Updating and utilizing dynamic process simulation in an operating process environment

This application is a partial continuation of US Patent Application No. 10 / 278,469 entitled "Smart Process Modules and Objects in Process Plants" filed October 22, 2002. In one place, the patent certificate was issued on September 19, 2006 as US Patent No. 7,110,835, "Integration of Graphic Display elements, It is a continuation of US Patent Application No. 10 / 625,481 filed on July 21, 2003, entitled "Process Modules and Control Modules in Process Plants". An application dated December 16, 2004, entitled "Smart Process Objects Used in a Process Plant Modeling System," which claims priority over the application. It is a partial continuation application of US Patent Application No. 11 / 014,307 and claims priority over the application. The entire disclosure of these applications shall be incorporated herein by reference.

The present invention relates generally to process plants, and more specifically to intelligent control and simulation environments that allow system-level simulation work of process plant control architectures to be integrated into and updated from an online control system.

Distributed process control systems, such as those commonly used in chemical processing processes, petroleum refining or other processes, are communicably linked to one or more field devices via analog, digital or analog-digital mixed buses. Includes one or more process controllers to be processed. Field devices, which can be, for example, valves, valve positioners, switches or transmitters (eg, temperature, pressure, level and flow sensors) are typically installed in a process environment and function in processes such as opening and closing valves and measuring process parameters. To execute. Also, smart field devices such as field devices that comply with the well-known Fieldbus protocol. device) can perform control calculations, alarm functions and other control functions that are generally performed within the controller. Also, the process controller is usually installed in a plant environment and receives signals that indicate process measurements made by the field equipment and / or other information about the field equipment, and also makes various decisions about, for example, process control. It executes a controller application for operating a control module or the like, generates a control signal based on received information, and cooperates with the control module or block executed in a field device (for example, a field device of HART or Fieldbus). (coordinate). The control module of the controller sends a control signal to the field equipment through the communication line, thereby controlling the operation of the process.

Information from field equipment and controllers is typically located away from control rooms or other harsh plant environments, such as operator workstations, personal computers, data historians, reporting programs, and centralized databases. It is available through a data highway connected to one or more other hardware devices. These hardware devices can, for example, change the settings of process control routines, modify the behavior of control modules in controllers or field equipment, display the current state of the process, display alarms generated by field equipment and controllers, employees. Run applications that enable operators to perform process-related functions such as process behavior simulation or process control software analysis testing, configuration database management and updating for the purpose of training.

Emerson Process as an example The DeltaV® control system sold by Management includes multiple applications that are housed in and run by different devices installed at different locations within a process plant. Configuration applications that reside on one or more operator workstations allow users to create or modify process control modules and download these process control modules via a data highway to a dedicated distributed controller. Communication, which is an object of an object-oriented programming protocol, typically provides functions within a control mechanism based on its inputs and supplies outputs to other functional blocks within the control mechanism. It consists of functional blocks that are interconnected as possible. Also, in the configuration application, the designer creates or modifies the operator interface used by the display application so that the data can be displayed to the operator and the operator can change settings such as setting points in the process control routine. Can make it possible to do. Each dedicated controller (and in some cases a field device) stores and runs a controller application that runs a control module assigned and downloaded to it to perform actual process control functionality. A display application that can run on one or more operator workstations receives data from the controller application via the data highway and uses this data with the designer, operator, or user interface of the process control system. It can be displayed to the user and can provide any number of different screen displays such as operator screen display, engineer screen display, engineer screen display, and the like. Data historian applications are typically stored in a data historian device that collects and stores some or all of the data supplied via the data highway, thereby. Will be executed. On the other hand, the configuration database application may run on yet another computer connected to the data highway and store the configuration and data of the current process control routine associated therewith. Alternatively, the configuration database may be installed on the same workstation as the configuration application.

As mentioned above, an operator display application is typically implemented system-wide on one or more workstations and provides an operator or maintenance personnel with preset screen displays regarding the operational status of control systems or equipment in the plant. To provide. Normally, these screen displays are an alarm screen that receives an alarm issued by a controller or device in the process plant, a control screen that shows the operating status of the controller and other devices in the process plant, and an operating status of the device in the process plant. It takes the form of a maintenance management screen that shows. These screen displays are generally preconfigured and configured to display information or data received from process control modules or devices in the process plant in a well-known manner. In well-known systems, objects with graphics associated with a physical element or logical element are used to form a display screen, which is a physical element for receiving data about the physical element or logical element. Alternatively, some are connected to logical elements so that they can communicate with each other. The object can display the flow rate measured by the flow rate sensor in a diagram by changing the graphic on the display screen based on the received data and showing, for example, a state in which the contents of the tank are halved. The information required for display is transmitted from the equipment or configuration database in the process plant, but the information is used only to provide the user with a display screen containing that information. As a result, all of the information and programming used to generate alarms, detect problems in the plant, etc. is generated by different devices associated with the plant, such as controllers and field devices, while configuring the process plant control system. Must be configured inside. Otherwise, this information will not be sent to the operator display screen and will not be visible while the process is running.

While error detection and other programming can help detect conditions and errors or warning alarms associated with control loops running on different controllers, as well as problems in individual devices, they are (possibly different) within the process plant. It is difficult to program a process control system to recognize conditions or errors that must be detected by analysis from another device (located at various locations) at the system level. Furthermore, the operator display screen is not normally used to show or present information about such system-level conditions to the operator or maintenance personnel. In any case, it is difficult to animate the objects in the operator's display screen in this way when the sources of information or data about different elements in the screen display are different. This is an animation and modeling of a material stream, such as the flow of fluid in a pipe or the state of movement of raw materials on a conveyor belt, as indicated by a simple line connecting the two devices on a screen display. This is a fact that is particularly applicable to. Also, there is currently no organized method for detecting specific conditions within the plant, such as flow conditions and material equilibrium, as the material passes through the plant, let alone perform these functions at the system level. Needless to say, there is no system that can be easily implemented.

Similarly, the method of using process simulation in a live process environment has traditionally been used, but nonetheless, simulation work is typically performed separately from the display and control work performed in the process plant's online environment. It can be difficult to set up or create a simulation of a process plant or part of a process plant because it must be performed. Also, even if a plant simulation could be formed, it would be difficult (if not impossible) to integrate this simulation into the operator display screen or control module used in the plant. For example, it is well known that when designing a plant, HYSYS (High-Fi Simulation Program) is used to perform process simulations, and later the same simulation is used to assist the plant in operation. One of the advantages of using process simulation in conjunction with an operating plant is that the performance of the actual plant can be compared to the design performance. However, the existing technology only shows the current values of the process parameters calculated by the simulation. Also, process simulations, even simple ones, can contain hundreds of configurable parameters, each of which affects the results of the simulation. As a result, the simulated plant may not match, or the simulated plant may not match the actual plant over time after the simulation is created due to changes in the plant or deterioration of plant equipment. Can occur. In existing techniques, such differences are generally resolved by engineers manually adjusting the configurable parameters of the simulation. However, such a simulation correction method requires an extremely large amount of time, is highly dependent on the know-how of the operator, and is prone to many errors.

The simulation system is integrated into the process control environment in a manner that facilitates the use of the simulation system and that automates and practically updates online process simulations. The disclosed simulation system makes the current and future values of process parameters available for performance evaluation and can be used to guide the operation of the plant. The simulation system can also be connected to various online processes or plant measurements and can be simulated by automatically updating the process model (s) used in the simulation system. These measurements can be used to keep the system coordinated with the actual operating state of the process plant.

The simulation system can be implemented in a smart process object with graphics and simulation elements used to depict and model the behavior of the plant or parts of the plant. Generally speaking, each smart process object that represents a physical device or entity in a process plant (valves, tanks, pipes, etc.) is used to depict the physical element in question and the element of modeling or simulation. Contains graphic elements that can be used in the graphic display. Specifically, a smart process object is a display element displayed to an operator, a data storage element for storing data about and received from related entities in the plant, and for communicating with other process objects. It may include methods and simulation algorithms that can be executed on stored and received data to detect plant or equipment conditions, including inputs and outputs, leaks and errors and other conditions.

Multiple to create a simulation system that renders and simulates the behavior of different parts of a process plant during configuration, and to create a process module that models or simulates the behavior of a portion of a process plant. Smart process objects can be connected together. In this regard, each process module (and each screen display associated with the process module) receives an input corresponding to a fluid, gas or other substance moving through the plant, produces its output and processes. Model or simulate the behavior of process elements in a plant for their effects on substances moving through the plant. Thus, the graphic display portion of a smart process object can be used to depict the behavior of an element within the plant (and the role or effect of that element in the plant). Also, the simulation elements of smart process objects can be used to simulate the effects of actual physical elements on the moving state of fluids or other materials in the plant. Also, data from the actual plant (eg, measured within the plant) can be communicated with or depicted in a graphic display created using smart process objects.

Smart connection objects can help model connections between physical entities in a plant to perform more detailed and accurate simulations. Such connections may specify, for example, pipe connections, duct connections, electrical connections or conveyor connections. Thus, the connection may relate to one of a number of different types of material flows flowing through the connection. The smart connection object can store connection parameter data related to the connection, such as information indicating the connection type or connection status. By running a smart connection object as part of a simulation system, you can generate a model of process plant behavior by displaying a graphic display of the connection and simulating the flow of material flowing through the connection. It will be easier.

Simulations are also provided via smart stream objects that can be associated with a stream of material (or flow of material) within the plant. Such a stream may represent a fluid, solid or gas flowing or moving through the plant. Also, each stream may contain characteristics or parameters such as stream pressure, volume, density, flow rate, composition, etc. that may change as the stream travels through different elements of the process module. Since a stream flows by the input and output of process control elements, the characteristics of the stream are generally brought about by the elements of the process such as valves and tanks through which the stream flows. For this reason, each element within a process module contains an algorithm for simulating the effect on the process element stream provided by its input.

The operator workstation or other computer runs an execution engine that runs the created graphic display or process module to bring about the behavior of the graphic display or process module created from the smart process object. As part of this behavior, the process module uses a method called a flow algorithm (which can be used specifically at the system level to detect process conditions and simulates the effect of process elements on the stream flowing through the plant). Can be done. As a result, process modules and graphic displays created from smart process objects allow the implementation of state and error detection routines on operator displays and can work with plant controllers and field devices, or the plant. It is possible to eliminate the need to provide this functionality in the controller and field device of the above. The process module also provides another level of programming flexibility within the process plant that can be used to provide even better complete information while maintaining an easy-to-use and easy-to-implement state. Provide to system configuration engineers. Furthermore, the graphic display can be animated with information determined or calculated by the flow algorithm of the process flow module to provide additional information to the operator.

With reference to FIG. 1, a process plant 10 as an example, in which a smart process object is used to graphically display a process and form a process module, is shown in detail. Here, both the graphic display of the process and the process module can be integrated into the control module to provide extended control and simulation within the plant environment. Specifically, process plant 10 has, for example, Fieldbus interface, Profibus interface, HART interface, standard 4-20. A decentralized process control system with one or more controllers 12 connected to one or more field devices 14 and 16, respectively, via an input / output (I / O) device or card 18 that may be an mA interface or the like. To use. The controller 12 is also connected to one or more host or operator workstations 20 and 22 via, for example, a data highway 24 which may be an Ethernet® link. Database 28 is connected to the data highway 24 and serves as a data historian to collect and store parameters, states and other data related to controllers and field devices in plant 10 and / or the current process control system in plant 10. Operates as a configuration database that stores the configuration of (downloaded and stored in controller 12 and field devices 14 and 16). Normally, the controller 12, the I / O card 18, and the field devices 14 and 16 are installed and distributed in a harsh plant environment in some cases. Operator workstations 20 and 22 and database 28 are typically installed in a control room or in a less harsh environment that is easily accessible by the controller or maintenance personnel.

As we all know, Emerson Process is an example. Each of the controller 12, which may be a DeltaV® controller sold by Management, provides a controller application that implements the control method using any number of different, independently executed control modules or blocks 29. Store and execute. Each functional block is a component or subroutine of an overall control routine and is characterized by functioning with other functional blocks (via communication called links) to implement process control loops within process plant 10. Each control module 29 can be configured from what is generally called a functional block. As is well known, functional blocks that can be objects in object-oriented programming protocols are generally associated with transmitters, sensors, or other process parameter meters to perform some physical function within process plant 10. It executes one of the input function, the control function related to the control routine that executes the control such as proportional / integral / differential (PID) and fuzzy logic, or the output function that controls the operation of some device such as a valve. Of course, there are also hybrid and other types of complex functional blocks such as model predictive controllers (MPCs) and optimization programs. The Fieldbus protocol and the DeltaV system protocol use control modules and functional blocks designed and implemented in object-oriented programming protocols, while control modules are designed and implemented using functional blocks or other specific programming techniques. It can be designed using any desired control programming mechanism, including, for example, sequential functional blocks, ladder logic, and the like.

In plant 10 shown in FIG. 1, field devices 14 and 16 connected to controller 12 can be standard 4-20 mA devices, such as HART, Profibus or FOUNDATIONTM, which include a processor and memory. It can also be a smart field device, such as a Fieldbus field device, or any other desired type of device. Some of these Fieldbus field devices and other devices (shown as collation number 16 in FIG. 1) may store and execute submodules or modules such as functional blocks associated with the control method implemented in controller 12. .. Fieldbus The functional block 30 illustrated in FIG. 1, which is located in two different field devices 16, is, as is well known, executed at the same time as the control module 29 in the controller 12 is executed to perform process control. Can be done. Of course, field devices 14 and 16 may use any type of device such as sensors, valves, transmitters, positioners, and I / O devices 18 may include any desired device such as HART, Fieldbus, Profibus. Any type of I / O device may be used as long as it complies with the communication or controller protocol.

In process plant 10 of FIG. 1, workstation 20 is provided with any authorized user (in this article, a system configuration engineer or, in some cases, a system configuration engineer) to display and provide functionality related to equipment, units, etc. connected within process plant 10. It includes a set of packaged operator interface applications and other data structures 32 that can be accessed by (also referred to as operators, but other types of users may also exist). The set of packaged operator interface applications 32 is stored in memory 34 of workstation 20, and each application or entity in the set of packaged applications 32 is a processor 36 associated with workstation 20. Adapted to be runnable. All of the set of packaged applications 32 are shown stored in workstation 20, but some of these applications or other entities are in plant 10 or in another workstation associated with it. Alternatively, it can be stored in a computer device and executed there. Furthermore, the set of packaged applications is displayed on a display screen 37 associated with workstation 20, or on any other desired display screen or display device, including handheld devices, laptops, other workstations, printers, and the like. Can provide output. Similarly, the applications in a set of applications 32 may be run separately on two or more computers or machines, or configured to function in relation to each other.

Generally speaking, a set of packaged applications 32 creates and uses three different types of entities whose behavior can be integrated to provide extended control, simulation and display capabilities within process plant 10. To provide or enable. More specifically, a set of packaged applications 32 is a graphic display 35 of the process (generally providing an operator display screen for a part of the process plant), a process module (generally providing a simulation of a part of the process plant). 39, and a control module 29 (generally providing or performing online control of a process) can be used to create and implement. The process control module 29 is a technique generally well known to those skilled in the art and may include any type of control module, such as a functional block control module. Generally, a process graphic display element 35, described in more detail below, is provided by an operator, engineer, or other display to provide information about the operation, configuration, or setup of a process plant and the elements within it to a user such as an operator. The element used. Process module 39 is typically closely related to process graphic display element 35 and is used to simulate the operational state of different elements connected in or within the process plant in the manner depicted by process graphic display 35. Can be done. The process graphic display 35 and process module 39 are illustrated as being stored and running on workstations 20 and 22, while the process graphic display 35 and process module 39 are processes such as laptops, handheld devices, etc. It can also be downloaded to other computers associated with Control Plant 10 and run there.

FIG. 2 is a diagram showing some applications and data structures, or other entities contained within a set of applications 32 on workstation 20. Specifically, a set of packaged applications 32 are control modules, process modules and process modules used by system configuration engineers to create control modules, process modules (also known as process flow modules) and associated graphic displays. Includes application 38 for graphic display configuration. The control module configuration application 38 can be any standard or well-known control module configuration application, while the process module and graphic display configuration application creates process modules and graphic displays that use one or more smart process objects. Can be done. The contents related to this are explained in more detail below. Furthermore, although the process module and the process graphic configuration application 38 are shown separately in the figure, it is possible to create both types of elements in one configuration application.

Library 40 of smart process object 42 contains a sample or standard smart process object 42 where it can be accessed, copied, and used by configuration application 38 to create process module 39 and graphic display 35. There is. Of course, the configuration application 38 can be used to create one or more process modules 39, each of which is configured or created from one or more smart process objects. It can also include one or more process flows or simulation algorithms 45 stored in the process module memory 46. The configuration application 38 can also be used to create one or more graphic displays 35, each of which is configured or created from one or more smart process objects 42, and , Can contain any number of interconnected display elements. Figure 2 shows an example of graphic display 35b depicting a set of process elements including valves, tanks, sensors and flow transmitters that are interconnected by connecting elements that can be pipes, conduits, power cables, conveyors, etc. Is shown as an expanded form including.

The execution engine 48 creates the process display screen for one or more operators defined by the graphic display 35, and performs the graphic display 35 and the process at run time to perform the simulation functionality associated with the process module 39. Operate or implement each of the modules 39. The execution engine 48 may generally be process module 39, specifically a rules database 50 that defines the logic implemented by the smart process objects within that module. Execution engine 48 may also use a connection matrix 52 that defines the connections between process elements within plant 10 (as well as within process module 39 to implement functionality for process module 39).

FIG. 2 is a diagram showing one of the smart process objects 42e in more detail. The smart process object 42e is shown as one of the standard smart process objects, but of course other smart process objects are generally the same or similar elements as described for the smart process object 42e. , Functional characteristics, parameters, etc., and the details or numerical values of these elements, functional characteristics and parameters may be changed or modified between smart process objects depending on the nature and use of the smart process object. Furthermore, while the smart process object 42e can be an object in an object-oriented programming environment and thus can contain data storage mechanisms, inputs / outputs and methods associated therewith, this smart process object is otherwise desired programming. It can be created by a paradigm or protocol and implemented within it.

Unsurprisingly, the pre-instantiated 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. However, after copying or creating an instance, the smart process object 42e can be connected to a particular entity within the process plant. In any case, the smart process object 42e includes a data storage mechanism 53 used by the smart process object 42e to store data received from or related to the associated logical entity. In general, the data storage mechanism 53 includes a data storage mechanism 53a that stores general or persistent information about the entity to which the smart process object 42e is associated, such as manufacturer, revision, name, type. The data storage mechanism 53b contains parameter data, state data, input / output data for the entity to which the smart process object 42e is involved, including data related to the entity that previously existed or exists in the process plant 10. Can store variable data, such as cost or other data subject to change. Of course, the smart process object 42e is periodic or non-regular from the entity itself via any desired communication link, from Historian 28 via Ethernet Bus 24, or in any other desired manner. It can be configured or programmed to receive this data (eg, cost data) at regular intervals. The data storage mechanism 53c involves the smart process object 42e and is the entity used for the actual display screen displayed to the operator via an operator interface such as screen 37 associated with workstation 20 in FIG. Can store the graphic display (graphic representation) of. Of course, the graphic display is information defined by parameters, or data storage mechanism 53b. It may contain placeholders (position retention symbols) of information about the entity (marked underlined within the data storage mechanism 53c), such as other variable data about the entity stored in. This parameter data may be displayed in a graphic placeholder when the graphic display is presented to the operator on the display device 37 as part of one of the graphic displays 35. The graphic display (and smart process object 42e) allows an operator or system configuration engineer to connect upstream or downstream components to process elements as depicted by the graphic display ("X" within the data storage mechanism 53c. Can include predefined connection points (marked by). Of course, these connection points also allow the smart process object 42e to recognize the elements connected to the smart object as being configured within the process module. Also, these connection points can specify the type of connection element required, such as pipes, ducts, and streams associated with the element. Can also be recognized as being configured within a process module. Also, these connection points can specify the type of connection element required, such as pipes, ducts, and streams associated with the element. Can also be recognized as being configured within a process module. Also, these connection points can specify the type of connection element required, such as pipes, ducts, and streams associated with the element.

The smart process object 42e also has one or more inputs 54 and outputs 56 to allow communication with other smart process objects inside or outside the process module in which the smart process object 42 is used. Can include. The configuration of input 54 and output 56 connections to other smart process objects can be done by the system configuration engineer simply connecting to these inputs and outputs of other smart process objects during process module configuration, or by smart. This can be done by specifying specific communications that occur between process objects. Some of these inputs and outputs can be defined as being connected to a smart process object that is connected to the predefined connection points for the smart process object above. These inputs 54 and outputs 56 may also be determined or defined by a set of rules in the rules database 50 and the connection matrix 52 after defining the connections between different devices or entities in the plant 10. The inputs 54 and outputs 56 (including associated data storage mechanisms or buffers) generally allow data to be communicated from other smart process objects to the smart process object 42e, or are smart processes. Object 42e Used to allow data stored or generated within it to communicate with other smart process objects. These inputs and outputs are also used to allow communication between the smart process object 42e and other objects in the process control system, such as the field devices 14 and 16, the control module in the controller 12. sell.

Also, as shown in Figure 2, the smart process object 42e can be an algorithm performed by the smart process object 42e during the execution of the process module where the smart process object 42e is used Method 60 ( It contains a method storage mechanism 58 used to store zero or one or more of the methods 60a, 60b and 60c in Figure 2). In general, method 60 stored in method storage 58 contains data and other data stored in data storage parts 53a and 53b to determine information about process plant 10 or entities within that plant 10. Data obtained from smart process objects in Or, use data obtained from other sources such as the configuration database or Historian 28 via inputs 54 and outputs 56. For example, the method 60 determines a malfunctioning or improper operating condition associated with an entity defined by smart process object 42e, an error associated with the same entity or another entity within process plant 10, and the like. sell. A method 60 is preconfigured or provided based on the type or class of the smart process object, and the method 60 is typically executed each time the smart process object 42e is executed within the run-time execution engine 48. Will be done. Some of the methods 60 cited as examples that can be provided within a smart process object, such as the smart process object 42e, are leak detection, dead zone, dead time, moving state, variability, condition monitoring, cost calculation, or such. Includes other states associated with the entity of.

The method 60 may also be provided to assist in simulating the behavior of a process entity associated with a smart process object of material flowing through that process entity. Thus, Method 60 simulates element behavior by calculating mass balance, energy balance, flow rate, temperature, composition, gas phase state, and other system-level or stream-level parameters associated with the material in plant 10. And can be provided to calculate the expected output based on the inputs provided thereby. Of course, these are just a few examples of the methods that can be stored and executed in the smart process object 42e, and there are many other methods that can be used. Such methods are generally determined by the type of entity depicted, how the entity is connected and used in the process plant, and other factors. While the smart process object 42e can store and execute methods for detecting system-level states, errors, etc., these methods are also for devices, for logical elements such as process control modules and loops, and for other systems. It is important to note here that it can be used to determine other information about non-level entities. If desired, method 60 can be programmed or provided in any desired programming language such as C, C ++, C #, and is referenced during execution by the applicable rules in the target rules database 50 of the smart process object 42e. , Or can be done for it.

If desired, each smart process object may include a library of applicable algorithms or methods that can be used to define the simulation behavior of the smart process object when connected within a process module. Such a library is illustrated in the pull-down menu 61 of smart process object 42e in FIG. 2, and similar menus may be associated with each of the other smart process objects. The system configuration engineer places this smart process object in process module 39 by selecting one of the simulation algorithm libraries (so-called method 1, method 2, etc.), for example via pull-down menu 61. If so, you can define the simulation behavior of a smart process object. In this way, the system configuration engineer can define different simulation behaviors for the smart process object, depending on the type or nature of the process in which the smart process object is used in the model.

If desired, the system configuration engineer will instead provide proprietary (proprietarily developed) or other user-provided algorithms to define the simulation behavior of the process elements defined by the smart process block. sell. Such a user-defined algorithm (shown in the pull-down menu 61 with the item name "user-defined") is such a smart process when the smart process object is placed in or used by process module 39. Provided to or stored in an object. This feature allows the user to customize the simulation behavior, thereby providing better or more accurate simulation. When desired, and as will be seen in the detailed description below, the smart process object 42 or each process module 39 disables the use of simulation algorithms within the smart process object and instead hi-fi simulation. It may include a package or, for example, an operator-invotable switch (such as an electronic switch or flag) that determines the operation of the process module by a program provided by HYSYS. The smart process object or process module in this case obtains the simulated parameters from the hi-fi simulation, as opposed to using the simulation algorithms contained within the smart process object itself.

During execution of the graphic display 35 or process module 39 by the execution engine 48, the engine 48 communicates with each of the smart process objects in the graphic display 35 or process module 39 defined by inputs 54 and outputs 56. And, the function provided by the method 60 can be executed by executing the method 60 for each of the objects. As mentioned above, the functionality of method 60 can be provided within the programming within the smart process object, or implements the functionality defined by a set of rules in the rules database 50 executed by the engine 48. Therefore, it can be defined by the rules based on the type and class of smart process objects, identification information, tag names, etc.

The instance of the smart process object 42e has a tag or a unique name corresponding to the context (state, context, etc.) of the process module related to the smart process object 42e, and this tag or a unique name. Is used to provide communication to or from the smart process object 42e and may be referenced by the execution engine 48 during run time. The process module tag must be unique in the configuration of the control system. This tagged specification allows elements in process module 39 to be referenced by the graphic display 35 and process module 39 of another process, as well as the elements of control module 29. Furthermore, the parameters of the smart process object 42e can be simple parameters that recognize the expected units and their associated attributes, such as simple numbers, structured parameters or smart parameters. Smart parameters can be interpreted and used by the process rules engine or execution engine 48 to ensure that all signals are transmitted or properly converted in the same unit. You can also apply smart rules to turn a group of alert alarms for smart process objects (or process modules) on and off to create smart alert strategies and / or interfaces for operators. Furthermore, the class of smart process objects is related to the classes of equipment and modules provided within the process control scheme of plant 10 and is well known between the smart process objects and process variables that it must interpret or access. A link mechanism can be provided.

Smart process objects are also used in process graphic displays or process modules to prevent them from going into different modes such as OFF, start, normal mode at run time, operation mode, state and alarm. It can include motion, can provide a state related to the object based on its current operating state, and is based on the detected state (parameters are out of range / limit, highly variable, etc.). Can provide alarms and alarms. Smart process objects can also have a class / subclass hierarchy that allows them to be categorized in a class library so that they can be collected together in a complex structure or the like. Furthermore, the smart process object controls so that the smart process object can recognize when its associated entity is being used or obtained (eg, by a batch control process within plant 10). Information from other elements such as modules and other objects may be available.

A smart process object can be associated with any desired process element, such as a physical device such as a pump, tank, valve, or a logical configuration such as a process area, measurement or actuator, control scheme. In some cases, smart process objects can relate to connectors including pipes, conduits, wires, conveyors or other devices or entities that move materials, electricity, gases, etc. from one point in the process to another. Also, a smart process object (sometimes a "smart link" or "connector" in this article) associated with a connector (although the actual device or connector itself may not be tagged or communicate within process plant 10). (Called "elements") are tagged and are typically used to represent the flow of material between other elements in the process.

In general, smart links or smart connector objects are different substances or phenomena. Includes properties or parameters that define how an electric current (such as an electric current) flows through a connection (eg, steam, electric current, water, sewage, etc.). These parameters are the type and nature of the flow through the connector (overall velocity, coefficient of friction, type of flow such as turbulent or non-turbulent, electromagnetic, etc.) and the direction or direction of flow through the connector. Can indicate multiple directions. A smart link may include programming or a method that ensures that the unit of the connection source and destination object to which the smart link is connected matches, and if they do not match, returns the unit. Smartlink methods also pass through the connector using a model or algorithm to estimate the velocity or nature of the flow through the actual connector, the length and size of the physical connection, the delay in flow, etc. Flow can be modeled. Parameters stored for smart process objects (eg friction parameters) can be used in these methods. Thus, essentially a smart link or connector element allows a smart process object to recognize other upstream / downstream objects or entities. Of course, smart links can, for example, in any desired or convenient manner, the connections between other objects, the types of fluids such as liquids, gases and currents in the system, and the upstream and downstream settings of entities. , Other entities located upstream and downstream of the entity of the smart process object, materials, fluids, current flow directions, etc. can be defined. In one embodiment, matrix 52 may be created prior to execution of the process flow module, thereby smartly interconnecting different devices in the plant (ie, interconnecting different smart process objects). Can be defined for links. In fact, execution engine 48 uses matrix 52 to identify upstream and downstream entities, thereby defining communication between a smart process object and the methods associated with that smart process object. To do. Furthermore, it has one or more sets of rules that allow smart process objects to interact with each other (depending on the needs of methods within the smart process object) to exchange data and output. The influence of smart objects related to the connection may be eliminated (resolved).

Also, if desired, the main statement that the smart process object 42e may correspond to the type of object or is specially prepared (depending on its importance and application) for the situation of the device to which the smart process object 42e is involved. Documents can include hot links such as URLs. The documents may be supplied by the supplier or may be user-specific. Some examples of the documents include system setting / configuration, processing procedures at start-up and stop, operation and maintenance documents. If desired, the operator may click on an object displayed on the operator's display screen to view details (if applicable) and general-purpose documents regarding the status of the object or associated device. The operator can also add, delete, change, etc. to documents such as maintenance requests, history of operational problems, etc. independently of the system software. In addition, to provide the ability to add knowledge links to objects in the operator interface, to allow quick navigation of relevant information associated with objects, and to identify objects of a particular object type (and even object identification). These hotlinks may be user-configurable or user-modifiable to provide the ability to add customer-specific work instructions (also to instances of).

The process module and process graphic are described above as being created together by interconnecting different smart process objects, but may be created separately. For example, a smart process object may be used to create a process graphic, and upon completion of creation, a process module for the graphic may be generated based on the graphic elements and their interconnection in the graphic display. Alternatively, first create a process module using the smart process object, then use the graphic display elements in the smart process object used to create the process module to graphic the process module by the configuration application 38. The display may be automatically generated. Furthermore, by creating the process module and the graphic display separately and referencing the individual elements within these two elements to each other (eg, utilizing the tag characteristics of the elements within the graphic display and the process module). You may connect them manually. With this mechanism, smart process objects can be referenced by multiple displays. In any case, once the creation is complete, the graphic display of the process and the associated process modules usually alternate between parameters and information as requested or required, but can also be run independently or separately. It is possible.

To be more comprehensive, the features and possible examples of smart process objects that can be used in (or to create) process graphic displays and process modules are described in more detail below. After that, a mode in which the process graphic display and the process module created by using the described elements and features are integrated into the control module to provide advanced control and simulation functions will be described. As will be clear from the following, the elements and features of the smart process object are, of course, not limited to the elements and features discussed here, and if desired, other features and features may be displayed in a process graphic. And can be used in one or both of the process modules (or to create them). Furthermore, as will be apparent below, the simulation procedures used in one or more simulation systems described below relate to simulation systems built using smart objects. It is not necessary to use smart objects in these simulation systems, and instead when developing or implementing these simulation systems, other types of programming Techniques can also be used.

Generally speaking, a set of predefined graphic elements may be incorporated into the configuration application to allow the user to build an operator or graphic display that reflects the process plant. These graphic elements are designed to dynamically display online measurements and actuators that connect to the control system. Unmeasured parameters that reflect process behavior can also be calculated using the online process simulation provided in the process module and can also be shown as an integral part of the associated graphic display.

In addition, in online or offline work environments used for simulation for technical design / implementation or training purposes, the process simulation provided by the process module is used in place of process measurements in graphic elements and related control modules. sell. These numbers calculated by the associated process module can be based on the position or state of the actuator as well as the manual disturbance values as shown in the process graphic. As such, the graphic display and control module can be used in both online and control situations, and in both online and offline simulation situations. Also, in many cases the static parts of graphic elements may look similar to the 3D components contained in well-known graphic libraries, but further unique features or characteristics of these graphic elements, these elements. The information displayed by, and the links to the control system input / output and process simulation modules, are described below with some possible graphic element types and examples.

Graphical elements and simulation algorithms in process modules associated with smart process objects are generally referred to as multiple different types of processes, including stream elements, process connection elements, actuator elements, processing elements, measurement elements and estimation characteristic elements. It belongs to one of the elements. Stream elements generally define the material flow within the process plant and graphically display any parameters that define the composition, density, flow rate, temperature, pressure, weight, and / or other material flow on the screen. Can be displayed on. The flow element is defined at the time of inputting the process module and can be prepared for the element in the process module. It also allows the flow of materials to be modeled and depicted graphically by the process module. Similarly, a stream element may be illustrated at the output or end of the process module in order to graphically illustrate the output of the material in a portion of the process plant displayed graphically. Stream elements can also be used to define how different graphic displays (and associated process modules) connect with each other. For example, an output stream within one process module can be an input stream within another process module and can supply the values used by the input stream of another process module. A stream can include four parts: name (eg, pH stream), direction (eg, inflow), measurement (eg, flow rate, pressure, temperature) and composition (eg, nitrogen, ammonia, etc.). However, other parts or parameters can be included in the stream if desired.

Process connection elements define how materials in a plant, such as solids, liquids, vapors, and gases, are delivered or transported from one device to another. Three different types of process connectors can be used to clearly illustrate the raw material flow through the process, including piping, ducts and conveyors. Of course, other connecting elements such as electrical cables for handling power currents in the electrochemical process can be used as well. Piping is commonly used to illustrate (and simulate) the flow of liquids and high pressure vapors or gases in a plant. Ducts are commonly used to illustrate (and simulate) the flow of low pressure gas in a plant. Conveyors are commonly used to illustrate (and simulate) the state of movement of solid material between processing equipment. For this reason, each process connection element defines a connection type such as a pipe connection, a duct connection, or a conveyor connection used to supply material on the input or output side of the equipment.

If desired, the properties of the material transported by the connection are determined by the upstream input. This information may be available as a characteristic of the connection element on the graphic display, along with a connection state variable that defines whether the connection is complete. The connecting element may start from a processing element output, an actuator element output or a stream element output. Similarly, connecting elements can be terminated at processing element inputs, actuator element inputs or stream inputs.

The characteristics of the connecting element may be automatically displayed by placing the cursor on the connecting element in the graphic display. Further, by placing a measurement or estimation characteristic element (defined below) on the connection element, the characteristic related to the connection element may be displayed on the screen as a permanent display. If desired, press the left mouse button on the output of an element (on stream output, processing element output, actuator element output, etc.) and hover the cursor over the input of the element while holding down the mouse button. You can also create a connection element with. In order to establish an accurate connection, the input / output type (pipe, duct or conveyor) of the upstream element and the input / output type of the downstream element must match. The connection will automatically indicate the type of upstream element.

If desired, the piping element can be displayed or depicted in the process graphic display as a piping connection, the duct element (eg, air or gas) can be displayed in the form of a duct, and the conveyor element can be displayed in the form of a conveyor belt. The connections of pipes, ducts and conveyor elements can be automatically routed between processing elements, and the direction of flow can be indicated by arrows outside the depiction of these elements. If the upstream output is shared by two connections, the pipe, duct or conveyor may contain a "T" element. Similarly, the "T" element can also be used to concatenate multiple outputs. The color of the conveyor element or other graphic characteristics can also be changed to indicate its state (eg, running / stopped, flowing / stopped, connected, etc.). Generally, the raw material flow along the conveyor is determined by the motor drive mechanism connected to the conveyor. Therefore, the actuator of the motor drive mechanism (which is the actuator described in more detail below) may be connected to the conveyor. Also, measuring elements (discussed below) can be connected to pipes, ducts and conveyor elements, thereby, for example, the speed of a conveyor. It will be possible to display measurements related to a pipe, duct or conveyor element, such as the flow of material in a pipe or duct, the characteristics of the material on or in a conveyor, pipe or duct (eg, moisture or weight). .. Also, the property elements displayed may be added to display, for example, the properties of the material (eg, the components of the material) on or in a pipe, duct or conveyor that are not measured.

If desired, each of the pipes, ducts and conveyor connecting elements may graphically or dynamically reflect the lost connection (eg, by color change) and also selected properties (pressure, temperature). , Length, etc.) may be graphically or dynamically reflected (eg, due to color changes) outside the set limits. In addition, the parameters calculated by the relevant process module can also be displayed on the graphic. For example, the characteristics provided by the upstream connection (good or bad connection, limiting one or more parameters of the selected connection element, etc.) are displayed graphically and the connection element, or Information about the flow flowing by the connecting element can be provided to the operator.

Generally speaking, an actuator element is an element that performs some flow-related invoking function and can be installed between different 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), (with ON-OFF valve). Actuators, dampers (with drive mechanism), feeders (with speed change motor), conveyor motor drive mechanism (which can be attached to conveyor elements), and the like.

By graphically depicting a valve element, the intended valve position within the associated control block that controls the valve (eg, by animation), valve malfunction (eg, by color change), valve full opening. / Closed position (eg by color change), and AO, DO, DC, set point, PV, OUT, mode, etc. can be dynamically reflected (eg by string of numbers or other indicators). Simulation elements related to valve elements (used in process modules) are simulation elements that calculate valve actuator related parameters such as outlet pressure, mass flow rate, liquid temperature, liquid composition, suction pressure and outlet pressure. Can have an algorithm. Also, if desired, simulated or calculated parameters can be displayed in the process graphic. However, the user or system configuration engineer typically refers to the AO, DO or DC block in the control module associated with the valve, as well as the type of valve. (For example, linear, rapid opening, equality <%>, valve size, etc.) and opening / closing stroke time must be set. Of course, the simulation algorithm that can be used to simulate the behavior of a valve with respect to the material flowing through the valve may depend on the valve type and sizing information.

The graphic depiction of the pump elements describes the motor state (eg, by color change), the associated DO or DC functional block mode and setpoint (eg, using the symbol string), and (using the speed change drive mechanism). It can dynamically reflect the motor speed (if used), the AO setpoint (if using a speed change drive mechanism), PV, OUT mode, and other desired parameters. Similarly, process simulations (used in process modules) for this element can determine or calculate parameters such as outlet pressure, liquid composition, liquid temperature and mass flow rate. (Note that the parameters can be displayed in a graphic display.) In this case, the user may need to define a pump curve based on the type of pump. However, the user can refer to the DO or DC block related to motor start / stop, the related AO functional block of the speed change drive mechanism (if used), and the pump to define the operation of the pump. Curves (eg pressure vs. flow) can be set.

Graphical depiction of the actuator elements of the push blower or suction blower shows the motor status, DO or DC function block mode and set points, motor speed AO set points, PV, OUT, DO or DC function block modes (shift drive mechanism). Can be provided with a depiction that dynamically reflects (if used) and other desired parameters (both can be displayed in a graphic display). A process simulation element (used in the process module) for this element can determine or calculate parameters such as outlet pressure, gas composition, gas temperature and gas flow rate. (Also, the parameters can be displayed in a graphic display.) The user can refer to the relevant DC block for motor start / stop, the AO block of the speed change drive mechanism (if used), and A fan curve (flow rate relative to pressure) can be set to define the simulated fan behavior.

In some cases, a particular actuator type can only be used with a particular type of connection (eg, pipe, duct or conveyor). The table below defines some of the connection limits given as examples for typical actuator elements.

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The processing element somehow includes plant equipment for processing the material or stream in the plant. Generally speaking, all inputs and outputs between processing elements are created via connecting elements. Standard processing elements include tanks (vertical and horizontal), heaters, static mixers, reactors, mixers, air heaters, and other elements that perform simple or standard processing operations of any type. For standard processing elements, the user can specify the number of input / output points to the element as well as the characteristics of the physical equipment (eg, size, capacity, etc.). The simulation algorithm and static display of these standard processing elements can be set by the user at configuration time as described above, but not modified or modified. Of course, if desired, other, generally more complex plant equipment (eg, distillation columns, evaporators, separators, boilers, etc.) can be implemented as custom processing elements. The static display, the number of input / output points, and the simulation algorithm of such a custom processing element can be modified and modified to satisfy 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 in the creation of another processing element.

Tank standard processing elements (either vertical or horizontal) can be constructed based on piping connections to the tank. In addition, the tank element dynamically reflects the liquid level in the tank (for example, using dynamic animation), and the liquid level is full (100%) or empty. It can also be reflected dynamically (using, for example, color changes). Process module simulations for tanks can calculate and display parameters such as outlet temperature, outlet composition, liquid temperature and simulated tank level levels via a graphic display. However, in order to connect the tank to the system, the user or system configuration engineer must configure the number of I / O connections, complete connections to the tank, tank characteristics, size (eg diameter and height), etc. It is possible.

The heater processing elements, through the graphic display, the heat transfer coefficient (eg, using color change), the temperature of the product at the outlet, the temperature of the product at the inlet, the outlet pressure (assuming a constant drop), etc. Can be dynamically calculated and reflected. The user or system configuration engineer may need to configure the complete connection to the heater, the surface area of the heater and the heat transfer coefficient during cleaning.

Of course, other processing elements such as static mixers, reactors, mixers, air heaters, heat exchangers, etc. may have display and simulation capabilities tailored to the requirements of these types of equipment. Non-standard processing elements such as distillers, evaporators, separators, boilers, etc. are graphically used with custom processing elements that can be defined by the user if the simulation associated with the vessel is not included in the standard selection. Can be represented. The processing in these elements can be described or defined as a step response model associated with each input to each output of the vessel. The input can be a stream of gas and / or a stream of liquid. As an option, the user may define an equation indicating the relationship between the input and output of the processing element depending on the situation. Also, these equations can be stored in the process module using the relevant elements to perform the simulation. If desired, it may provide a display of some simple static charts to help users quickly create static graphics associated with custom processing elements. With these simple graphics, the user only has to specify the desired number of input / output connections and the type of connection supported by the custom processing element (eg, pipe, duct or conveyor). The graphic units will also be displayed accordingly and will be immediately available for use in creating operator graphics. If desired, when the user decides to specify the simulation algorithm as a step response, the gain and any dynamic characteristics associated with each input / output of the process element can be specified. When the user chooses a custom algorithm, an expression editor may be provided to the user, who may use it to define the simulation algorithm. The characteristics of the custom processing element output can be calculated separately based on the selected method. In addition, the user may refer to one or more algorithms that he or she has defined in another embedded software.

In addition, some predefined complexes or boilerplate may be provided to create custom processing elements. These stereotypes include, for example, outflow gas O₂Includes boiler boilerplate with custom algorithms to calculate or outflow CO, generated steam, boiler fuselage level and boiler draft, etc. Such a boilerplate can be based on a single fuel input. However, by modifying and modifying the standard, it becomes possible to simulate a boiler with a plurality of fuels. Other predefined formats may include special vessel tank-centrifugal separator formats that are used with spray dryer custom processing elements and may include a step response model to model the operation of the separator. .. Similarly, column boilerplate, spray dryers and evaporator bodies can utilize step response models to define the expected process response. In the evaporator, the concentration of vapor emission and outlet flow can be calculated based on the concentration of energy input and input flow. Multiple evaporator elements can be connected together with heat exchanger and ejector elements to create a multi-utility evaporator. Similarly, special vessel tank-exhaust stack custom stylized elements can be used with boiler processing elements. In this case, the characteristics of the inlet can be maintained throughout the stack, without modification if desired, or to reflect the emission reductions made in the stack.

Other types of elements that can be used to create graphic displays and process modules include measurement and characteristic elements. Measuring elements include transmitter elements and switch elements (which can be used in the graphic display to access measurements associated with the physical transmitter). In general, the transmitter element drives defective or unknown conditions associated with the actual transmitter (sensor), modes of associated AI functional blocks in the control module, measurements and units of measure, etc., or other data associated with the actual transmitter. Can be reflected. In offline mode (or simulation mode), the transmitter element can be used to access and display the simulation values provided by the process module rather than the values associated with the AI or PCI block, or The measurements can be used to provide the relevant AI blocks in the control module as measurements used in the simulated control routine. Transmitter elements can be added to connecting or processing elements, and when such transmitter elements are added to the display, the user generally associates them with AI, PCI, or AI, PCI, or The DI block needs to be identified. In online mode, the value of the measurement can be shown next to this measurement element. In offline mode (or simulation mode), simulated values of measurements (as developed by the corresponding process module) can be displayed automatically. During online operation, the user can choose to switch control and display to simulated values in the event of a measurement error.

The switch element can dynamically reflect a bad or unknown state, the mode of the associated DI (eg manual or OS) and the discrete value of the switch (on, off, etc.). In offline simulation mode, the user manually inputs the value and state of the switch by selecting the simulation value or manual value and state to access and change the switch parameters in the graphic display and control module. By doing so, the switch display element can be used. However, users generally configure switch elements by providing references to related DI blocks in the control scheme, references to element characteristics that trigger the switch, and limit values and deadbands associated with switch state changes. Must.

Estimated characteristic elements display the estimated characteristics of the system as generally determined by the process module and may be added to the connection or processing element to display any characteristics of the element. When this element is placed in a connecting element or a piece of equipment, the user can browse and select the characteristics that are to be displayed. Thus, simulated properties that are not provided by physical measurements can be displayed through the use of estimated property elements. Such estimated characteristic elements can dynamically reflect normal or bad connections, estimated characteristic values, and characteristics or changes that deviate from the associated limits. In general, the user must set a reference to the characteristic of the element and a change in limit value or color that should be displayed when the characteristic deviates from the limit value.

Naturally, by attaching transmitter elements and estimation characteristic elements to the processing elements, actuator elements and connecting elements, the characteristics related to the input / output of these process elements can be measured during online operation or with online simulation. It can be referenced in both offline simulations. These characteristics may be displayed as visible in a graphic display.

Generally speaking, an operator may perform one or more Process Modules 39 or Graphical Display so that it can be performed while Process 10 is running or in a simulation environment. The configuration application 38 can be activated or run to create. In one embodiment, the configuration application 38 presents a configuration screen as shown in FIG. 3 to the system configuration engineer. As can be seen in FIG. 3, the configuration screen display 64 includes a library or standard column 65 and a configuration column 66. The boilerplate 65 contains a depiction of a plurality of sets of boilerplate smart process objects 67 (which may include the smart process object 42 of FIG. 2 and may be any of the above connection, measurement, stream, processing and estimation characteristic elements). I'm out. If desired, a non-smart element 68 with only a graphic definition may also be provided. Fundamentally, boilerplate 67 and 68 are generic objects that can be dragged onto configuration field 66 to create an instance of a smart process object in a process module and / or graphic display. .. In the figure, the partially completed process graphic display 35c is interconnected with one valve and two by a flow path connector where it could be the smart link or connector element such as providing stream output. Shown with one tank, two pumps, one flow transmitter and two sensors. Note that the graphic display 35c can consist of both smart process objects and non-smart elements.

When creating a graphic display (or process module) such as the graphic display 35c, the system configuration engineer selects the smart process object 67 and element 68 shown in the boilerplate 65 and drags them over the configuration column 66 to any desired. Can move to the position of. Generally, the system configuration engineer will select one or more smart device process objects 67a or non-smart elements 68 that depict the device and drag them onto the configuration column 66. The system configuration engineer can then use the smart connector process object 67b to interconnect the smart device process objects in configuration column 66 and place the input / output streams 67c in the screen display. Furthermore, non-smart elements can be added to the screen display. In this process, the system configuration engineer can change the characteristics of each smart process object, such as by using the pop-up characteristics menu. Specifically, the methods, parameters, tags, names, hotlinks, modes, classes, inputs / outputs, etc. associated with these smart process objects can be changed. When a process or system configuration engineer creates a process module using any of the elements that typically represent a process's configuration, area, etc., the system configuration engineer may use rules or other functions associated with the module. Gender can be defined. Such rules can be execution rules that are related to the performance of system-level methods, such as mass balance and flow rate calculations. The process engineer or operator may also add trends and faceplates that are useful when the process display screen is online. After creating the graphic display 35c, the system configuration engineer may save the screen display in memory and then, at or after that, execute the screen display in such a manner that the execution engine 48 can provide the graphic display. Can be instantiated and downloaded to engine 48. Of course, the system configuration engineer is the same or It is also possible to create a process module in a similar way. (However, different graphics may be drawn on the elements of the process module as opposed to the process graphic display elements.) In addition, the operator may choose to enable the detail display level during plant operation. For example, one of the detail display levels may indicate the composition at each connection.

As mentioned above, a process graphic or process module may be provided with a particular tag. For example, a graphic display or a smart process object element in a process module can be written or selected at runtime by the execution engine 48 based on other factors such as a single facility or route selected in the process control system. It may have a tag containing an alias so that it can be provided. The use of aliases and indirect references in process control systems is described in detail in US Pat. No. 6,385,496, which is assigned and incorporated herein by reference to the patentee of the present invention. Any of these techniques can be used to provide and eliminate the aliases contained in the tags for the smart process objects described herein. By using aliases and their equivalents, the same process module can contain different display configurations, such as multiple units of equipment, or can be used to support different display configurations, such as multiple units of equipment.

The screen display 64 of FIG. 3 shows tabs (display view 1, display view 2, and display view 3) of display views having different process modules or graphic displays. These tabs can be used by different users associated with processes that use the same smart process object to access and create different views.

Generally speaking, when a system configuration engineer creates a process module or graphic display, smart process objects are automatically stored in the database along with the connections between each object by the configuration application 38. The database can then be used, for example, to create other process modules and graphic displays that can use the same smart process object, one or more, to provide different display views. So, of course, when creating a second display view, the system configuration engineer simply puts the smart process object already created and stored in the database and that smart process object in the second display view. You will be able to create a second view by simply referencing any method stored in it for placement. In this way, as the process control module and graphic display are created, the data is populated into the database, and the database always uses another display by using a smart process object that already exists in the process flow database. You will be able to create and execute views, modules and graphic displays. Also, the use of such a database allows each smart process object in the database to support a process module or be used within the process module and referenced in multiple graphic displays. As a matter of course, a process module can be constructed by constructing a screen display for these modules and then specifying a flow algorithm used in the process module or associated with the process module. Of course, the individual process modules can be distributed to different computers and run by those different computers. Also, the process modules may be communicatively connected to each other on either the same or different computers so that they operate in tandem with each other. like this

As described above, the system configuration engineer may attach or provide a simulation algorithm of the process module as part of the process module or graphic display / creation work. These simulation algorithms are preconfigured to calculate or determine specific process or system level characteristics such as mass balance calculations, flow rate calculations, efficiency calculations, economic calculations, etc. for processes depicted or modeled by the process module. Can be done. As a result, the process module itself may include mode, state and alarm behaviors, can be assigned to workstations , and can even be downloaded as part of a display download. If desired, the simulation algorithm uses the data provided in the smart process object of the process module to perform process simulation-related mass equilibrium calculations, thermal equilibrium calculations, flow routing calculations, flow efficiency calculations, flow optimization calculations, economics. It can be performed by the execution engine 48 to perform calculations or other desired calculations. Furthermore, these simulation algorithms access parameters from control methods (ie, control modules associated with and downloaded to controllers, field devices, etc.) and, conversely, send data or information to these control modules. Can be provided.

Unsurprisingly, the execution engine 48 is needed to allow the process algorithm to perform the whole process object and link amalgamation configured on all screen displays. .. Thus, in general, the simulation algorithm (in the process module) runs regardless of what related graphic display is loaded (ie, called to display information to the user) or not. Is supposed to be done. Of course, the simulation algorithm can be collated across process 10 or across a defined subset of process 10. More notably, during the execution of any particular process module, the execution engine 48 is a screen on which interconnected objects or entities within the process module are drawn based on the graphic representation associated with that process module. The display can be displayed on the operator interface and presented to the operator. Screen display parameters, graphics, etc. will be determined by the configuration and interconnection of smart elements within the process module. In addition, warning alarms and other information provided on this screen display or other screen display can be defined and generated by simulation algorithms and methods within smart process objects associated with a particular process module.

If desired, the execution engine 48 may provide a screen display of the process module to one or more operator interfaces, or the methods, alarm behaviors, associated with it by the execution engine 48 continuing to execute the process flow module. It can be configured or set so that the screen display is not provided even if a flow algorithm or the like is executed.

If desired, a process module can be automatically generated from the graphic display, and vice versa. Also, the functionality available to the process module is determined by the process graphic elements. What should be clarified here is that it is preferable to build the process module so that it can shadow the graphic display of the process. As a result, when a user configures a graphic display of a process, the user can gain the ability to include additional information about the process module, such as a stream such as mass flow or energy flow. These streams are used in the process module to establish the start conditions required by the simulation function block.

Also, since a process module is an actual software module that runs on a computer, it can also be referenced by the controller module to use parameters, control methods, screen displays, etc. associated with the controller module. It is also possible for the process module to refer to. This ability can also be used to create process modules independently of the graphic display of the process.

Generally speaking, a process module consists of processing elements, streams and their associated connections. Since there is a one-to-one correspondence between the process graphic element (in the process module) and the simulation element, build a graphic display and automatically generate the corresponding process module from the screen display in question. Is possible for the user. Of course, if desired, the user may create a process module and then use the graphics in the smart process object to automatically create a graphic display from that module. However, in order to enable automatic generation of process modules, the user may need to identify the characteristics of the actuator, connection or processing element associated with the measurement and estimation characteristic elements. The user may also need to create a process simulation before creating the process graphic (and in some cases before the control module is built). After the simulation is built, it will be possible to write a reference to the I / O block in the control module. Also, once the associated graphic display is created, it will be possible to collate with existing process modules to set characteristic references.

In some cases, the process graphic may not contain all the details needed to build a process simulation. Therefore, it is desirable to provide an editor to allow the user to edit the simulation or process module automatically created from the process graphic. Also, since it may be necessary to display the same equipment by a plurality of process graphics, it may be necessary for each element to be able to refer to an existing process module in drawing the process graphic.

Generally speaking, the simulations corresponding to the processing elements will have a common structure. If desired, the simulation parameters and block input connections are stored in the process module so that no reference to the control module is required. Further, the number of input / output connections supported by the simulation may be extensiblely defined, and the result obtained by executing the simulation may be reflected in the connection of the simulation output or as a parameter of the simulation. Also, the simulation algorithm can be defined as a step response or can be input by the user. When the simulation algorithm is input by the user, the user can specify the dynamic characteristics of each output independently.

Furthermore, a common set of parameters may be supported for input / output connections. Parameters related to input / output connections can be communicated between blocks as array parameters or structures, and connection status (eg good, bad, restricted, etc.), flow rate parameters, pressure parameters, temperature parameters, specific heat parameters. , Density parameters, or other parameters such as desired parameters may be included. In some cases, other parameters such as stream composition may be provided or used in the simulation algorithm. Standard and extended stream elements may be provided to support this requirement. As part of the extended stream element configuration, the user may select a set of predefined data groups to define the stream elements. Such extension of connection is possible only when connecting to a block that uses this information. In general, extended parameters may include a group name and a particular element consisting of a plurality. For example, the fuel inflow stream to the boiler processing element includes the fuel system and the amount of carbon, hydrogen, sulfur, oxygen, water and nitrogen (all can be expressed in% by weight if desired). May contain fuel components. In another embodiment, a steam stream is used for the turbogenerator processing elements, and the connections to the relevant simulations are steam assembly, steam heat of vapor function entering the stage (real value), and steam heat function leaving the stage (real value). ), An extended parameter set including the steam heat function (in the case of isentropic expansion), etc. can be used.

Extended group sets can also be used if the simulation elements in the process module are used as an interface to the Hi-Fi simulation package. In this case, the composition of some streams may be visible in the process graphic. Also, if desired, interactive to facilitate the creation or modification of the values displayed on the graphic display, as well as the creation or modification of the associated faceplate and detail screen display of the control module presented on the graphic display. An editing program may be provided.

FIG. 4 is a diagram showing a graphic display 100 as an example, which can be created by using the above-mentioned elements and a configuration application. Specifically, graphic display 100 depicts a portion of a process plant that produces white vinegar from water, acids and bases. As shown in FIG. 4, the graphic display 100 of the process includes four stream elements 102 that define the "base supply", "acid supply", "water supply" and stream of cooling water in the inputs into it. There is. The base supply stream 102 extends through the pipe connection element 104 to the actuator element illustrated as the valve 106. The output of the valve 106 is connected to the first input of the mixer 108 via the piping connection element 104. In a similar manner, the "acid supply" 102 is first connected to the transmitter element 110 and from there to a further valve 112 connected to the mixer 108. The acid supply 102 and the transmitter 110, the transmitter 110 and the valve 112, and the valve 112 and the mixer 108 are connected via a pipe connecting element 114.

As is obvious from the figure, 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 extends through the valve 128 to the heat exchanger 122 and exits the heat exchanger through the valve 130 to provide the return water stream element 131. Similarly, the output of the heat exchanger 122 is delivered through the transmitter element 132 and the valve 134 to provide the output, i.e. the acetic acid stream element 136. In all cases, although not necessarily specifically called, the elements in the graphic display are connected to each other via piping connection elements.

Not surprisingly, the graphic display 100 is the display element itself to indicate or display parameters such as set point (SP) values, output (OUT) values, such as process variable (PV) values associated with different elements. A display box 140 is shown which can be generated as a characteristic of or can be another element represented as an estimated characteristic element (s) or a transmitter element (s) that refer to a block in the control module. It is also possible for the screen display 100 to display other values related to the participating element when the user hovers the cursor over any element. For example, the cursor may be placed on one of the stream elements (such as acetic acid stream output 136) to graphically display the composition, pressure, temperature, density, flow rate, etc. of the acid stream at this point in the process. .. Of course, the values and parameters displayed on the graphic display 100 are from the actual attendant transmitter in the process control system (eg from the AI block in the control system) or the process module that simulates the functionality of the element. Can be sourced from simulation elements. Graphical display 100 of FIG. 4 is provided to the user during the process of producing white vinegar, or for the purpose of simulating the process, for example used for designing or performing worker training activities. Can be done.

Figure 5 shows (or simulates) a wider range of process plants with different graphic displays to form a higher level screen display (or process module). (And different process modules) are connected together. The process graphic 100 is shown folded in the screen display 150 of FIG. 5 in a named or labeled box with a set of stream inputs and outputs shown as connection points. If desired, the user can deploy the process graphic 100 of FIG. 5 to the state shown in FIG. 4, for example by double-clicking to select it. Other folded graphic displays 152 and 154 are also shown connected to the base supply, acid supply, water supply and cooling water supply via input stream elements 156 and 158. The stream output 136 of the process graphic display 100 is connected to the stream input 160 of the white vinegar storage tank 162. Similarly, the stream outputs of the process graphic representations 152 and 154 are individually connected to the stream inputs of the storage tanks 163 and 164 for malt vinegar and pickling vinegar. Not surprisingly, Process Graphics 152 and 154 should provide, for each reason, a graphic of a portion of the process plant that produces malt vinegar and pickling vinegar, as well as a display view of the data and graphics for these parts of the process plant. It is composed of.

However, FIG. 5 shows that different parts of the process plant displayed graphically can be connected together via a connection between stream elements. Specifically, a stream element may be included in the screen display to define the starting point characteristics associated with the connection element. The stream element can also be used as a connection point between different screen displays. For connections between screen displays that extend beyond the margins of such a page, the user can click on the stream to immediately recall the related screen display that includes the connection being referenced. Is also good. Thus, generally speaking, the mass / composition of a stream element is usually to define the starting point characteristics of the process input (ie, the composition of the feedstock at the starting point, etc.) or to a stream connection on another screen display. It will be used to define the link. Connections can be formed at the inputs or outputs of material / composition stream elements. For stream elements, users typically use the name of the stream (which should be system specific), the characteristics of the stream (if there is no reference input or input connection), and the mass content of different components of the stream (one or more streams). (If composed of components of), pressure flow or fluid mass, temperature, specific heat, density, required connection type (pipe, duct, conveyor), and attended input stream (access stream on another screen display) (If used to) can be configured. Similarly, an energy stream element is used to define the starting energy associated with a process input (eg, BTU / time transfer), or to define a link to the energy characteristics of a stream connection on another screen display. Can be used.

Figure 5 shows the use of streams to interconnect different collapsed graphic displays, but to interconnect different process modules (and to illustrate the interconnect). The same procedure can also be used. Specifically, the process module can be folded to illustrate the input / output of the name and stream element. Also, communication connections or link depictions between stream outputs and stream inputs of different process modules can be used to communicatively connect or connect these folded process modules to other process modules.

FIG. 6 is a diagram showing a process module 100a corresponding to the graphic display 100 of FIG. As will be clear from the following description, the process module 100a contains a block representing a smart object simulation of each physical element shown in the graphic display of FIG. To make the figure easier to understand, each simulation block in FIG. 6 corresponding to the elements in FIG. 4 is shown with an "a" added to the same reference number as in FIG. Therefore, the mixer simulation block 108a of FIG. 6 is a simulation corresponding to the mixer 108 depicted in FIG. Similarly, the valve simulation blocks 106a, 112a and 118a are connected to the valves 106, 112 and 118 shown in FIG. 4 in a communicable manner.

Thus, the process module 100a of FIG. 6 contains a process simulation element (which may be represented as a functional block associated with or specified by the smart process object) for each element shown in the graphic display 100. Also, these simulation blocks are interconnected by the method in which the connecting elements are specified in the graphic display 100 and by using the connecting elements specified in the graphic display 100. If desired, the process module 100a can be created automatically after the graphic display 100 is being created, or even during the graphic display 100 creation.

As shown above, each of the process simulation elements in the process module 100 is based on the nature of the material stream (s) provided to these simulation elements at the input and the behavior of the machinery used in the process. Includes simulation functionality (eg algorithms, rules, transfer functions, etc.). These simulations are illustrated in FIG. 6 by SIM blocks within each of the processing, actuator and transmitter elements. The dynamics of the device and its effect on the stream can therefore be modeled or simulated within the process module 100a. Examples of some possible properties that will be available for simulation blocks related to actuators and processing elements are outlet temperature (based on suction temperature, flow rate and heat capacity), inlet fluid mass within the element and Included are outlet flow rates (based on build-up), outlet pressures (based on an estimated pressure drop across the device unit or downstream pressure), and outlet compositions (based on complete mixing and inlet composition). When performing custom calculations, for example, built-in dynamic characteristics associated with exit characteristics can be added based on the primary system + dead time system response to changes in process input. If desired, the user can specify the dead time and delay time associated with each calculated characteristic. For example, for process measurement elements such as transmitters and switches, and connection elements, it is naturally considered that dynamic characteristics are not introduced into the participation characteristics. However, transitions and other characteristics may be modeled if desired. However, in many cases, the characteristics from the upstream connection are immediately reflected in the downstream connection.

Process module 100a can be used to simulate the behavior of a portion of the plant depicted in process graphic 100. Since the values from the simulation elements in the process module 100a are automatically communicated and displayed in the graphic of the graphic display 100 and can be used in the control module, this simulation result is integrated into the screen display 100. Similarly, the training teacher may use the screen display to create or modify characteristics in the simulation performed by process module 100a.

For high-fidelity simulations such as those provided by HYSYS, CAPE, etc., if desired, define measurement and actuator element I / O references and then use these references to perform, for example, input / output in the simulation. The high-fiction simulation can be added to the simulation functional characteristics by automatically creating the DCS interface table currently used in. Standard processing element boilerplate can be defined for each HYSYS component (or other Hi-Fi simulation component) that can be used to build a high-fidelity process simulation. Such a high-fidelity simulation 165 is shown in FIG. 6 with a communicable connection to the process module 100a. In this case, the user may choose to disable the simulation provided for each of the simulation elements in the process module 100a and instead use the simulation parameters provided by the Hi-Fi simulation 165. The user may specify the use of Hi-Fi Simulation 165 by enabling 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 blocks in process module 100a act as shadow blocks, i.e. their simulation algorithms (SIM). Block) is not executed, instead block parameters are read and written by Hi-Fi Simulation 165. However, the block of process module 100a still communicates the same parameters and other information to process graphics and control module, process graphics 100 (finally used in Hi-Fi simulation 165) and control module 29. Receive information from.

Not surprisingly, by using the process module in this way, in a manner that can be viewed and used by operators, engineers, etc. (ie, using the graphic display 100 of the process associated with the process module 100a) within the process plant. It will be possible to provide a simple and convenient way to connect high-fidelity simulation packages (software products). Specifically, the stream parameters of the process module can be connected to (or related to) the flow modeled in the high-fiction simulation, and the routing within the process module is automatically assembled. Can be, or can be associated with routing in high-fidelity simulations. In practice, a process module is, in this case, a variable or place of data where it provides a convenient way to map the data in the Hi-Fi simulation package to the control module and graphic display used in the control and simulation environment of the process plant. Used as a holder.

Furthermore, by using the process module and associated graphic display, another screen for hi-fi simulation (as the user generally pays a high cost to generate by the hi-fi simulation provider at this time). The need to provide a display is reduced or eliminated. Rather, since the process module is already connected to the graphic display, the graphic display is used when connecting the process module to the high-fidelity simulation package to provide the user with information as calculated by the high-fidelity simulation package. However, the user or operator may be able to perform input operations to the Hi-Fi simulation package. Furthermore, since the process module is communicably connected to the control module, the parameters or data generated by the Hi-Fi simulation package can be used in the control module to perform online control operations. By using the process module in this way, not only can the high-fidelity simulation package be integrated into the control module, but it can also be run in parallel with the control module.

As is also apparent from the above description, the process module and graphic display are comprehensively designed to provide an operator view of a portion of process plant 10 along with the process module that simulates the behavior of the process plant depicted by the graphic display. Can be created and executed. Conveniently, the process module and graphic display can be additionally integrated into one or more control modules (performing control work on the section or part of the process plant) (eg, communicably connected). Can be done). Thus, the control module 29 shown in FIG. 1 may be communicably integrated with one or more of the process module 39 and the graphic display 35 shown in FIG. Of course, the control module 29, the process module 39 and the graphic display 35 are implemented on any other computer or device in plant 10 as requested or required in any particular case, other than those shown in FIG. sell.

7A and 7B are diagrams showing in more detail the integration of control module 29, process module 39 (used as part of the simulation system), and graphic display 35. Specifically, graphic display 35 includes valve 186 connected in series with the output of recycling tank 182 as well as valve 180 connected to input of recycling tank 182 and pump 184. Elements 180-186 are connected together via a plumbing connection element (no reference sign), and a stream element is provided for input and output of graphic display 35, defining a stream of material in that respect. It is designed to do.

As a result of the configuration of the graphic display 35, the process module 39 that can be created at the same time as the graphic display 35 is as valve element 180a, tank element 182a, pump element 184a and valve element 186a corresponding to the physical elements depicted in the graphic display 35. Contains the process simulation elements shown. The control module 29, which controls at least some of the physical elements associated with (or depicted in) the graphic display 35, provides control within (or in connection with) the elements depicted by the graphic display 35 and the process module 39. However, it contains a set of interconnected functional blocks. In this embodiment, the control module 29 includes two control loops 190 and 192. The first control loop 190 is provided in the tank 182 with an analog input (AI) function block that receives inflow information about the flow of fluid into the tank 182, a proportional / integral / differential (PID) control function block that performs PID control, and a tank 182. It has an analog output (AO) functional block that operates the valve 180 to provide the desired flow of material to be fed. Similarly, the control loop 192 is a valve to provide control of the liquid level in the tank 182 with an AI functional block that provides tank level information measured by a level sensor in the tank 182 and a PID control block. It includes an AO functional block that receives control signals from the PID control block to operate the 186. The control module 29 also indicates a discrete input (eg, indicating the on / off state or operating state of the pump 184, which can be used by control loops 190 and 192 to perform control work on the tank 182 if desired). It also contains (DI) functional blocks.

Not surprisingly, any element contained in any of the graphic display 35, process module 39 and control module 29 by alternating information between these different entities (as described in more detail below). It may communicate with another of the element (via the associated communication tag) to provide better or even more extended control, simulation and operator display screens. For example, as shown in FIG. 7B, the PID control block of loop 190 may be configured to provide information to graphic display 35 to display the current flow set points used by the PID control element, or The set points used by the control module 29 can be read from the graphic display 35 as indicated by the arrow lines between these elements. Similarly, the tank element 182a of process module 39 produces a simulation output showing the simulated tank level as determined by the simulation algorithm in element 182a, the AI function of control loop 192 of process control module 29. Can be provided to the block. The simulated tank liquid level may also be shown on graphic display 29 as additional information that can be displayed by the operator.

If desired, the AO block of control loop 192 may provide information to valve 186 of graphic display 35 and receive information from valve 186 of graphic display 35. In addition, the AO functional block of loop 192 can also 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 valve position with the actual valve position measured by the control loop 192 to determine if there may be any malfunction in the physical element. If there is a difference in a particular number, the process module 39 may contain software that generates an alarm or warning on the graphic display 35 that indicates a possible problem within the process plant (eg, failure sensor, etc.). Also, as illustrated in FIG. 7B, the valve element 186a may provide a graphic display 35 for the operator to display or use simulated measurements or parameters. Such simulated measurements or parameters may indicate a simulated or predicted flow from valve 186, or other simulated parameters associated with valve 186. Of course, in order to provide better or more extended control, simulation or screen display, other desired information or data, including measured data or simulated data or graphic display data, can be displayed in graphic display 35, process module 39 and control. It can be provided for the elements of module 29.

Generally speaking, there are a number of benefits that result from integrating a process module (in addition to a graphic display, if desired) into a control module. In one embodiment, as described above, a simulation is performed in the process module to detect problems that may occur in the system, and the simulated or predicted measurements, parameters or other process values. Can be compared with the measured or calculated parameters provided by the control module. For example, the presence of a large difference between the output flow from the valve calculated by process module 39 and the output flow from the valve measured by the process itself generates an alarm indicating that there is some equipment problem. It can be a premise to do. Conversely, the control module 29 provides simulated parameters to provide control extensions in situations where the control module 29 is aware of failure sensors or other elements that are no longer valid and are not available to the control module. Can be used. In this case, the control module 29 does not require operator involvement and does not stop the process, as developed by the process module (known to be defective, may be accompanied by a defective condition, etc.) ) Measurements or parameters can be automatically replaced with simulated output. Also, displaying both the simulated and actual control data on the same screen display makes it easier for the operator or user to detect problems in the plant, or is useful in simulation mode. Alternatively, it can provide advantages such as being useful in performing better design work and the like.

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

Process module 202 is associated with a portion of the process having a mixer and valves controlled by control module 200. Specifically, the process module 202 has valves (actuator elements) 211, 212 and 213 that simulate the flow of three streams entering the mixer element 214 (indicated by the arrow to the left of the process module 202). Valve element 215 simulates the flow of fluid exiting mixer element 214 to define the output stream to the right of process module 202, and transmitter element 217 is a measurement of fluid exiting mixer element 214. The composition can be shown (or simulated). Note that for clarity, the connecting elements are shown as simple lines in the process module 202.

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

As will be apparent from the description below, the logical elements within the process module 202 and the control module 200 are, in a desired or useful manner, from the process module 202 to the control module 200 and vice versa from the control module 200. It can be communicably interconnected to process module 202 so that it can provide information. In one embodiment, the communication connection (illustrated by dotted line 218) is the output of transmitter element 217 of process module 202 (displaying a simulated measurement of the material composition in mixer 214) and the process control module 200. It can be configured between the simulated input "SIM # IN" of AI block 206 in. In this way, the simulation measurement of the liquid level level of the fluid in the mixer 214 is provided to the AI block 206, and the AI block 206 has, for example, a defective state in the signal at the control input (IN) of the block. This simulated input can be used if it is known to be defective 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 physical measurements are not valid or available, thereby allowing the control module 200 to present a defective sensor. Allows it to continue to function and provide control underneath. Also, using such a connection, in simulated mode where valid simulation data (provided by simulation process module 202) is used during offline operator training or to test the control module 200. The control module 200 can be executed.

Alternatively or additionally, the communication connection (illustrated by dotted line 219) models the output of AO block 208 in the process control module 200 and the actual valve controlled by AO block 208 in the process plant. It can be configured between the input of the modified valve element 211. Here, does valve element 211 have the correct simulated data (ie, the measurements and parameters calculated by the SIM block of valve element 211) (or match the data used in the actual control routine 200)? Data obtained from the actual valve or data sent to the actual valve can be used to determine if. When there are significant differences, the process module 202 can generate alarms or warnings that indicate problems that may occur, or real data to provide better or more accurate simulations within the process module 202. Can be used. For example, the valve element 211 may use the actual control data at the valve element 211 position in the SIM block to reflect the actual valve position in the simulation. Of course, other connections between the elements in process module 202 and the elements in control module 200 allow data flow in either direction between these two modules for extended control and / or simulation. It can be configured to provide. Furthermore, any data from process module 202 or control module 200 may be automatically made available to the operator via the graphic display associated with process module 202.

FIG. 9 is a diagram showing a simulation system 250 for a part or part of a process plant. The simulation system 250 comprises a plurality of simulation blocks 252, 254 and 256 and, if desired, smart connection elements 260 and 262 connecting the simulation blocks 252, 254 and 256. Of course, in certain embodiments, the simulation system 250 can be run in parallel (eg, at the same time or in conjunction with) a process control routine that operates within the actual process plant. The simulation system 250 is also connected to a component of the process plant (or to the control system of the process plant) in a manner described in more detail below in order to perform extended and more accurate simulation work. Can be done.

Specifically, as shown in FIG. 9, the pump simulation block 252 is used to simulate one or more processes (eg, the operation of a part of the process plant, such as the operation of equipment in the process plant). Equipment) Contains a simulation routine 271 that implements or uses model 272. Specifically, the simulation routine 271 simulates or estimates the flow, pressure, and / or other process variables deployed by or in the actual pump de device in the process plant to be simulated. For example, various input information to block 252 provided by other simulation blocks, control systems, users, etc. is used. These flow, pressure, and / or other simulated simulated variables supply these measurements to the valve simulation block 254, along with other pumped material or flow characteristics (viscosity, material equilibrium, etc.). Provided to the connection object 260 where you want to. If desired, the connection object 260 is a simulation developed by block 252 based on a simulation operation of the connection structure in the process plant to provide elements such as simulated flow and pressure to valve simulation block 254. It can be a smart connection object that handles output variables. Of course, the connection object 260 does not have to be a smart connection object, but a valve for providing an indicator of pressure or flow or other simulated simulation process variables developed and output by pump simulation block 252. It can also be a simple link between simulation block 254 and pump simulation block 252.

Similarly, valve simulation block 254 is based on simulated simulated inputs to valve simulation block 254 provided by connecting object 260 and valve-related measurements or conditions (such as valve position). Includes a simulation routine 273 that includes and uses one or more process models 274 (which may include equipment models) to model valve behavior. To reiterate, one or more simulated simulated output variables (eg, simulated simulated flow from a valve) by simulating the behavior of an actual valve in a process plant in any well-known embodiment. And the simulation routine 273 uses process model 274 to generate simulated pressure at the valve output, simulated temperature of the fluid in or at the valve output, etc.) Can be done. Indicators of these simulated simulated process variables can be provided to connector object 262 where they can process these variables to provide input to reactor simulation block 256. Again, of course, the connector object 262 can be a simple communication link that provides the output of valve simulation block 254 to the input of reactor simulation block 256.

As shown in FIG. 9, the reactor simulation block 256 is in the process plant based on the inputs to the reactor simulator block 256 provided by the connector object 262 and the state and variables (equipment variables) of the reactor. It also includes a simulation routine 275 that uses one or more process models 276 to simulate the operation of the reactor. Process model 276 is used to generate one or more simulated simulated outputs of the reactor that may include process fluid temperature, pressure, material equilibrium, etc. Thus, as is apparent in this case, when the process simulation is performed as one or more blocks representing process equipment, the output of these blocks is a simulation calculated based on the inputs to the process simulation block. Represents a process condition.

The process models 272, 274 and 276 can be any desired type of process model, including parametric and non-parametric process models. For example, process models 272, 274 and 276 can be first-principles models such as linear + insensitive time system process models (generally used in model predictive control (MPC) techniques, neural network models and fuzzy logic. It can also be a process model that reflects the input / output curves of a series of impulse or step responses based on measured values generated during process operation (such as a logical model), and the entire disclosure is referred to herein by reference here. US Pat. No. 7,113,834 (issued September 26, 2006) entitled "State Based Adaptive Feedback Feedforward PID Controller" "Adaptive Feedback / Feedforward PID It could be the type of process model disclosed in US Pat. No. 6,577,908 (issued June 10, 2003) entitled Controller, or any other type of process model. Also, the models used in simulation blocks 252, 254 and 256 may be created in any manner, especially for the purpose of simulation by users or designers, etc. However, these models may optionally be controlled. Alternatively, it can be copied from a part of an online control system that uses a process model to perform optimization work. For example, an MPC controller typically generates a process model for use by a controller during an online control work, and this process. The model may be imported into one or more applicable or related simulation blocks for use in performing simulation work on the MPC controller or a portion of the plant controlled by the MPC controller.

The configuration of the simulation system as shown in Figure 9 helps to provide simulation work offline, while running and doing so with the simulation system 250 online or in parallel processing mode for the process plant. Automatically or semi-automatically the process models 272, 274 and 276 to provide a better and more accurate simulation system by incorporating the actual process plant changes that may occur after the simulation system 250 is created. It turns out that it is also possible to update. In particular, an additional standard input to the simulation block of the simulation system 250 (eg, blocks 252, 254, 256, etc.) (where the standard input corresponds to, for example, the block output parameter, simulation block 252, By adding (representing actual process measurements associated with 254 and 256 output parameters), with measured values of simulated parameters as measured within a running or online process as part of the simulation algorithm. It is possible to automatically correct the process models 272, 274 and 276 used by simulation blocks 252, 254 and 256 to compensate for the differences between the calculated (simulated) output.

Includes model regeneration block 280 where it can be used to update or regenerate 274 and 276. More specifically, the model regeneration block 280 uses a measurement that shows the actual process variables (as measured, for example, by a control system in a process plant), and this measured process variable (PV). Can be compared to the output of the simulation block corresponding to the measured process variable (at the same time as the measured process variable). The model regeneration block 280 can utilize such comparison results to update or regenerate the process model used within the process simulation block when developing a simulated simulated output. According to this functional characteristic, a single PV flow measurement 284 can be used by the model regeneration block 280 in the valve simulation block 254 (eg, by the control system used in the process plant). Is illustrated as being fed back to the valve simulation block 254. Here, PV flow rate measurement 284 is, or represents, the measured flow output of a valve in a process plant simulated by valve simulation block 254. Similarly, PV pressure measurements 286 and PV temperature measurements 288 are shown in FIG. 9 as being fed back to the reactor simulation block 256 for use by the model regeneration block 280 of the reactor simulation block 256. .. In this case, PV pressure measurement 286 and PV temperature measurement 288 represent measured values of pressure and temperature at the output of the reactor simulated by the reactor simulation block 256. Of course, other types and numbers of PV measurements can also be fed back to simulation blocks 252, 254 and 256. (In this case, the nature and identity of these measurements are generally selected based on the details of the running simulation or process model. Is done. ) In any case, measurement feedback signals from the process plant may be used to modify or update simulation blocks 252, 254 and 256 to more accurately reflect process operation during continuous operation of the process plant. Such updates may include calculations of corrections or update factors applied to the output of these models. In this way, the simulation system 250 was introduced into or associated with the changing situation and unmodeled changes in the process plant in order to provide more accurate simulations. Adapts to non-linearity and other changes in the plant.

In addition to performing better simulations and thus generating more accurate simulated or predictive process variables, the process models 272, 274 and 276 developed and adapted or regenerated by the simulation system 250 are within the process plant. It can be exported (regularly or at the time of regeneration) to perform other tasks (eg control tasks, user interface tasks, optimization tasks, etc.). For example, if the models generated or updated in simulation blocks 252, 254 and 256 are step or impulse response models, these models may be provided to the MPC controller for use in generating MPC matrices and controllers. .. See here for an example of a mixed MPC and optimization routine system in which these update models generated by the simulation system can be used to generate MPC controllers, optimization routines, etc. "Integrated Model Predictive Control and Optimization within a Process Control" These include those disclosed in US Pat. No. 7,050,863 (issued May 23, 2006) entitled "System." Thus, in this case, the simulation block can be created to utilize a step response or finite impulse response model to simulate complex equipment, process control loops or process responses. For example, DeltaV The MPC-SIM block is designed to provide simulation in this way. By taking such an approach, when modifying or correcting process models 272, 274 and 276, it is possible to easily make corrections for online measurements similar to those performed in MPC control. Similarly, process models 272,274 and 276 can be other types of models as disclosed in U.S. Pat. Nos. 6,577,908 and 7,113,834, and are re-used with the adaptive PID control techniques described in these patents. It can be used. As a result, simulation blocks 272, 274 and 276 or parts thereof can actually be sent back to the control system for use in controlling the process plant. Further, if desired, different sets or combinations of process models from different simulation blocks can be combined and used for online process operations such as sending back and operating control and optimization routines. Moreover, in one case, the process model can be developed for control or optimization routines or other routines used during online control work, and can be imported from the control system into the simulation system, as described above. It can be updated in such a simulation system and then returned to the control system (in an updated or adapted state) by a controller or optimization routine (where the pre-adaptation model was originally created for it). Can be used.

User may provide manual feedback to regenerate 274 and 276. For example, in some cases, it is known that an abnormality due to a sensor malfunction or communication abnormality, or an abnormality due to a mode state related to measurement (for example, the possibility of inaccuracies) exists in the measured process variable. Process variable measurement may not be available for some reason. In another case, process variable measurements may not be available directly from the plant's control system, as they may have been generated offline, such as in the laboratory. In yet another case, the particular process variable or other variable used by one of the model regeneration blocks 280 was not actually measured, was an estimate, or was simply provided by the user. It can be a thing. In these cases, it is desirable to allow the user to provide an indicator of the actual value of the simulated process variables used by the model regeneration block 280. This technique is used as a "correct" or "measured" variable corresponding to the output of a simulation block (254 or 256) (and thus used to perform model regeneration) of a process variable. It is shown in FIG. 9 with UI blocks 290 and 292 that are connected to or in communication with a user interface or other device that allows the value to be specified by the user. In this way, the user can have simulation blocks 252, 254 and 256 regenerate the model used in it and specify the values used to do so. The figure shows only two UI blocks that allow user control over feedback to simulation blocks 254 and 256, but of course any desired feedback variable. To provide a number of UI feedback paths or connections in any simulation block, and to process variable measurements generated by sensors or other elements in the control system.

Furthermore, if both the measured process variables and the variables provided by the user are provided to the simulation block, the simulation block will use one of these variables as the primary input and the other. The variable can be used as a backup input for use when the primary input fails (or when the primary input is unavailable or is known to produce apparently inaccurate results). .. Thus, for example, the simulation block may automatically or primarily use the measured PV signal fed back from the process control network to regenerate the model, but when the measured PV signal fails. Alternatively, if the measured PV signal is not available or is known to produce apparently inaccurate results, the model regeneration block 280 instead inputs the process variables provided by the user. Can be used.

It is also possible to calculate future values (not just current values) of the block's output parameters as part of the simulation algorithm used in any of the simulation blocks 252, 254 or 256. Thus, as shown in FIG. 9, the valve simulation block 254 provides the user with a graph or trend table 294 relating to the simulation of the flow out of the valve that will be simulated at some point in the future (eg, period). Can be provided in the user interface (not shown). Such future flow characteristics can be developed by running the simulation system 250 over a period of time to estimate future values of output variables for a particular future period of interest. Similarly, as shown in FIG. 9, the reactor simulation block 256 may provide a plot or trend table 296 for simulated output temperatures simulated based on the process model or other algorithm used therein. .. Of course, estimates of future process variables can be calculated, for example, using techniques similar to those used in MPC control to make future predictions. U.S. Pat. No. 7,050,083 discloses some of these techniques in more detail. Graphic elements or graphic interface elements by simulation blocks 252, 254 and 256, where desired, to allow access and display of these future values by other applications or by user interfaces or other involved equipment in the process plant. Can be provided.

Moreover, as a matter of course, in addition to the future predicted value or the future simulated value of one or more process variables, or the currently measured process variable value and the current predicted process variable value fed back to the simulation block. Other simulation outputs can be used to regenerate or update the process model in the simulation block of FIG. 9 with or with it, or instead of using it. In this case, future values calculated for a particular process variable or other process element can be calculated and stored, and then the actual value of the process variable can be measured at a point corresponding to each of the calculated future values. The difference (s) between the measured process element value at a particular point in time and the predicted future value at that particular point in time then regenerates the process model used in the simulation routine to develop the future value. Can be used for. Using future values to regenerate the process model is particularly suitable when the process model is an impulse response model (such as a finite impulse response model) or a step response model.

Thus, as described above with reference to FIG. 9, actual process measurements allow for automatic correction of the process model used in the simulation block based on the comparison of calculated and measured values of the same process elements. Can be used in simulation blocks to do so. Further, when the process measurement becomes unavailable or becomes unavailable due to, for example, a defect in the measuring ability, the process is performed based on the comparison between the input value and the calculated value by manually inputting the value. The model can be corrected. Furthermore, if the process simulation is based on step or finite impulse response, or other techniques such as neural networks or first-principles models, and other commonly used techniques, the calculated and measured values (s) and measurements (s). Yes) The process model can be automatically corrected based on the differences between them. More specifically, the techniques previously used in MPC apply, for example, to the process model (or to the output of the process model) where the correction factors are calculated based on the difference between the measured and simulated values of the process parameters. It can be used to correct the process model (s), including bias correction, where the bias between the actual process plant and the process model is completely eliminated. Of course, other correction methods can be used as well. In addition, as such an amendment method, "Multiple-Input / Multiple-Output Control Blocks with Non-Linear Predictive Capabilities" (provisional) published on December 9, 2004, which is incorporated in this paper by referring to the entire disclosure here. Translation:

Also, if the process simulation is based on step or finite impulse response, or other techniques such as neural networks or first-principles models, and other commonly used techniques, to calculate future output values and display them on the screen. Can be saved. Again, for models based on step and finite impulse responses, future values can be calculated using techniques previously used in MPC. In addition, the process simulation environment may support display elements / applications that allow the display of both current and future simulation output values. For example, a user interface window may be provided to indicate future output value trends using any desired display technique such as trend graphs, bar graphs, numerical tables and graphs.

If desired, the process modules described herein may provide and simulate redundant functionality within a process control network or process plant. Specifically, the process module simulates the behavior of the actual redundant elements (such as redundant devices and redundant control blocks) provided in the process plant, and actually (for example, when the spare redundant elements take over). Can detect or simulate the behavior of redundant elements in. In addition, if desired, the process module and its simulation capabilities can be used as one of the redundant pairs of elements in the process plant. In this case, the process module (or any part thereof) may have preliminary data (such as signals or calculations) or if a primary device (and actual physical device) fails or a problem associated with it is detected. It can act as a backup device that provides redundant data. In this case, the process module acting as a redundant element may be communicably interconnected with the control module (performing the control or detection operation) in any well known manner to provide redundancy capability. Using the process module as a redundant element in the process plant in this way is particularly useful when the process module is connected to one or more high-fidelity simulation packages in the above embodiments.

Not surprisingly, the functionality of the smart process objects, graphic display elements and process modules described herein can also be operated on operator workstation 20, such as controllers and field devices in plant 10. No need to download or configure in it. Therefore, it can be said that this functionality can be implemented, displayed, changed, and the like more easily. Moreover, while normally not all information about equipment at the system level is available to each controller and field equipment in process plant 10, according to this functionality, all of that information is It will be available in the operator workstation 20 in general, specifically in the execution engine 48, making system-level decisions easier than making decisions in process equipment, controllers, and so on. However, if deemed more advantageous, some of the logic associated with the process module, such as primitives, may be embedded in the equipment, equipment and controllers within the process plant. By using smart process objects to create integrated process control modules and graphic displays, for example, you can automatically detect leaks and generate smart alarms with minimal user configuration work, or within plant 10. Calculate and track the flow and mass balance of the plant, track losses within the plant 10, provide high-level diagnostics to the plant 10, and simulate plant operation during technical design and operator training. It becomes possible to let the execution engine 48 perform such things as.

FIG. 10 illustrates an aspect applicable to integrating a process module and a graphic display with an execution engine 48 used in a process plant with a distributed control method. As shown in FIG. 10, the screen display class definition 220 created (or associated with it) by the process module provides screen display to the operator during execution by the execution engine 48 and any desire during control method documentation. Provided to the control system configuration database and engineering tool 222 that can use and organize the screen display class definitions in the above manner. Process algorithm 224 may be connected to these screen display class definitions before run time. And then, the display class definitions and flow algorithms that are interrelated (combined) with it are applied to the graphic display / process module runtime environment (which can be implemented as one or more execution engines 48 on one or more workstations). Can be instantiated and provided to. The graphic display / process module runtime environment 226 uses the download script parser 228 to parse the code during execution (ie, to perform just-in-time object code conversion), and Uses the rule-based execution engine 230 to perform flow algorithms or other rule-based procedures provided or interrelated to the display class. During this process, the graphic display / process module runtime environment 226 provides data or information to the control module runtime environment 232, or to access data or other information from the control module runtime environment 232. Can communicate with the control module run-time environment 232 which can be executed in the controller and field equipment associated with the process. Of course, the graphic display / process module runtime environment 226 is controlled using any desired or preconfigured communication network, such as the Ethernet® bus 24 shown in Figure 1. Can communicate with the module runtime environment 232. Furthermore, other methods of integrating the graphic display, process modules and control modules described herein into a standard process control system or process plant may be used as well.

Any software described herein may, at the time of implementation, be stored on a magnetic disk, laserdisc or other storage medium, or any computer-readable memory such as the RAM or ROM of a computer or processor. In addition, any well-known or desired delivery method (eg, stored on a computer-readable disk or other portable computer storage mechanism, or telephone line, Internet, World Wide Web, other local area networks or wide area networks, etc. This software may be provided to users, process plants or operator workstations using (such as through the communication channels of). (Note that such delivery is considered to have the same or similar meaning as providing the software via a portable storage medium.) Moreover, the software is provided directly without modulation or encryption. It can be modulated and / or encrypted using any of the appropriate modulated carriers and / or cryptographic techniques before being transmitted over the communication channel.

In the above, the present invention has been described with reference to specific examples (which are merely embodiments illustrating the present invention and do not limit the present invention), but for those skilled in the art, the present invention It should be clear that changes, additions or deletions may occur to the embodiments disclosed herein without departing from the spirit and scope of the invention.

<figref num="1">A distributed process control network within a process plant that contains operator workstations that perform screen display routines that use smart process objects to create process modules and graphic displays to simulate the operation of the process plant. Block diagram.</figref><figref num="2">A logical block diagram of a set of applications and other entities (including smart process objects and process modules) stored on the operator workstation in Figure 1, where they can be used to perform extensions in a process plant.</figref><figref num="3">A diagram showing a simplified depiction of a configuration screen used by a system configuration engineer to create a process graphic display or process module using smart process objects stored in an object library.</figref><figref num="4">A diagram showing a detailed depiction of a graphic representation of a process, given as an example, including depictions of streams and connecting elements within a process plant, created by interconnecting the graphic representation elements of a number of smart process objects.</figref><figref num="5">A diagram showing a graphic representation of a set of minimized processes, including a graphic representation of the process in Figure 4, interconnected to a graphic representation that includes a larger area of the plant.</figref><figref num="6">A diagram showing the process modules associated with the graphic display of the process in Figure 4, along with the interconnection of high-fidelity simulation routines.</figref><figref num="7A">A logical block diagram showing a graphic display integrated within a process plant and communication interconnects between process modules and control modules.</figref><figref num="7B">A logical block diagram showing a graphic display integrated within a process plant and communication interconnects between process modules and control modules.</figref><figref num="8">FIG. 5 illustrates a simplified depiction of a process module given as an example of having blocks interconnected with functional blocks within a control module to provide advanced control and simulation capabilities.</figref><figref num="9">Demonstrates a simulation system that has multiple simulation blocks that use a process model to provide future-predicted process values and updates the process model based on process measurements or user input. Simplified block diagram.</figref><figref num="10">A logical block diagram showing how process modules and simulation systems that use smart process objects can be created in a control network and implemented within an existing process control network.</figref>