurately reflects real-world behavior rather than relying on idealized assumptions or reference data.
Solution Approach 2:
The positioner performs self-assessment by determining its own simulation parameters based on actual signal responses. This self-service approach allows the system to automatically update its digital twin with accurate, real-time parameters without external intervention, improving both simulation accuracy and defect identification reliability.
2Productivity
If complex optimization simulations are performed to achieve optimal operation, then design optimization can be achieved, but computational resources and data transmission efforts increase significantly
Solution Approach 1:
The patent applies partial action by performing optimization simulations only when necessary and using simplified simulation models. The positioner determines simulation parameters and updates the digital twin selectively, rather than continuously running complex optimizations, thereby achieving design optimization while reducing computational resource consumption and data transmission requirements.
3Productivity
If digital twin simulation is used for plant design and control, then optimized operation can be achieved, but discrepancies between simulated and real conditions lead to suboptimal performance
Solution Approach 1:
The patent applies feedback by continuously comparing actual positioner signal responses with simulation predictions and using this information to update simulation parameters. The positioner determines simulation parameters based on real signal responses and feeds this information back to the digital twin, creating a closed-loop system that progressively improves simulation realism and operational optimization.
Data Source
AI summary
A positioner for a process plant, such as a chemical plant, a power plant, or a food processing plant, may include a control valve for controlling a process fluid flow of the process plant, a pneumatic actuator for actuating the control valve, and positioner electronics for determining and providing a pneumatic control signal for the actuator based on a control variable. The positioner electronics may include a signal receiving interface for receiving the control variable. The positioner electronics may include a computing device configured to determine at least one simulation parameter that characterizes a signal response of the positioner to a received control variable. The positioner electronics may include a signal output interface for outputting the at least one simulation parameter.