Virtual Control System Simulation for Process Validation
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Solution Overview
Problem
The existing methods for validating and testing control system designs in process plants are inefficient, requiring actual hardware and lengthy development times, and often result in delays and risks due to the inability to pre-test process control logic before installation.
Innovation Solution
A simulation generator and method that automatically creates process models and connects them to control system interfaces, allowing for realistic stimuli to be provided to the control system for validation and operator training without the need for complete control system hardware, using a rules-based approach to facilitate computer-automated construction of simulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional control system validation methods are used requiring actual hardware, then the control system can be tested with real physical processes, but the development time is lengthy and project delays occur
Solution Approach 1:
The patent creates a virtual copy of the control system that replicates the functionality and behavior of the actual hardware. This virtual model allows complete testing and validation without requiring physical equipment, thereby eliminating time delays while maintaining validation accuracy through faithful reproduction of control logic and process dynamics
Solution Approach 2:
The virtual control system enables all validation and testing activities to be performed in advance before actual hardware is available. This preliminary action allows project teams to complete control system verification during the design phase, eliminating the sequential dependency that causes project delays
2Manufacturing precision
If control system checkout is performed on a full high-fidelity OTS, then the quality and performance significantly increase, but the development lead-time is extended
Solution Approach 1:
A high-fidelity virtual replica of the control system is created that preserves all functional characteristics and control logic. This copy enables comprehensive quality validation and performance testing without requiring the extended development timeline of a physical OTS, as the virtual model can be instantiated and tested immediately
Solution Approach 2:
The virtual control system allows quality assurance activities to be performed preliminarily during the design and configuration phase. All checkout procedures can be executed in advance with the same rigor as physical systems, eliminating the need to wait for hardware completion while maintaining high quality standards
3Object-affected harmful factors
If control system validation is performed before installation, then the risk of equipment damage and project delays is reduced, but existing methods require complete hardware availability which defeats the purpose
Solution Approach 1:
The virtual control system provides a complete functional replica that enables validation activities without requiring physical hardware. This eliminates the risk of equipment damage during testing while maintaining all validation capabilities, as the virtual model can be manipulated and tested without physical constraints or damage risks
Solution Approach 2:
The essential validation functionality is extracted from the physical hardware context and implemented in a virtual environment. This separation allows validation to proceed independently of complex hardware requirements, eliminating both the hardware complexity barrier and the associated risks while preserving the core validation objectives
Data Source
AI summary
A method and system for automatically generating simulations for a distributed control system is disclosed herein. A programmed process model generator automatically incorporates a variety of process model data from pre-defined model libraries into descriptions of process equipment including control devices to render simulation models of various degrees of fidelity.