Process control system element

The present invention generally relates to process plants, and more particularly to intelligent control and simulation environments that allow users to integrate browsing, simulation, and control at the system level of process plant control structures. It is a thing.

Distributed process control systems used in chemical, petroleum, or other processes are communicably connected to one or more field devices via analog buses, digital buses, or combined analog / digital buses. It typically has one or more process controllers. These field devices may be, for example, valves, valve positioners, switches, and transmitters (eg, temperature sensors, pressure sensors, level sensors, and flow rate sensors) and are installed in the process environment to open and close valves. And perform process functions such as measuring process parameters. Smart fieldbuses, such as fieldbus devices that comply with the well-known Fieldbus protocol, also perform control calculations, alarm functions, and other control functions commonly implemented within the controller. Process controllers are also typically installed in the plant environment, receiving signals that represent process measurements created by field devices and / or other information related to these field devices, and processes. It makes control decisions, generates control signals based on the information it receives, and executes various control modules that work with control modules or blocks that are executed in field devices, such as HART field devices and Fieldbus field devices. The control module in the controller sends these control signals to the field device via the communication line to control the operation of the process.

Information from field devices and controllers can be obtained from operator workstations, personal computers, data historians, reporting devices, centralized databases, etc. that are typically installed in control rooms or elsewhere away from harsh plant environments. Or, it is common for multiple other hardware devices to be made available via the data highway. These hardware devices can, for example, change the settings of process control routines, modify the behavior of control modules in controllers or field devices, view the current state of processes, view field devices and alarms raised by controllers, and work. Run applications that may allow operators to interact with process-related functions such as simulating process behavior, updating the configuration database, etc. for the purpose of training personnel or testing process control software.

As an example, the DeltaV® control system sold by Emerson Process Management is stored in and executed by various devices located at various locations within the process plant. Has an application. Configuration applications on one or more workstations allow users to create or modify process control modules and download these control modules to a dedicated distributed controller via the data highway. .. Typically, these control modules consist of communicably interconnected functional blocks that are objects in an object-oriented programming protocol that perform functions within a control scheme based on input. , Provides output to other functional blocks in the control scheme. The configuration application also provides an operator interface used by the browsing application to display data to the operator and to allow the operator to change settings in process control routines such as configuration points. Allows designers to create or modify. Each dedicated controller and, in some cases, field devices store and execute controller applications that execute control modules that are assigned and downloaded to implement actual process control functions. The browsing application is run by one or more operator workstations, receives data from the controller application via the data highway, and uses the user interface to display this data to the designer, operator, or user of the process control system. However, it can provide any of a number of different views, such as operator view, engineer view, technician view, and so on. The data historian application is provided on the data highway Data Historians that collect and store some or all of their data are typically stored and run by this device, while configuration database applications are additional computers connected to this data highway. It can be executed within and store the settings of the current process control routine and related data. Alternatively, the configuration database can be installed on the same workstation as the configuration application.

As mentioned above, an operator display application typically runs within one or more workstations throughout the system and operates a preconfigured display screen for the operational state of the control system or device in the plant. Or provide it to maintenance workers. Generally, these display screens are an alarm display screen that receives an alarm generated by a controller or device in the process plant, a control display screen that shows the operating status of the controller or other device in the process plant, and a control display screen in the process plant. It takes the form of a maintenance display screen that shows the operating status of the device. These display screens are typically preconfigured to display information or data received from process control modules or devices in the process plant in a known manner. Some known systems have graphics associated with a physical element or logical element and are communicably coupled to the physical or logical element to receive data about the physical or logical element. A display screen may be created using. This object modifies the graphic on the display screen based on the received data, indicating, for example, that the tank is half full and the flow rate measured by the flow sensor. The information required for the display screen is transmitted from the device or configuration database in the process plant, but the information is used only to provide the user with a display screen having that information. As a result, all information and programming used to generate alarms, detect problems in the plant, etc. is generated by different devices such as controller and field devices associated with the plant during the configuration of the process plant control system. , Must be configured within it. Only then will this information be displayed during process operation.

<p> Error detection programming and other programming are useful in detecting conditions, errors, alarms, etc. associated with control loops running on different controllers and problems within individual devices, but within the process plant. It is not easy to program a process control system to recognize system-level conditions or errors that must be detected by analyzing data from a variety of devices that can be installed in a distributed manner. In addition, operator display screens have typically not been used to show or present such system-level state information to operators or maintenance workers, and in any case, various in the display screen. It is difficult to animate an object in an operator display screen with information or data from such various sources for an element. This fact is especially true for the animation and modeling of material flow, such as the flow of fluid in piping, the movement of raw materials on conveyor belts, etc. The flow of material is generally represented by connecting two devices on the display screen with a single line. Moreover, as materials move throughout the plant, there is currently no systematic way to detect specific conditions within the plant, such as flow conditions and mass balance. Moreover, it is not easy to realize a system that executes these functions at the system level.</p><p> Similarly, simulation activities typically need to be performed separately from the display screen, and control activities need to be performed in the process plant's online environment, so simulation of the process plant or part of the process plant. It is difficult to create. Moreover, when a simulation of a plant is created, it is difficult, if not impossible, to integrate this simulation with an operator display screen or a control module running within the plant.</p>

<p> A U.S. patent application filed on October 22, 2002, entitled "Smart Process Modules and Objects in Process Plants," which expressly incorporates all disclosures of that patent by reference herein. As also disclosed in No. 10 / 278,469, smart process objects with both graphical and simulation elements are utilized to represent and model the behavior of a plant or part of a plant. Generally speaking, each smart process object represents a physical device or physical entity (eg, valve, tank, pipe, etc.) in the process plant and within a graphical display screen to represent that physical element. It includes available graphical elements and algorithmic modeling or simulation elements that model or simulate the behavior of the process elements when operating in the plant. Specifically, a smart process object communicates with a display screen element displayed to the operator, a data storage unit that belongs to a related entity in the plant and stores data received from that related entity, and other process objects. To simulate the behavior of process entities, as well as the inputs and outputs to do so, the methods that can be executed on stored and received data to detect plant or device states such as leaks, errors and other states. It has a simulation algorithm that can be used for.</p><p> Interconnect multiple smart process objects to create display screens that represent the behavior of different parts of a process plant, and to create process modules that model or simulate the behavior of parts of a process plant. It is possible. Through its communication path, each process module (and each display screen associated with the process module) receives inputs and outputs outputs for fluids, gases, or other materials that move throughout the plan and the process plant. The behavior of a process element within is modeled or simulated from the aspect of the element's influence on the material moving throughout the plant. In this way, the graphic display screen of the smart process object is used to represent the behavior of the element in the plant (and the role or impact of that element in the plant), and the simulation element of the smart process object is used to represent the fluid in the plant. Alternatively, it is possible to simulate the effect of actual physical elements on the movement of other materials. In addition, data from an actual plant (for example, data measured in the plant) can also be communicated to a graphic display screen created using the smart process object and displayed on that display screen.</p><p> Streams of material in the plant can be modeled to perform more sophisticated and accurate simulations. Such streams can represent fluids, solids, and gases that flow or move throughout the plant, and each stream can vary in pressure, volume, and flow as the stream travels through various elements of the process module. Can have properties or parameters of the stream, such as composition. Since the stream flows through the inputs and outputs of the process control elements, the properties of the stream are typically affected by the process elements (valves, tanks, etc.) through which the stream flows, and therefore. Each element within a process module may have an algorithm at the input of the process element to simulate the effects of that process element on the stream described above.</p><p> To influence the behavior of graphic display screens or process modules created from smart process objects, the operator workstation or other computer runs an execution engine that runs the created graphic display screens or process modules. As part of this task, the process module executes a method called a flow algorithm. These methods can be used to detect process states, especially at the system level, and to simulate the impact of process elements on streams flowing through the plant. As a result, process modules and graphic display screens created from smart process objects allow the execution of state and error detection routines on the operator display screen and operate in conjunction with this feature or in the plant controller. And the need to include this feature in the field device can be eliminated. The process module also provides the operator or configuration engineer with additional programming freedom within the process plant. This degree of programming freedom can be used to provide operators with even better and more complete information, yet it can still be easily used and implemented. In addition, the graphic display screen can be animated using information determined or calculated by the flow algorithm of the process flow module to provide further information to the operator.</p><p> In addition, process modules can be communicably interconnected with display screens and control modules to provide better simulation and control within the process plant. Specifically, the actual numerical values of the process parameters are measured by the control module and provided to the process module to simulate a part of the controlled plant, then these measured values are such as sensor failure, etc. It can be compared with the predicted values produced by the process module to detect possible problems within the plant. Alternatively, the simulation output of one or more of the process modules is fed to the simulation inputs of one or more functional blocks or other elements in the control module, and the control module detects an error in the measured valve, or controls. If the control module itself (or the operator monitoring the operation of the control module) detects that the module is not functioning correctly, the control module uses these simulation inputs to perform control activities. sell.</p><p> To maximize the usefulness of the integration for this enhancement, the configuration engineer can use any of the various objects in the process module to configure the process model for use within the process plant. You can choose from a number of standards or a given algorithm, and you may provide a claimable or user-specified algorithm to more accurately model or simulate the behavior of the actual plant. In addition, the configuration engineer may combine high fidelity simulation packages such as those provided by MIMIC, HYSYS, etc. into the process module. This allows the process module to perform a high fidelity simulation package and access the simulation parameter values created by the high fidelity simulation package as if those numbers were generated by the process module itself. become. Due to this versatility, the operator or other user can be fed to the process graphic display screen and is utilized by the control module to provide better or enhanced control within the process plant. It is possible to have simulation functions with various degrees of freedom that can be done. This integrated simulation also provides advanced error detection or advanced problem detection within the process plant, and also provides simulation control inputs to the controller when actual or measured control inputs are not available. It can also be used to do.</p>

<figref num="1">A distributed process control network installed within a process plant that has an operator workstation that runs display routines that utilize smart process objects to create process modules and use graphic display screens to simulate process plant behavior. It is a block diagram of.</figref><figref num="2">A logical block diagram of a set of applications and other entities stored within the operator workstation of FIG. 1, used to achieve advanced functionality within a process plant, and having smart process objects and process modules. Is.</figref><figref num="3">It is a schematic diagram of a configuration screen used by a configuration engineer to create a process display screen or a process module using a smart process object stored in an object library.</figref><figref num="4">FIG. 5 is a detailed view of an example of a process graphic display screen having a display screen of streams and connection elements in a process plant created by interconnecting graphic display screen elements of a plurality of smart process objects.</figref><figref num="5">By being interconnected, it becomes a larger graphic display screen for the plant, which is a diagram of a set of minimum process graphic display screens including the process graphic display screen of FIG.</figref><figref num="6">FIG. 5 is a diagram of a process module related to the process graphic display screen of FIG. 4, which also illustrates interconnection with a high fidelity simulation routine.</figref><figref num="7A">FIG. 6 is a logical block diagram illustrating the interconnection of communications between a graphic display screen, a process module, and a control module, as integrated within the process plant.</figref><figref num="7B">FIG. 6 is a logical block diagram illustrating the interconnection of communications between a graphic display screen, a process module, and a control module, as integrated within the process plant.</figref><figref num="8">FIG. 5 is a schematic diagram of an example of a process module having blocks interconnected with functional blocks within the control module to provide advanced control and simulation functions.</figref><figref num="9">It is a logical block diagram of a method in which a process module utilizing a smart process object is created in an existing process control network and can be executed in the process module.</figref>

With reference to Figure 1, the smart process objects used to form both graphical display screens and process modules that can be integrated with the control module to provide advanced control and simulation within the plant environment are illustrated in detail. ing. Specifically, the process plant 10 utilizes a distributed process control system with one or more controllers 12, where each controller 12, for example, has a Fieldbus interface, a Profibus interface, a HART interface, and a standard 4. -20 Connected to one or more field devices 14, 16 via an input / output (I / O) device or input / output (I / O) card 18, which can be an interface such as a milliamp interface. The controller 12 is also coupled to one or more host or operator workstations 20, 22 via, for example, a data highway 24, which may be an Ethernet® link. Database 28 is connected to the data highway and serves as a data historian to collect and store parameter data, status data, and other data related to the controller and field devices in process 10 and / or controller 12 and field devices. It can act as a configuration database that stores the current settings of the process control system in plant 10, downloaded to 14 and 16 and stored therein. Although controller nodes 12, input / output cards 18, and field devices 14 and 16 are typically installed in potentially harsh plant environments and distributed throughout such plant environments. On the other hand, operator workstations 20, 22 and database 28 are often installed in a control room or other less harsh environment that is easily accessible to controller or maintenance workers.

As is known, each controller 12 may be, for example, a DeltaV controller sold by Emerson Process Management, which is controlled by utilizing a plurality of different and individually executed control modules or control blocks 29. Store and execute the controller application that realizes the strategy. Each of these control modules 29 consists of blocks commonly referred to as functional blocks, each functional block being part of an entire control routine or a subroutine to execute a process control loop within process control plant 10. It works in cooperation with other functional blocks (via communication called links). As is well known, functional blocks are objects in object-oriented programming protocols and are associated with control routines that perform input functions, PID controls, fuzzy logic controls, etc. associated with transmitters, sensors, or other process parameter measurement devices. It is common to perform either a control function that controls the operation of a device, or an output function that controls the operation of a device, such as a valve, to perform some physical function within the process control system 10. Needless to say, there are also hybrid functional blocks such as model prediction controllers (MPCs), optimizers and other types of complex functional blocks. The Fieldbus protocol and the DeltaV system protocol utilize control modules and functional blocks designed and executed by object-oriented programming protocols, which control modules of any choice, including, for example, sequential functional blocks, ladder logic, etc. It can be designed using programming schemes and is therefore not limited to being designed and executed using functional blocks or other specific programming techniques.

In the plant 10 illustrated in FIG. 1, the field devices 14 and 16 connected to the controller 12 may be standard 4-20mA devices, a HART field device with a processor and memory, a Profibus field device, Alternatively, it may be a smart field device such as a FOUNDATION® Fieldbus device, or any other desired type of device. Some of these devices, such as the Fieldbus field device (labeled by reference numeral 16 in FIG. 1), contain and execute modules or submodules, such as functional blocks related to the control strategy implemented by controller 12. .. The functional block 30 is illustrated in FIG. 1 as being located within two different devices of the Fieldbus field device 16, but as is known, the module within the controller 12 to provide process control. It may be executed in cooperation with the execution of. Of course, field devices 14 and 16 can be any type of device such as sensors, valves, transmitters, positioners, etc., and I / O device 18 can be any desired communication protocol such as HART, Fieldbus, Profibus, etc. Alternatively, it may be any type of I / O device as long as it conforms to the controller protocol.

In process plant 10 of FIG. 1, workstation 20 has a package consisting of an operator interface application and other data structures, and authorized users (although other types of users may exist, as used herein). Anyone (sometimes referred to as a configuration engineer and operator) can access this package to browse connected devices, units, etc. within Process Plant 10 and provide functionality related to them. is there. Package 32 of this operator interface application is stored in memory 34 of workstation 20, and each of the applications or entities in package 32 of the application is configured to be executed by a processor associated with workstation 20. Although the entire application package 32 is illustrated as being stored within workstation 20, some of these applications or other entities are within plant 10 or other associated workstations or computers. It may be stored and executed in. In addition, the above application packages can be displayed and output on a display screen 37 associated with workstation 20, or on any other desired display screen or display device, including portable devices, laptops, other workstations, printers, etc. It is possible to provide. Similarly, applications within application package 32 can be configured to be isolated, run by two or more computers or machines, and work together.

Generally speaking, application package 32 provides three different types of entities or allows them to be created and used. The behavior of these three different types of entities can be integrated with each other to achieve a high degree of control, simulation, and display capabilities within Process Plant 10. More specifically, the application package 32 includes a process graphic display screen 35 (generally a display screen that provides an operator display screen that belongs to a part of the process plant) and a process module 39 (generally one of the process plants). It can be used to create and execute a module that provides a simulation of a part) and a process control module such as a control module 29 that provides or executes online control of a process. The process control module 29 is a technique generally well known in the art and may have any type of control module, such as a functional block control module. The process graphic display element 35, described in more detail below, is an operator, engineer, or other operator, engineer, or other operator to provide information to the user, such as an operator, about the operation, configuration, or configuration of the process plant and the elements within it. It is generally an element used by the display screen. The process module 39 is typically coupled in close proximity to the process graphic display element 35 and is connected in the process plant operation or within that process plant as shown on the process graphic display screen 35. It can be used to simulate the behavior of some of the various elements that exist. The process graphic display screen 35 and process module 39 are illustrated as being stored and executed in workstations 20 and 22, while the process graphic display screen 35 and process module 39 are laptops, portable. Process including device etc.

Figure 2 illustrates some of the applications and data structures or other entities within application package 32 on workstation 20. Specifically, application package 32 is a graphic display configuration application 38 used by configuration engineers to create control modules, process modules (also called process flow modules), and their associated graphic display screens. And have. The graphic display configuration application 38 may be any standard or known control module configuration application, but the process module and graphic display configuration application utilizes one or more smart process objects to utilize the process module and You can create a graphic display screen. The characteristics of smart process objects are described in more detail below. In addition, although the process module and graphic display configuration application 38 are shown separately, a single configuration application may create both of these types of elements.

Library 40 of smart process object 42 has a sample or template of smart process object that can be accessed, copied, and utilized by configuration application 38 to create process module 39 and graphic display screen 35. Needless to say, configuration application 38 can be used to create one or more process modules, each module consisting of or created by one or more smart process objects 42. , Can have one or more process flow algorithms or simulation algorithms 45 that can be stored in process module memory 46. In addition, configuration application 38 can be used to create one or more display screens 35, each display screen consisting of or created by one or more smart process objects 42. It can have any number of display elements that are interconnected. One of these graphic display screens 35b is magnified and illustrated in FIG. 2 and is a pipe, tank, sensor, flow transmitter connected to each other by connecting members that may be pipes, conduits, power cables, conveyors, etc. It has a display of a set of process elements such as.

The execution engine 48 graphically displays during execution time to create one or more process display screens defined by the graphic display screen 35 for the operator and to perform simulation functions related to process module 39. Activate or execute each of screen 35 and process module 39. The execution engine 48 may utilize the rules database 50, which defines the logic to be implemented by process modules 39 as a whole, and more specifically by the smart process objects within those modules. The execution engine 48 may also utilize a connection matrix 52 that defines the connections between the process elements within the plant 10 and the process module 39 to implement the functionality of the process module 39.

Figure 2 illustrates one of the smart process objects 42e in more detail. This smart process object 42e is illustrated as one of the smart process object templates, but it goes without saying that other smart process objects are also the same described in relation to the smart process object 42e described above. Or they typically have similar elements, features, parameters, etc., and the details or numbers of these elements, features, and parameters are per smart process object, depending on the characteristics and use of the smart process object. Can be changed to. Further, the smart process object 42e is an object in an object-oriented programming environment and therefore has a data storage part, a data input / output part, and related methods, but this smart process object is other desired. It may be created and executed according to the programming paradigm or protocol of.

Needless to say, the smart process object 42e is an object associated with a particular type of entity, such as a physical or logical entity, in process plant 10 of FIG. 1 before it is instantiated. However, after this smart process object 42e is copied and instantiated, it can be pinned to a particular entity within the process plant. In any case, the smart process object 42e includes a data storage unit 53 that stores data received from or belongs to the logical entity with which the smart process object 42e is associated. This data storage unit 53 has a data storage unit 53a that stores general or permanent information about the entity to which the smart process object 42e belongs, such as manufacturer, update, name, type, and so on. Is common. The data storage 53b may include parameter data, state data, I / O data, or other data about the entity to which the smart process object 42e belongs, such as the entity's past point in time or the entity's current point in process plant 10. It may include a data storage unit 53a that stores variable data such as data associated with that entity or data that is changing. Of course, the smart process object 42e is cyclical or non-periodic, from the entity itself via any desired communication link, from Historian 28 via Ethernet Bus 24, or in any other desired way. It may be configured or programmed to receive this data (eg, cost data) on a periodic basis. The data storage unit 53c may store a graphical representation of the entity to which the smart process object 42e belongs and is used for the actual display screen to the operator via an operator interface such as screen 37 associated with workstation 20 in FIG. .. Of course, this The graphical representation is for information about an entity (and underlined in the data storage 53c), such as information defined by parameter data or other variable data about an entity stored in data storage 53b. It also has a (marked) placeholder. This parameter data may be displayed in a graphical placeholder as part of the display screen of one of the graphical display screens 35 when the graphical representation is presented to the operator on the display device. The graphical representation (and smart process object 42e) also allows the operator or configuration engineer to attach upstream or downstream components to the process element as described by the graphical representation (and). It may have a predefined connection point (marked by an "X" in the data storage 53c). Of course, these connection points also allow the smart process object 42e to recognize that the element is connected to the smart object as configured in the process module, and can be used like pipes, ducts, etc. You can also specify the type of connecting member that needs to be done, the stream associated with that element, and so on. Predefined connection points that allow operators or configuration engineers to attach upstream or downstream components to process elements as per (and marked with an "X" in data storage 53c). Can have. Of course, these connection points also allow the smart process object 42e to recognize that the element is connected to the smart object as configured in the process module, and can be used like pipes, ducts, etc. You can also specify the type of connecting member that needs to be done, the stream associated with that element, and so on. Predefined connection points that allow operators or configuration engineers to attach upstream or downstream components to process elements as per (and marked with an "X" in data storage 53c). Can have. Of course, these connection points also allow the smart process object 42e to recognize that the element is connected to the smart object as configured in the process module, and can be used like pipes, ducts, etc. You can also specify the type of connecting member that needs to be done, the stream associated with that element, and so on.

The smart process object 42e also includes one or more input 54 and output 56 to enable communication with other smart process objects inside or outside the process module in which the smart process object 42 is utilized. Can be prepared. The connection of these inputs 54 and 56 to other smart process objects can be done by simply connecting the other smart process objects to these inputs and outputs during process flow module configuration, or by simply connecting them to these inputs and outputs. It can be configured by a configuration engineer by specifying the specific communications that need to occur between smart process objects. Some of these inputs and outputs are defined as being connected to a smart process object that is connected at a predefined connection point of the smart process object, as described above. These inputs 54 and outputs 56 may also be determined or defined by a set of rules in the rules database 50 and a connection matrix 52 that define the connections between the various devices or entities in the plant 10. .. The input unit 54 and the output unit 56 have a data storage unit or a data buffer associated with them, and generally, to provide data communication from another smart process object to the smart process object 42e, or a smart process. It is used to provide communication to other smart process objects for the data stored within object 42e or the data generated thereby. These inputs and outputs also provide communication between the smart process object 42e and other objects such as control modules within controllers 12, field devices 14, 16, etc. in the process control system. Can be used as much as possible.

As illustrated in FIG. 2, the smart process object 42e can be executed by the smart process object 42e while the process module in which the smart process object 42e is utilized is running (and methods 60a, 60b, in FIG. 2). It also has a method storage unit 58 used to store zero, one, or multiple methods 60 (exemplified as 60c). Generally, the method 60 stored in the method storage unit 58 is obtained from the data stored in the data storage units 53a and 53b and other smart process objects via the input unit 54 and the output unit 56. Determining information about process plant 10 or any entity within that plant by utilizing data or data from a configuration database or other sources such as historian 28. For example, method 60 may determine degraded or bad operating conditions associated with an entity defined by smart process object 42e, errors associated with that entity or other entities within process plant 10. Method 60 can be preconfigured or provided based on the type or class of the smart process object and will be executed each time the smart process object 42e is executed within the execution engine 48 during the execution time. Is common. Examples of methods 60 that can be provided within a smart process object, such as the smart process object 42e, include leak detection, dead zone detection, dead time detection, movement detection, fluctuation detection, condition monitoring detection, computing costs, or their entities. For example, detection of other related conditions.

Method 60 may also be provided to facilitate simulating the behavior of a process entity associated with a smart process object of material flowing through the process entity. Therefore, Method 60 is a mass balance (MASS). BALANCE), energy balance, flow rate, temperature, composition, steam state, and predicted output based on the inputs provided to calculate parameters at other system or stream levels related to the materials in plant 10. It can be provided to simulate the behavior of an element to calculate. Of course, these are just a few examples of the methods stored and executed within the smart process object 42e, and there are many other methods available. Such methods are generally determined by the type of entity represented, the method to which the entity is connected and used in the process plant, and other factors. The smart process object 42e can store and execute methods for detecting states, errors, etc. at the system level, but these methods are logical such as devices, process control modules, and process control loops. It can also be used to determine other information about the element and other non-system level entities. If desired, method 60 may be programmed or implemented in any desired programming language, such as C, C ++, C #, etc., or may be executed for the smart process object 42e during execution. You may refer to the rule database 50 that needs to be set, or you may define the adaptable rules in that rule database 50.

If desired, each smart process object may have an applicable algorithm library or an applicable method library. These libraries, when connected within a process module, can be used to define the simulation behavior of smart process objects. Such a library is illustrated in the pull-down menu 61 on the smart process object 42e of FIG. 2, and a similar menu may be associated with each of the other smart process objects. When a configuration engineer places a smart process object inside process module 39, for example by selecting one of the libraries of simulation algorithms (called method 1, method 2, etc.) via pull-down menu 61, It becomes possible to define the simulation behavior of the smart process object. In this way, the configuration engineer can define different simulation behaviors for this smart process object, depending on the type or characteristics of the process modeled with it.

If desired, instead, the configuration engineer provides an algorithm that can claim ownership or an algorithm specified by another user to define the simulated behavior of the process elements defined by the smart process block. May be good. Such a user-specified algorithm (the algorithm exemplified as the "user-specified" item in the pull-down menu 61) is such that if a smart process object is placed in or used in process module 39. Can be provided and stored in smart process objects. This feature allows the user to customize the simulation behavior as needed, thus achieving even better or more accurate simulations. If desired, the smart process object 42 or each process module 39 disables the use of simulation algorithms within the smart process object and is provided by HYSYS in its place, as described in more detail below. It may have an operator startable switch that triggers the operation of the process module as determined by the high fidelity simulation package or high fidelity simulation program. In this case, the smart process object or process module gets the simulation parameters from the high fidelity simulation, as opposed to utilizing the simulation algorithm within the smart process object itself.

While the execution engine 48 is executing the graphic display screen 35 or the process module, the execution engine 48 is defined by the input 54 and the output 56 to each of the smart process objects in the graphic display screen 35 or the process module 39. It is possible to execute each method 60 of those objects to perform the communication to be performed and to perform the functions realized by the method 60. As mentioned above, the functionality of Method 60 may be programmatically provided within a smart process object or defined by a set of rules within Database 50. The execution engine 48 executes the set of rules based on the type, class, identification, tag name, etc. of the smart process object in order to realize the function defined by the set of rules.

The instance of the smart process object 42e has a tag or a unique name within the context of the process module to which the smart process object 42e is associated, and this tag or the unique name is the smart process object 42e. It is used to realize communication and can be referenced by the execution engine 48 during the execution time. The process module tag must be unique within the control system configuration. According to this tag specification, the elements in the process module 39 can be referred to by the process graphic display screen 35, the process module 39, and the elements in the control module. Further, the parameter of the smart process object 42e can be a simple parameter such as a simple numerical value, a structured parameter, or a smart parameter that predicts and determines a unit related to the parameter. The process rules engine or execution engine 48 can interpret and utilize smart parameters to ensure that all signals are transmitted in the same unit or that all signals are converted correctly. is there. It is also possible to utilize smart rules to turn on and off a swarm of alarms for a smart process object (or process module) to create a smart alarm strategy and / or smart alarm interface for the operator. In addition, it associates device and module classes with the smart process object class in the process control strategy of plant 10 and provides a known relationship between the smart process object and the process variables it needs to interpret or access. It is possible.

Smart process objects also have an operating mode, status, and alarm behavior when used within a process graphic display screen or process module, which allows these smart objects to have an execution time. During, it can be switched to different modes such as stop mode, start mode, standard mode, provide the status related to the object based on the current operating state, out of parameter range, parameter limit, parameter high fluctuation, etc. An alarm can be provided based on the detection status. The smart process object also has a class / subclass hierarchical structure, which allows the smart process object to be classified in the class library and collected together in a composite structure. In addition, smart process objects are control modules and others to allow smart process objects to recognize when related entities are busy, or when, for example, related entities are bound by batch control processes within plant 10. Information from other elements such as the object of can be used.

A smart process object can be associated with a physical device such as a pump, tank, valve, or any desired process entity such as a logical entity such as a process area, measurement or actuator, control strategy, etc. In some cases, smart process objects can be connected members such as pipes, conduits, wires, conveyor belts, or other devices or entities that move materials, electricity, gas, etc. from one point in the process to another. Can be associated. Also, smart process objects associated with connecting members, sometimes referred to herein as smart links or connecting elements, may also communicate (even if the device itself or the connecting member itself is not marked, or within process 10). It is usually tagged (even if it is not possible) and used to represent the flow of material between other elements in the process.

Smartlinks have properties or parameters that define how various materials or phenomena (such as electric current) (eg, steam, electric current, water, sewage, etc.) flow through the connection. These parameters include the type and characteristics of the flow through the connection (eg, normal velocity, coefficient of friction, type of flow such as turbulent or non-turbulent, electromagnetic, etc.) and the direction of flow through the connection. Can be shown. A smart link can have programming or methods that match the unit from which it connects with the unit of the object to which it connects, and if they do not match, perform a conversion. The SmartLink method also uses a model or algorithm to estimate the speed or characteristics of the flow through the actual connecting member, the length and size of the physical connection, the transport delay, etc., and the flow through the connecting member. Can be modeled. Parameters stored for smart process objects (eg, friction parameters) can be utilized in these methods. Thus, the smart link or connecting member essentially allows the smart process object to recognize other upstream and downstream objects or entities. Of course, smart links can be any desired or convenient way, for example connections between other objects, types of fluids such as liquids, gases, currents in the system, upstream of entities for this smart process object. It is possible to define the direction of movement of other entity identifications, materials, fluids, currents, etc. that exist on the side and downstream sides. In one embodiment, the connection matrix 52 is created prior to the execution of the process flow module and defines the interconnections between different devices in the plant, and thus the interconnections between different smart process objects, for smart links. Can be done. In fact, the execution engine 48 uses the connection matrix 52 to identify the upstream and downstream entities, which allows the smart process object and its smart process object. You can define communication with the methods associated with the project. In addition, by smart process objects to understand the impact of smart objects related to output connections, to interact and retrieve data from each other, depending on the need for methods within the smart process object. One or more sets of rules may be provided to be utilized.

If desired, the smart process object 42e can also provide a hot link, such as a URL, to the main documentation. This documentation may be applicable to the type of object or (depending on its importance and application) may be limited to the instance of the device to which the smart process object 42e belongs. The documentation may be provided by the distributor or specified by the user. Examples of documentation include configuration documentation, start and stop procedural documentation, operational documentation, and maintenance documentation. If desired, the operator may click on an object displayed on the operator display screen to view instance-specific documentation (if any) and comprehensive documentation for that object or its associated device. The operator may also be able to add / remove / modify documentation such as maintenance requests, records of operational problems, etc., independently of the system software. In addition, these hotlinks provide customer-specific work instructions, to provide the ability to add knowledge links to objects in the operator interface, and to provide quick navigation to the appropriate information related to the object. It can be configured and modified by the user to provide the ability to add object type-specific work instructions or object instance-specific work instructions.

Process modules and process graphics are described above as being created together by interconnecting various smart process objects, but may be created separately. For example, a process graphic may be created using a smart process object, and when completed, a process module for that graphic may be generated based on the graphic elements and their interconnects within the graphic display screen. .. Alternatively, a process module is first created using a smart process object, and once it is created, it can take advantage of the graphic display elements in the smart process object used to create the process module. A graphic display screen for the process module may be automatically created by configuration application 38. In addition, the process module and the graphic display screen are created separately and referenced to each other (for example, using the tag properties of the elements in the graphic display screen and the process module) so that they are individually in these two entities. Elements may be combined with each other. By this mechanism, one smart process object can be referred to by a plurality of display screens. In either case, once created, the process graphic display screen and its associated process modules can be executed independently or separately. However, if desired or necessary, the process graphic display screen and its associated process modules generally communicate parameters and information with each other.

For further understanding, some possible features and examples of smart process objects that can be used within or to create process graphic display screens and process modules are described in detail below. The following describes how process graphic display screens and process modules created using the described elements and features are integrated with the control modules to achieve a high degree of control and simulation capabilities. Needless to say, the elements and features of a smart process project are not limited to the elements and features described herein, and if desired, within one or both of the process graphics and process modules. Other features and elements may be utilized in or to create them.

Generally speaking, a set of predefined graphic elements may be provided within the configuration application to allow the user to build an operator display screen or graphic display screen that reflects the process plant. These graphic elements are designed to dynamically represent online measurements and actuators that interface with the control system. In addition to this, non-measurement parameters that reflect process behavior can be calculated using an online process simulation provided within the process module and displayed as an inseparable part of the associated graphic display screen.

In addition, in offline environments used for engineering simulation purposes or training simulation purposes, the process simulation provided by the process module can be used in place of process measurements in graphic elements and related control modules. .. These numbers calculated by the relevant process module can be based on the actuator position or state shown in the process graphic and the manual disturbance value. In this way, graphic display screens and control modules are utilized both online or in control situations and offline or in simulation situations. Also, in most cases, the static parts of graphic elements appear to resemble the three-dimensional components contained in known graphic libraries, but with additional unique features or properties of these graphic elements, these elements. The information displayed by and the links of these elements to the control system I / O and process simulation modules are described below in relation to several possible types and examples of graphic elements.

Generally speaking, the graphic elements and simulation algorithms in a process module associated with a small process object include a stream element, a process connection element, an actuator element, a processing element, a measurement element, and a property guessing element. Classified into one of several different types of process elements. Stream elements typically define a stream of material in a process plant and are graphically represented to represent composition, density, flow rate, temperature, pressure, weight, and / or other parameters that define the stream of material. Can be displayed on the display screen. A stream element may be defined at the input of the process module and donated to an element within the process module, thereby allowing the flow of material to be modeled by the process module and displayed on a graphic display screen. Similarly, stream elements may be shown at the output or end of the process module to display some material output of the process plant shown by the graphic display screen on the graphic display screen. Stream elements can also be used to define how various graphic display screens (and related process modules) are interconnected. For example, the output stream in one process module is the input stream in the other process module and can supply the numbers used in the input stream of the other process module. A stream can have four parts: name (eg pH stream), direction (eg inflow), measurement (eg flow rate, pressure, temperature), and composition (eg nitrogen, ammonia, etc.) sell. However, the stream may have other parts or parameters if desired.

Process connection elements define how materials in a plant, such as solid materials, liquids and vapors, and gases, are delivered or transported from one device to another. Three types of process connecting members can be used to articulate the flow of material throughout the process, including piping, ducts and converters. Of course, other types of connecting elements such as electrical cables that deal with power currents in electrochemical processes and the like may be used as well. Piping is commonly used to show (and simulate) liquid flow and high pressure vapor flow or high pressure gas flow in a plant. Ducts are commonly used to show (and simulate) low pressure gas flow in a plant. Conveyors are commonly used to show (and simulate) the movement of solid materials between processing units. As a result, each process connection element defines the type of connection, such as a pipe connection, duct connection, or conveyor connection, used to supply material at the input or output of the device.

If desired, the properties of the material transported by the connecting member are determined by the upstream input. The sum of this information and the connection status variable that defines whether the connection is complete can be made available on the graphic display screen as a property of the connection element. The connecting element can start with a processing element output, an actuator element output, or a stream element output. Similarly, the connecting element may terminate at the processing element input, actuator element input, or stream input.

The properties of the connection element can be displayed automatically when the Casa is placed on the connection member in the graphic display screen. Also, the properties associated with the connection element can be permanently displayed on the display screen by placing the measurement element or prediction property element (as defined below) on the connection element. If desired, the connecting element can element the Casa by pressing the left mouse button on the element output (eg, stream output, processing element output, or actuator element output) and holding down the mouse button. It can be created by moving over the input section. The input and output types (pipes, ducts, or conveyors) of the upstream and downstream elements must match for a successful connection establishment. The connection described above automatically mimics the type of upstream element.

If desired, the piping element may be represented as a pipe connecting member on the process graphic display screen, the duct element (eg, air or gas) may be represented as a duct, and the conveyor element may be represented as a conveyor belt. Piping element connecting members, duct element connecting members, and conveyor element connecting members are automatically routed between processing elements, and arrows may be displayed outside these element displays to indicate the direction of flow. A "T" element is included in the pipe, duct, or conveyor if the upstream output is common to the two connecting members. Similarly, multiple output units can be combined using the "T" element. The color or other graphic properties of the conveyor element may change to indicate its status, such as running / stopped, flowing / non-flowing, clogging, and so on. Generally speaking, the flow of material along a conveyor is determined by the motor drive connected to that conveyor. Therefore, motor drive actuators (actuator elements described in more detail below) may be connected to the conveyor. In addition to this, measuring elements (described below) are connected to pipe elements, duct elements, and conveyor elements, allowing the display of measurements associated with that pipe element, duct element, or conveyor element. To do. These measurements include properties such as the speed of the conveyor, the flow rate of the material in the pipe or duct, and the material on or in the conveyor, pipe, or duct, such as moisture, weight. It is also possible to add display property elements to display unmeasured properties of a material on or in a pipe, duct, or conveyor, such as the composition of that material.

If desired, each of the piping connection element, duct connection element, and conveyor connection element should be such that the connection is damaged and the selected properties (pressure, temperature, length, etc.) are outside the configured limits. It can be reflected imagewise and dynamically (for example, by changing color). In addition, the parameters calculated by the relevant process modules can be displayed as images. For example, the properties provided by the upstream connection member, such as whether the connection status is good or bad, the limit of one or more selected parameters of the connection element, etc., are the connection element or its connection. It can be displayed on a graphic display screen to provide information about the stream transferred by the element.

Generally speaking, an actuator element is an element that performs an actuation function on a stream and can be placed between various connecting elements or between processing and connecting elements. Examples of actuator elements include adjustment valve (with actuator), on / off valve (with actuator), pump (with motor), push blower (with motor), suction blower (with motor), discharge device (with on / off valve), damper. Examples include (with drive), feeder (with variable speed motor), conveyor motor drive (which can be attached to a conveyor element), etc.

The graphic display of the valve element is the predicted valve position (eg by animation), the valve failure (eg by color change), and the valve fully open / closed position (eg by color change). It can dynamically reflect the AO, DO, DC, set value, PV, OUT, mode, etc. of the control block responsible for controlling the valve (by a string of numbers or other signs). Simulation elements related to valve elements (used within the process module) have simulation algorithms that calculate parameters related to valve actuators such as discharge pressure, mass flow rate, liquid temperature, liquid composition, inlet pressure, and outlet pressure. Can be done. These simulation parameter values or calculation parameter values may be displayed in the process graphic if desired. However, the user or configuration engineer, along with the type of valve (eg, linearity, rapid opening, equal percentage characteristics, valve dimensions), goes to the AO block, DO block, or DC block in the control module associated with the valve. It is often necessary to configure the stroke time from opening to closing. Of course, the simulation algorithms available to simulate the operation of the valve on the material flowing through the valve can depend on information on the type and dimensions of the valve.

The graphic display of the pump element shows the status of the motor (for example, using color changes) and its associated DO or DC function block mode and set amount (for example, using strings). Dynamically dynamic motor speed (if variable speed drive is used), AO setting, PV, OUT mode (if variable speed drive is used) and other desired parameters Can be reflected in. Similarly, process simulations for this element (used within the process module) can determine or calculate parameters such as discharge pressure, liquid composition, liquid temperature, and mass flow rate, and these parameter values. Can be displayed in the graphic display screen. The user may need to define the pump curve based on the pump type, however, the user can refer to the DO or DC blocks associated with starting / stopping the motor and (used by variable speed drives). Configure a reference to the AO functional block for variable speed drives and a pump curve (eg, pressure-flow rate) to define the operation of the pump, if any) related to the above blocks. Can be done.

The graphic display of the actuator element for the indentation blower or the actuator element for the suction blower shows the motor status, DO function block mode or DC function block mode and set value, and the motor (if a variable speed drive is used). Speed, AO settings, PV functional block mode, OUT functional block mode, DO functional block mode, or DC functional block mode (if variable speed drives are used) and other desired parameters. It is possible to have a display that is dynamically reflected, and it is possible to display any one of these in the graphic display screen. The process simulation element for this element used within the process module can determine or calculate parameters such as discharge pressure, gas composition, gas temperature, and gas mass flow rate, and these parameter values are graphical. It can be displayed in the display screen. The user is simulating the blower with a reference to the DC block related to starting / stopping the motor and a reference to the AO functional block for the variable speed drive (if a variable speed drive is used). A blower curve (pressure-flow rate) can be configured to define the behavior.

In some cases, certain types of actuators may only be used with certain types of connecting members, such as pipes, ducts, or conveyors. The table below specifies some of the exemplary connection restrictions for typical actuator elements.

<tables num="1"><img file="JP2012256366A_D0001.tif" /></tables>

The processing element comprises plant equipment that processes the material or stream in the plant in some way. Generally speaking, all input and output of processing elements are done through connecting elements. Standard processing elements include tanks (vertical and horizontal), heaters, fixed mixers, reactors, mixers, air heaters, and perform some type of simple or standard processing activity. It has other elements to do. For standard processing elements, the user can specify the number of inputs and outputs of the element, along with physical device properties such as dimensions, volume, and so on. The simulation algorithms and static representations of these standard processing elements can be configured so that they cannot be modified by the user, but can be selected at configuration time as described above. Of course, if desired, other, usually more complex plant equipment (eg, distillation columns, evaporators, separators, boilers, etc.) can be implemented as custom processing elements. The static representation, number of inputs and outputs, and simulation algorithms of such custom processing elements can be modified to meet the requirements of the user interface. Once a custom processing element is defined, it can be saved as a complex or template that can be reused or used as a starting point for the creation of other processing elements.

A tank standard processing element (either vertical or horizontal) can be configured based on a pipe connection to the tank, and the tank element (eg, utilizing dynamic animation). It can reflect the level of water in the tank and whether it is 100% full or empty (eg, using color changes). The tank process module simulation can calculate and display parameters such as outlet temperature, outlet composition, liquid temperature, and tank simulation water level via a graphic display screen. However, in order to connect the tank to the system, the user or configuration engineer needs to configure the number of I / O connections, the complete connection to the tank, the tank properties such as size (eg diameter and height), etc. There may be.

The heater processing element has a heat transfer coefficient (eg, utilizing color changes), an outlet product temperature, an inlet product temperature, an outlet pressure (assuming a constant pressure drop), etc., via a graphic display screen. Can be dynamically calculated and reflected. The user or configuration engineer may need to configure the complete connection to the heater, the surface area of the heater, and the heat transfer coefficient (when clean).

Of course, other processing elements such as fixed mixers, reactors, mixers, air heaters, heat exchangers, etc. may have display and simulation capabilities tailored to these types of devices. Non-standard processing elements such as distillation columns, evaporators, separators, boilers, etc. can be image-displayed using custom processing elements, in which simulations related to the vessel are It can be defined by the user if it is not included in the standard choices. The processing in these elements can be described or defined as a step response model, with each input in the container associated with its respective output. The input can be a gas stream and / or a liquid stream. The user can selectively define equations that describe the relationship between the inputs and outputs of the processing element, and these equations are within the process module that utilizes the element to perform the simulation. Can be stored in. If desired, some simple static graph representation may be provided to help the user quickly create static graphics associated with the custom processing element. When these simple graphics are used, the user only needs to specify the desired number of I / O connections and the types of connections supported by the custom processing elements (eg pipes, ducts, conveyors). is there. In response, the graphic item is displayed and can be used immediately for creating operator graphics. If desired, if the user chooses to specify the simulation algorithm as a step response, it is possible to specify the gain and arbitrary dynamics associated with each input / output of the processing element. When the user selects a custom algorithm, a representation editor may be provided for the user to define the simulation algorithm. Custom processing element output properties are measured separately based on the method chosen Can be calculated. In addition, the user may refer to one or more of the algorithms defined in the individual software assemblies.

In addition, multiple pre-defined complexes or pre-defined templates may be provided to create custom processing elements. These templates have, for example, boiler templates with custom algorithms for calculating outflow gas O2, outflow gas CO, generated steam, boiler drum level, and boiler draft. Such a template may be based on a single fuel input. However, by modifying the template, it becomes possible to simulate a boiler with multiple fuels. Other pre-defined templates can include container-cyclone separator dedicated templates, which are also used with spray dryer custom processing elements and have a step response model to model the behavior of the separator. It can be done. Similarly, column templates, spray dryers, and evaporator bodies can utilize step response models to define predictive process responses. In the evaporator, it is possible to calculate the concentration of the outlet flow and the emission of steam based on the concentration of the energy input and the input flow. Multiple evaporator elements can be interconnected together with heat exchanger elements and exhaust device elements to create a multi-effect evaporator. Similarly, a custom container-exhaust template can be used with boiler processing elements. In this case, the inlet flow properties may be transported through the exhaust stack without any modification if desired, or are transported to reflect the emissions reductions performed within the exhaust stack. May be good.

Other types of elements available for creating graphic display screens and process modules include measurement elements and property elements. The measurement element comprises a transmitter element, which can be used in a graphic display screen to access measurements associated with a physical transmitter and a switch element. In general, the transmitter element dynamically reflects the poor or uncertain status associated with the actual transmitter (sensor), the mode of the associated AI functional block within the control block, the measured value or the unit of measure, etc. It can dynamically reflect other data related to the actual transmitter. In offline mode (or simulation mode), the transmitter element is used to access and display the simulation values provided by the process module rather than the numbers associated with the AI or PCI blocks. It can be used to provide measurements to related AI blocks within the control module as measurement results used in a simulated control routine. Transmitter elements can be added to connecting or processing elements, and when such transmitter elements are added to the display screen, the user is providing the measurements described above in the controller scheme. It is common to need to identify an AI block, PCI block, or DI block. In online mode, the above measurements may be displayed next to the measurement element. In offline mode (or simulation mode), the above simulation measurements (created by the corresponding process module) may be displayed automatically. In online operation, the user may choose to switch control and display to simulated numerical values under poor measurement conditions.

The switch element dynamically reflects the poor or uncertain status, its associated DI (eg manual or OS), and the discrete value of the switch (on, off, etc.). In offline simulation mode, the user can access the switch parameters within the graphic display screen by selecting the simulation value or manual value and status and manually entering the value and status of the switch. A switch display element can be used to change the. However, the user can provide a reference to the relevant DI block in the control scheme, a reference to the element property that activates the switch, and the limits and dead zones associated with changing the state of the switch. Must be configured.

Estimated property elements typically display the estimated properties of the system as determined by the process module and can be added to the connection or processing element to display any properties of that element. When this element is mounted on a connecting element or a single device, the user can browse or select the properties displayed. Therefore, simulation properties that are not available by physical measurement can be displayed using estimated property elements. Such an estimated property element can dynamically reflect good / bad connections, estimated property values, and accompanying out-of-limit or out-of-change properties. It is common for the user to configure a reference to a property that needs to be displayed, and a limit and color change for that element if that property exceeds the limit.

Needless to say, by mounting the transmitter element and the estimation property element on the processing element, the actuator element, and the connection element, the properties related to the input and output of these process elements can be obtained during online operation or offline simulation. It may be referred to. These properties may be visible on the graphic display screen.

Generally speaking, an operator can run configuration application 38 to create one or more process modules 39 or graphic display screens and run them while process 10 is running or in a simulation environment. is there. In one embodiment, the configuration application 38 presents the configuration engineer with a display screen as illustrated in FIG. As can be seen from FIG. 3, the configuration display screen 64 includes a library area or template area 65 and a configuration area 66. Template area 65 has an image of a set of smart process object templates 67, which set contains the smart process object 42 of FIG. 2 and also includes the connection elements, measurement elements, processing elements, and the above-mentioned connection elements, measurement elements, processing elements, and so on. It can be one of the estimated property elements. If desired, a non-smart element 68 that only has a graphic definition may also be provided. In essence, templates 67, 68 are inclusive objects, and you can drag these inclusive objects and drop them in configuration area 66 to create smart process objects in the process module and / or graphic display screen. It is possible to create an instance of. The partially completed process graphic display screen 35c has one valve, two tanks, two pumps, one flow transmitter and two sensors connected to each other by a flow path connecting member. Although exemplified as having, the flow path connecting member described above may be a smart link or a connecting member element described above that provides stream output. The graphic display screen 35c may be composed of both smart process objects and non-smart objects.

When creating a graphic display screen, such as the graphic display screen 35c (or process module), the configuration engineer selects smart process objects 67 and elements 68 in template area 65, drags them to configuration area 67, and there. It can be dropped in any desired position. Generally, the configuration engineer selects one or more smart device process objects 67a or non-smart element 68 that represent the device and drags them into the configuration area 66. The configuration engineer then interconnects the smart device process object in configuration area 66 with the smart connector object 67b and drops the input / output stream 67c onto its display screen. In addition, non-smart elements may be added to the display screen. During this process, the configuration engineer will use pop-up property menus, etc. to take advantage of each property of the smart process object, especially the methods, parameters, tags, names, hotlinks, modes, classes, related to these smart process objects. Input / output etc. can be changed. When a process engineer or configuration engineer creates a process module with each desired element to represent a process configuration, region, etc., the configuration engineer defines rules or other features associated with that module. Can be done. Such rules may be execution rules, such as those related to the execution of methods at the system level, such as mass balance and flow rate calculations. The process engineer or process operator may also decide to add trends and faceplates that are beneficial when the process display screen is online. After creating the graphic display screen 35c, the configuration engineer said It is possible to save the display screen in memory and then or after that, instantiate the display screen in a way that the execution engine 48 can provide a graphic display screen and download it to the execution engine 48. Of course, the configuration engineer can create process modules in the same or similar way. However, a different graphic can be displayed in the process module as opposed to the process graphic display element. In addition, the operator may choose to operate the level of detail while operating the plant. For example, one of the levels of detail is to display the composition at each connection.

As mentioned above, process graphics or process modules are provided with specific tags. For example, a smart process object in a graphical display screen or process module may be written by the execution engine 48 during execution time based on other factors, such as the route selected within the device or process control system. Tags with possible aliases may be provided. The use and indirect reference of alias names in process control systems is described in detail in U.S. Pat. No. 6,385,496, which is assigned to the assignee of the invention and is expressly incorporated herein by reference. It is used here. Any of these techniques may be used to provide and parse aliases for the tags for smart process objects described herein. Using aliases and the like, the same process flow module can have different views for multiple sets of devices, or can be used to support different views for multiple sets of devices.

The display screen 64 of FIG. 3 illustrates tags (View1, View2, and View3) of various views of the process module or graphic display screen. These tags can be used to access different views of different users associated with a process and to create different views by leveraging some of the same smart process objects in them.

Generally speaking, when a configuration engineer creates a process flow module or graphic display screen, the configuration application 38, along with the smart process objects, automatically stores the connections between them in the database. This database can then be used to create other process modules and graphic display screens. This graphic display screen may provide different views using, for example, one or more of the same smart process objects. Therefore, when creating a second view, the configuration engineer simply references the smart process object that has already been created and stored in the database and any methods that are stored with it. Can be placed in the second view. In this way, it is possible to grow the database as process control modules and graphic display screens are created, leveraging smart process objects that already exist in the process flow database for other views, modules, And you can use this database at any time to create and run graphic display screens. Utilizing such a database, each smart process object in the database may support or be utilized in process modules and be referenced within multiple graphic display screens. Needless to say, the process module may be constructed by constructing the display screens of these modules and then specifying the flow algorithm used in or associated with the process module. Of course, the individual process modules may be distributed and executed by different computers, and the process modules may work together on the same computer or different computers. Therefore, they may be connected so as to be able to communicate with each other. Once this is done, the input and output streams are externally referenced to interconnect the process modules.

As mentioned above, as part of creating a process module or graphic display screen, the configuration engineer can include or provide a simulation algorithm for the process module. These simulation algorithms preliminarily calculate or determine specific process or system level properties such as material balance calculations, flow rate calculations, efficiency calculations, economics calculations, etc. for the processes displayed or modeled by the process module. Can be configured to. As a result, the process module itself has a mode operation, a state operation, and an alarm operation, is assigned to the workstation, and can be downloaded as part of the display screen download. If desired, the simulation algorithm leverages the data provided in the process module's smart process object for mass balance or heat balance, flow routing, flow efficiency, flow optimization, and economics associated with process simulation. It may be performed by the execution engine 48 to perform the calculation, or any other desired flow-related calculation. In addition, these simulation algorithms are able to access parameters from control strategies, ie parameters from control modules that are associated with and downloaded by them, such as controllers, field devices, and vice versa. It is possible to provide data or information to the control module of.

Needless to say, the execution engine 48 is needed to allow the process algorithm to be executed throughout the concatenation of all process objects and process links configured on all display screens. .. Therefore, it is common for a simulation algorithm (in a process module) to be executed regardless of whether any relevant graphic display screen is loaded, or called, and displaying information to the user. Of course, the simulation algorithms can be checked against each other over the entire process 10 or over a defined subset of process 10. Also, needless to say, no matter what particular process flow module is running, the execution engines 48 are interconnected within that process module based on the graphic display screens associated with that process module. A display screen displaying the object or entity being displayed can be provided to the operator on the operator interface. The display screen parameters, graphics, etc. are determined by the configuration and interconnection of smart elements within the process module. In addition, alarms and other information provided on this display screen or other display screens are defined and generated by methods within smart process objects and simulation algorithms associated with a particular process module. If desired, the execution engine 48 may provide a display screen for the process module in more than one operator interface, or the execution engine 48 continues to execute the process flow module, thereby the associated method. It may be configured or configured not to provide a display screen even though it is performing alarm functions, flow algorithms, and so on.

If desired, the process module can be automatically generated from the graphic display screen and vice versa, and the functions available to the process module are determined by the process graphic element. What needs to be clarified is that the process module is preferably constructed to follow the process graphic display screen. As a result, when the user configures the process graphic display screen, the user can further include information for the process module, such as a mass stream or an energy stream. These streams are utilized within the process module to establish the start conditions required by the simulation function block.

In addition to this, the process module is essentially a software module that runs within the computer, so it refers to the controller module to take advantage of the parameters, control strategies, display screens, etc. associated with the controller module. It can also be referenced by the controller module. It is also possible to use this capability to create a process module independently of the process graphic display screen.

Generally speaking, a process module is composed of processing elements, streams, and their associated connecting members. Since there is a one-to-one correspondence between the process graphic element and the simulation element (in the process module), the user builds a graphic display screen and automatically creates the corresponding process module from that display screen. It is possible. Of course, if desired, the user may create a process module and then automatically create a graphic display screen from that module using the graphics in the smart process object. However, to allow automatic generation of process modules, the user may need to identify actuator element properties, connection element properties, or processing element properties associated with the measurement and estimation property elements. The user may also need to create a process simulation before creating the process graphic or, in some cases, before the control module is built. After the simulation is built, it is possible to write to the I / O block reference in the control module. Also, once the related graphic display screen is created, it will be possible to browse to an existing process module to set a property reference.

In some cases, the process graphic may not have all the details needed to build a process simulation. Therefore, it is desirable to provide an editor that allows the user to edit the simulation module or process module automatically created from the process graphic. In addition, since it may be necessary for a plurality of process graphics to display the same device, it is necessary for the element to be able to refer to an existing process module when constructing the process graphic.

Generally speaking, the simulations corresponding to the processing elements have a common structure. If desired, the block input connections and parameters of the simulation are stored within the process module so that no reference to the control module is required. In addition, the number of I / O connections supported by the simulation may be defined as extensible, the results from running the simulation may be reflected in the simulation output connections or as parameters of the simulation, and the simulation algorithm may be stepped. It may be defined as a response or entered by the user. If the simulation algorithm is input by the user, the user can specify the dynamics of each output independently.

In addition, a common parameter set may be supported for I / O connections. Parameters related to I / O connections are communicated between blocks as array parameters or array structures, connection status (eg good, bad, restricted, etc.), mass flow parameters, pressure parameters, temperature parameters, specific heat parameters, It can have parameters such as density parameters, or other desired parameters. In some cases, other parameters such as stream composition may be provided and utilized in the simulation algorithm. Standard and extended stream elements may be provided to support this requirement. As part of this extended stream element configuration, the user may select a set of predefined data groups to define the stream element. Such extended connections are only allowed to connect to blocks that utilize this information. In general, extended parameters can have a group name and a specific number of elements. For example, the fuel input stream to the boiler processing element includes the fuel set and the amount of carbon, hydrogen, sulfur, oxygen, water, and nitrogen (all by weight% if desired) in the fuel. It may have components of that fuel. As another example, the turbo generator processing element utilizes a steam stream and the associated connection to the simulation is a steam set, a (real) steam enthalpy entering the stage, a (real) steam enthalpy leaving the stage, An extended parameter set with steam enthalpy (in the case of equientropy expansion) etc. can be utilized.

The extended groupset can also be used when the simulation elements in the process module are used as an interface to a high fidelity simulation package. In this case, it is possible to make the composition of some streams visible in the process graphic. It is also interactive to facilitate the creation or modification of numerical values on the graphic display screen, its associated faceplate, and on the control module detail screen presented on the graphic display screen, if desired. Editors may be provided.

FIG. 4 shows an exemplary graphic display screen 100 that can be created using the elements and configuration applications described above. Specifically, the graphic display screen 100 shows a part of a process plant that produces white vinegar from water, acid, and salt. As illustrated in FIG. 4, the process graphic display screen has four stream elements at its input section, defining a salt supply section, an acid supply section, a water supply section, and a stream of cooling water. The salt supply stream 102 passes through the pipe connection element 104 and is fed to the actuator element in the form of a valve 106. The output portion of the valve 106 is connected to the first input portion of the mixer 108 via the pipe connection element 104. Similarly, the acid supply 102 is connected to the transmitter element 110 and then to an additional valve 112, which valve 112 is connected to the mixer 108. The acid supply unit 102 and the transmitter element 110, the transmitter element 110 and the valve 112, and the valve 112 and the mixer 108 are connected via a pipe connection element 114, respectively.

For easy understanding, the output of the mixer 108 is connected to the heat exchanger 122 via piping and two transmitters 124, 126. The cooling water stream 102 is fed through the valve 128 to the heat exchanger 122 and out of the heat exchanger through the valve 130 to give rise to the recirculated water stream element 131. Similarly, the output of the heat exchanger 122 is carried through the transmitter element 132 and the valve 134 to provide the output acetate stream element 136. Specifically, although not always, the elements of this graphic display screen are connected to each other via piping connection elements in all cases.

The display box 140 is illustrated in the graphic display screen 100 and displays parameter values such as process variables (PV), set values (SP), and OUT values related to various elements. Needless to say, the display box 140 may be generated as a property of the display element itself, or is another element in the form of a transmitter element and an estimated property element, or an element that references a block in a control module. You may. In addition, if the user hovers over any of the above elements, the display screen 100 may display other numbers associated with that referenced element. For example, if you place a Casa on one of the stream elements (eg, acetic acid stream output 136), the graphic will show the composition, pressure, temperature, density, flow rate, etc. of the acetic acid stream at the moment of the process. Is displayed. Of course, the numerical values and parameter values displayed on the graphic display screen 100 are from the actually referenced transmitter in the process control system (for example, the AI block of the control system), or a process module that simulates the function of that element. Can be transported from the simulation element. The graphic display screen 100 of FIG. 4 may be provided to the user during the operation of the process of producing white vinegar, or to realize a simulation of the process that can be used, for example, to perform a design activity or an operator training activity. May be provided.

Figure 5 shows how different graphical display screens (and likewise different process modules) can be interconnected to form a higher level display screen that better describes (or simulates) the process plant. Illustrate. In the display screen 150 of FIG. 5, the process graphic 100 is simplified to a box having a name or label and a set of input / output units represented as connection points. If desired, the user may enlarge the process graphic 100 of FIG. 5 to the process graphic shown in FIG. 4 by selecting the graphic described above and, for example, double-clicking. In addition, other simplified graphic display screens 152, 154 are connected to salt supply, acid supply, and water supply, and further to cooling water via input stream elements 156, 158. It is shown as. The stream output unit 136 of the process graphic display screen 100 is connected to the stream input unit 160 of the white vinegar holding tank 162. Similarly, the stream output of the process graphic display screen 152 is connected to the stream input of the malt vinegar holding tank 163, and the stream output of the process graphic display screen 154 is connected to the stream input of the pickering vinegar holding tank 164. ing. Needless to say, the process graphic 152 may be configured to provide a graphic of a part of the process plant that produces malt vinegar, and the process graphic 154 is a part of the process plant that produces pickling vinegar. It may be configured to provide graphics, and data and graphic views for these areas of this process plant may be viewed by magnifying these display screens.

However, Figure 5 shows that the various graphical areas of the process plant can be interconnected by the connections between the stream elements. Specifically, a stream element may be included in the display screen to define the initial properties associated with the connection element. The stream element can also be used as a connection point between display screens. In the case of such an off-seat connection between display screens, the user can click on the stream to instantly bring up the associated display screen that contains the referenced connection. Therefore, generally speaking, the mass / composition of a stream element is to define the initial properties of the process input, such as the initial feedstock composition, or to define a link to a stream connection on another display screen. It is normal to be used. A connection may be formed at the input or output of the mass / composition stream element. For stream elements, the user uses the name of the stream (which must be unique within the system), the properties of the stream (if no reference input or input connection exists), and the mass fraction of the various components of the stream. (If the stream is composed of more than one component), pressure or mass flow rate, temperature, specific heat, density, required connection type (pipe, duct, conveyor), reference input stream (other) It is common to configure (when used to access streams on the display screen). Similarly, energy stream elements are used to define the initial energy associated with the process input, such as BTU / HR transfers, or to define links to the energy properties of stream connections on other display screens. sell.

Figure 5 illustrates the use of streams to interconnect various reduced graphic display screens, but to interconnect various process modules (and to view their interconnects). ), The same procedure may be used. Specifically, it is possible to shrink process modules to display their names and stream element inputs and stream element outputs, and these reduced process modules are the stream outputs and streams of various process modules. It is possible to communicatively combine or connect to another process module by utilizing the communication connection with the input unit or the display of the communication link.

FIG. 6 illustrates the process module 100a corresponding to the graphic display screen 100 of FIG. As will be appreciated, the process module 100a has a block representing a smart object simulation for each of the physical elements shown in the graphic display screen of FIG. For ease of understanding, each simulation block in FIG. 6 corresponding to the element in FIG. 4 is given a code with the same code plus an "a". Therefore, the mixer simulation block 108a of FIG. 6 is a simulation corresponding to the mixer 108 shown in FIG. Similarly, the valve simulation block 106a corresponds to and communicably coupled to the valve 106 shown in FIG. 4, and the valve simulation block 112a corresponds to and communicably coupled to the valve 112 and is valve simulation. Block 118a corresponds to valve 118 and is communicably coupled to it.

Therefore, the process module 100a of FIG. 6 is a process simulation element for each element displayed on the graphic display screen 100 (a process simulation element that can be represented as a functional block associated with or specified by a smart process object). These simulation blocks are connected to each other by the method specified in the graphic display screen 100 and by using the connection elements specified in the graphic display screen 100. If desired, the process module 100a may be created automatically after the graphic display screen 100 is being created, or even during the creation of the graphic display screen 100.

As mentioned above, each of the process simulation elements in the process module 100 has a simulation function based on the behavior of the mechanical devices used in the process and the characteristics of the stream of material provided at the input of these simulation elements. Has (for example, algorithms, rules, transfer functions, etc.). These simulations are illustrated in FIG. 6 by SIM blocks within each of the processing element, actuator element, and transmitter element. These allow device dynamics and stream effects to be modeled or simulated within process module 100a. Properties available for simulation blocks related to actuator and processing elements include outlet temperature (based on inlet temperature, inlet flow rate, inlet heat capacity), outlet flow rate (based on inlet mass flow rate, accumulation in the element), Includes outlet pressure (based on assumed pressure drop or downstream pressure before and after the unit) and outlet composition (based on complete mixing and inlet composition). When a custom calculation is performed, built-in dynamics related to the exit property may be added to changes in the process input, for example based on the first-order plus dead time response. The user may specify the wasted time and delay associated with each of the calculated properties, if desired. In the case of process measurement elements such as transmitters and switches and connection elements, it may be assumed that no dynamics are introduced in the reference properties. However, transitions and other properties may be modeled if desired. However, in most cases, properties from the upstream connection can be instantly reflected in the downstream connection.

The process module 100a can be used to simulate the operation of some of the plants shown in the process graphic 100. In this simulation, the numerical value from the simulation element in the process module 100a is instantly communicated to the graphic of the graphic display screen 100, displayed in the graphic, and used in the control module. Similarly, the training instructor can use its display screen to influence or change the properties of the simulation performed by process module 100a.

If desired, by defining I / O references for the measurement and actuator elements and automatically creating the DCS interface table currently used, for example in HYSYS, to perform I / O in the simulation. High fidelity simulations such as the high fidelity simulations provided by HYSYS, CAPE, etc. may be added to the simulation function. A standard processing element template can be defined for each HYSYS (or other high fidelity simulation) component that can be used to build a high fidelity process simulation. Such a high fidelity simulation 165 is illustrated in FIG. 6 as being communicably connected to the process module 100a. In this case, the user chooses to disable the simulation provided within each of the simulation elements in the process module 100a and instead uses the simulation parameters provided by the high fidelity simulation 165. sell. The user may specify the use of high fidelity simulation by activating switch 166 (which may be an electronic switch, flag, etc. configured within process module 100a).

Generally speaking, when switch 166 is configured to use high fidelity simulation 165, the associated simulation functional block in process module 100a acts as a shadow block. That is, those simulation algorithms (SIM blocks) are not executed, instead the block parameters are read and written by the high fidelity simulation 165. However, that block within process module 100a still communicates the same parameters and other information to the process graphic and control module, with information from process graphic 100 (eventually used in high fidelity simulation 165) and Receives information from control module 29.

Needless to say, by using the process module in this way, the process plant can be viewed and used by operators, engineers, etc. (ie, using the process graphic display screen 100 associated with the process module 100a). An easy and convenient way to connect high fidelity simulation packages within is realized. Specifically, the stream parameters of the process module are connected or associated with the flow rate modeled in the high fidelity simulation, and the routes within the process module are automatically constructed or constructed within the high fidelity simulation. Or it can be automatically associated with a route within it. In short, in this case, the process module is a placeholder for variables or data that provides a convenient way to map the data in the high fidelity simulation package to the control modules and graphic display screens used in the process plant control / simulation environment. It is used as.

In addition, the process module and associated graphic display screens reduce or eliminate the need for a separate display screen for high fidelity simulation. The display screen for high fidelity simulation is currently generally produced by a high fidelity simulation provider at a high cost for the user. Instead, the process module is already coupled to the graphic display screen, so if the process module is connected to a high fidelity simulation package, the graphic display screen will be calculated by the high fidelity simulation package. It can be used to provide information to the user and to allow the user or operator to manipulate the inputs to the high fidelity simulation package. In addition, since the process module is communicably connected to the control module, the parameters or data generated by the high fidelity simulation package can be utilized within the control module to perform online control activities. Utilizing the process module in this way allows the high fidelity simulation package to be run in parallel with the control module in addition to being integrated into the control module.

As is clear from the above description, the process module and the graphic display screen are integrated to provide an operator view of one area of the process plant 10 along with the process module that simulates the operation of the process plant indicated by the graphic display screen. It can be created and executed in the way that is done. Advantageously, the process module and graphic display screen can be further integrated (eg, communicably connected) with one or more control modules that perform control activities on the aforementioned areas or parts of the process plant. .. Thus, the control module 29 illustrated in FIG. 1 may be communicably integrated with one or more of the process module 39 and the graphic display screen 35 illustrated in FIG. Of course, the control module 29, the process module 39, and the graphic display screen 35, in any particular case, if desired or as needed, other than the computer or device illustrated in FIG. It may be implemented in other computers or devices in plant 10.

7A and 7B illustrate the integration of control module 29, process module 39, and graphic display screen 35 in more detail. Specifically, the graphic display screen 35 has a valve 180 connected to the input unit of the recycling tank 182 and a pump 184 connected in series with the valve 186 to the output unit of the recycling tank 182. Elements 180-186 are connected together by piping connection elements (without labeling), and stream elements are provided at the inputs and outputs of the graphic display screen 35 to define the stream of material at those points. To do.

As a result of the configuration of the graphic display screen 35, the process module 39 that can be created at the same time as the graphic display screen 35 is a valve element 180a, a tank element 182a, a pump element 184a, corresponding to the physical elements shown in the graphic display screen 35. And has a process simulation element in the form of valve element 186a. A control module 29 that controls at least some of the physical elements associated with (shown) the graphic display screen 35 is a set that provides controls within or related to the elements shown by the graphic display screen 35 and process module 39. Has interconnected functional blocks of. In this example, the control module 39 has two control loops 190, 192. The first control loop 190 consists of an analog input (AI) functional block that receives input flow information about the flow of fluid to tank 182 and a proportional integral differential (PID) control functional block that performs proportional integral differential (PID) control. And an analog output (AO) functional block that activates a valve 180 that allows a desired flow rate of material to flow into the tank 182. Similarly, the control loop 192 controls the level of the fluid in the tank 182 with the AI functional block, the PID control block, which provides information on the level of the tank as measured by the level sensor in the tank 182. It has an AO functional block that receives a control signal from the PID control block to operate the controlling valve 186. The control module 29 also represents, for example, the on / off state or operation of pump 184, and discrete inputs (DI) utilized by control loops 190, 192 to perform control activities on tank 182 if desired. It also has a functional block.

Needless to say, any one of the elements in any of the graphic display screen 35, the process module 39, and the control module 29 is with the other elements of these elements (with accompanying communication tags). It is possible to communicate (via) and provide information to each other between these different entities, which enables better or better control, simulation, and operator display screens. The details will be further described. For example, as illustrated in Figure 7B, the PID control block in loop 190 is configured to provide information to the graphic display screen 35 to display the current flow rate setting used by the PID control element. The setting value used in the control module 29 may be read out from the graphic display screen 35. This is indicated by a line with an arrow between these elements. Similarly, the tank element 182a of the process module 39 outputs a simulation output indicating the simulated liquid level of the tank to the control loop 192 of the process control module 29, as determined by the simulation algorithm in the element 182a. It may be provided to the AI function block. The simulated tank liquid level may also be displayed on the graphic display screen 29 as additional information for viewing by the operator.

If desired, the AO block of control loop 192 may provide and receive information to valve 186 of the graphic display screen 35. In addition, the AO block of control loop 192 can be configured to provide its control output to valve element 186a of process module 39. In this case, the valve element 186a can compare the predicted value of the valve position with the actual valve position measured in the control loop 192 to determine if the physical element has any malfunction. If there is a difference of more than a certain amount, the process module 39 may have software that generates alarms or alerts on the graphic display screen 35 that indicate problems that may occur in the process plant, such as defective sensors. Also, as illustrated in FIG. 7B, the valve element 186a may provide simulation measurements or simulation parameter values to be displayed to or made available to the operator. Such simulation measurements or simulation parameter values may represent simulated or predicted flow rates from valve 186 or other simulation parameter values associated with valve 186. Of course, in order to realize better or more enhanced control, simulation, or display screens of other desired information or data, including measured values, simulation data or graphic display screen data, the graphic display screen 35, It may be provided to the elements in the process module 39, and the control module 29.

Generally speaking, there are several advantages to integrating the process module with the control module and, if desired, with the graphic display screen. In one case, as mentioned above, the simulation performed by the process module uses simulated or predicted measurements, parameter values, or other process values to detect problems that may occur in the system. Compare with the parameter measurement or parameter calculation provided by the control module. For example, if the difference between the valve outflow calculated by process module 39 and the valve outflow measured within the process itself is large, an alarm is raised indicating that some device problem exists. It can be. On the contrary, the control module 29 recognizes a defective sensor or another element in an inoperable state or another element that cannot be used by the control module, and the simulation parameter value is used to realize the function enhancement control. Can be used. In this case, the control module 29 does not require the operator to be involved or stop the process, and the process module outputs the measured or measured parameter values (which may be considered defective, may have a defective status, etc.). It is possible to automatically exchange for the simulation output value provided by. Also, displaying both the simulation control data and the actual control data on the same display screen makes it easier for the operator or user to detect problems in the plant, which is convenient in simulation mode and has a better design. It is also beneficial in carrying out the activity.

FIG. 8 is a more detailed diagram of how the control module 200 can be communicably integrated with the process module 202 (and any graphic display screen associated with the process module 202). The control module 200 of FIG. 8 has three AI function blocks 204, 205, and 206, and the function block has an output unit connected to the control function block 207. The control function block may be a multiple input / multiple output control block, for example, such as a model predictive control (MPC) function block. The three control outputs from the control block 207 are conveyed to the control inputs of the three AO functional blocks 208, 209, 210. The AO functional block can control valves in the process of providing and mixing different fluids to the mixer, for example.

The process module 202 is associated with a part of the process having a mixer and a valve controlled by the control module 200. Specifically, the process module 202 has valves (actor elements) 211, 212, 213, which are indicated by arrows on the left side of the process module 202 for three streams to the mixer element 214. Simulate the flow of a stream). Valve element 215 simulates the flow of fluid from mixer element 214 to define the output stream on the right side of process module 202, and transmitter element 217 represents the measured composition of fluid flowing out of mixer element 214. Fluid (or can be simulated). For clarity, the connection element is shown as a single wire in Process Module 202.

In this case, AO functional blocks 208-210 can control the operation of the valves in the process plant indicated by valves 211-213 (in process module 202), while to AI functional blocks 204-206. The control input can be provided by a composition sensor, flow rate sensor, or other sensor indicated by transmitter 217 (in process module 202).

As will be appreciated, the logical elements within the process module 202 and the control module 200 provide information from the process module 202 to the control module 200 in a desired or informative way and process the information from the control module 200. They may be communicably interconnected to provide for module 202. In one example, the communication connection (illustrated by dotted line 218) is the output of transmitter element 217 of process module 202 (output representing simulated measurements of material composition in mixer 214) and AI in process control module 200. It can be built between the simulation input SIM_IN of block 216. In this way, simulated measurements of the fluid level of the fluid in mixer 214 are provided to AI block 206, which, for example, has a bad status signal at the control input (IN) section of that block. This simulation input can be used if it is known to be bad or for some reason. In this way, the AI block 206 can provide an approximation of the measurements associated with the AI block 206, even if the actual physical measurements are not valid or available. This allows the control module 200 to continue to function and provide control, even in the presence of defective sensors. Also, with such a connection, the control module can utilize valid simulation data (provided by simulation process module 202) during offline operator training or to inspect control module 200. It will be possible to operate in simulation mode.

Alternatively or additionally, the communication connection (illustrated by dotted line 219) is actually controlled by the output of AO block 208 in the process control module 200 and the AO block 208 in the process plant. It can be constructed between the input of valve element 211, which models the valve. Here, the valve element 211 is whether the simulation data (ie, the measured and parameter values calculated by the SIM block of the valve element 211) are correct or match the data used in the actual control routine 200. The data obtained from the actual valve or the data transmitted to the actual valve can be used to determine. If there is a significant difference, Process Module 202 can generate alarms or alerts that indicate possible problems, or use real-world data to process better or more accurate simulations. It can be realized within module 202. For example, the valve element 211 may use actual control data with respect to the position of the valve element 211 within the SIM block to reflect the actual valve position in the simulation. Of course, in the connection formed between the other elements of the process module 202 and the control module 200 to achieve enhanced control and / or simulation, the direction of data flow between these two modules. May be in either direction. Further, any data from the process module 202 or the data from the control module 200 may be automatically made available to the operator via the graphic display screen associated with the process module 202.

If desired, the process module may provide and simulate redundant functionality within the process control network or process plant. Specifically, the process module can simulate the behavior of actual redundant elements such as redundant devices, redundant control blocks, etc. placed in the process plant, and detect or simulate the behavior of the actual redundant elements. It is possible (for example, when backup redundant elements are replaced). Further, if desired, the process module having simulation capability may be utilized as one of a pair of redundant elements in one process plant. In this case, the process module (or any part of the module) is backed up or redundant data in the event of a major (and actual physical) device failure or a problem associated with it. It can act as a backup device that provides (signals, calculated values, etc.). In this case, the process modules acting as redundant elements may be communicably interconnected with the control modules (performing control or sensing actions) in any known way to provide redundancy capabilities. It is possible. This use of process modules as redundant elements within a process plant is especially beneficial when those process modules are connected to one or more high fidelity simulation packages as described above.

Needless to say, the smart process objects, graphic display elements, and process modules described herein can operate on the operator workstation 20 and are downloaded to the controller, field device, etc. in the plant 10. It does not need to be, or configured within them, thus facilitating the realization, viewing, modification, etc. of this feature. In addition, this feature makes it easier to make system-level decisions than to make system-level decisions within process devices, controllers, and so on. The reason for this is that system-level information about the device is typically all available on the operator workstation 20, and more specifically, all is available on the execution engine 48. In contrast, not all of this information is usually available to the respective controllers and field devices in the process plant. However, if it is beneficial to do so, some of the logic associated with the process module, such as basic instructions, may be incorporated into the devices, equipment, and controllers in the process plant. When the smart process module is used to create an integrated process control module and graphic display screen, the execution engine 48 automatically detects the leak and raises an alarm with minimal configuration activity by the user. Calculate and track flow and mass balances within plant 10, track losses within plant 10, provide advanced diagnostics for plant 10, and simulate plant operation during engineering design and operator training. Will be possible.

FIG. 9 represents one possible way to integrate the execution engine 48 with the process modules and graphic display screens used within the process plant. The process plant has a decentralized control strategy. As illustrated in Figure 9, the display screen class definition 220 created or associated with a process module that provides a display screen to the operator during execution by the execution engine 48 is a control configuration database and engineering tool. Provided in 222, the tool can utilize and organize these display screen class definitions in any desired way within the control strategy document. Process algorithm 224 can be connected to these display screen class definitions prior to execution time, and then this display screen class definition and the flow algorithm connected to it are instantiated and graphic display screen / It can be provided to the process module execution time environment 226 (this environment can be implemented in the form of one or more execution engines 48 within one or more workstations). The Graphic Display Screen / Process Module Execution Time Environment 126 utilizes the download script parser 228 to parse the code during execution (ie, to perform object code conversion in the just-in-time state) and of the display screen class. Utilizes the rule-based execution engine 230 to perform flow algorithms or other rule-based procedures provided for or combined with display screen classes. During this process, the graphic display screen / process module execution time environment 226 can communicate with the control module execution time environment 232. The control module execution time environment 232 is executed within the controller and field device associated with the process and provides data and information to the control module execution time environment 232, or data or other data from the control module execution time environment 232. Access information sell. Of course, the graphic display screen / process module execution time environment 226 utilizes any desired or preconfigured communication network, such as the Ethernet® bus 24 of FIG. 1, to utilize the control module execution time environment 232. May communicate with. In addition, other methods of integrating the graphic display screen, process module, and control module described herein into a standard process control system or standard process plant may also be utilized.

If implemented, any software described herein may be stored in any computer-readable memory, such as a magnetic disk, laser disk, or other storage medium, such as in the RAM or ROM of a computer or processor. Can be done. Similarly, the software can be transported to a user, process plant, or operator workstation using any known or desired transport method. Any known or desired transport method described above may include, for example, a computer-readable disk or other transportable computer storage mechanism, or telephone lines, the Internet, the World Wide Web, or other local or wide area networks. A method of using a communication channel such as is included. Transport by means of communication channels such as the telephone lines, internet, worldwide web, and other local area networks or wide area networks described above is the same as providing such software via transportable storage media or It is considered that they can be converted to each other. In addition, the software may be provided directly without modulation or encryption, or modulated using any suitable modulation carrier and / or encryption technology before being transmitted over a communication channel. And / or may be encrypted.

Although the present invention has been described with reference to specific examples, they are intended for illustration purposes only and are not intended to limit the invention. Therefore, it will be apparent to those skilled in the art that modifications, additions, or deletions may be made to the disclosed examples without departing from the spirit and scope of the invention.

10 process plant 12 controller 14, 16 field devices 20, 22 workstations 28 Configuration database