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    • 专利摘要:
    METHOD FOR MONITORING AN INDUSTRIAL PROCESS A plurality of real control inputs and real process measurements provided by a real automation system, which controls an industrial process, is continuously stored in a storage medium in a historian database. At the same time, a plurality of inputs and measurements of the control forecasting process provided by a virtual automation system, based on a simulation model, is continuously stored in a futuristic database. The operation from the past of the industrial process to the present moment, based on the data from the historian database, and the operation of future prediction of the industrial process, from the present moment onwards, based on the data from the futuristic database are displayed in the operator screen.
    公开号:BR112014000727B1
    申请号:R112014000727-6
    申请日:2011-07-11
    公开日:2021-01-12
    发明作者:Mats Friman；Mika Karaila；Ville Hietanen
    申请人:Valmet Automation Oy；
    IPC主号:
    专利说明:

    [0001] [0001] The present invention, in general, is correlated to the control of an industrial process by means of an automation system. Background of the Invention
    [0002] [0002] A process control or automation system is used to automatically control an industrial process, such as a chemical production process, oil refineries, pulp and paper mills and power plants. The process automation system normally uses a network to interconnect various components of the system, such as sensors, drivers, controllers and operator terminals. Process automation involves the use of computer technology and software engineering to help power plants and factories in general to operate more efficiently and safely.
    [0003] [0003] A process simulation is a representation of industrial processes and unit operations in software for the study and analysis of the behavior and performance of real or theoretical systems. Simulation studies are performed, not on real-world systems, but on a (usually computer-based) model of a system created with the purpose of studying certain dynamics and characteristics of the system. The purpose of any model is to enable its users to draw conclusions about the real system by studying and analyzing the model response. The main reasons for developing a model, contrary to the analysis of a real system, include economic aspects, unavailability of a “real” system and the objective of obtaining a deeper understanding of the relationships between the elements of the system.
    [0004] [0004] Process simulation always uses models that introduce approximations and assumptions, but it allows the description of a property with respect to a wide range of properties, such as temperatures and pressures, which cannot be covered by real data. The models also allow interpolation and extrapolation - within certain limits - and make it possible to search for conditions outside the range of known properties. In process automation, the simulator can use measurements to show not only how the plant is working, but also to simulate different modes of operation and find an optimal strategy for the plant.
    [0005] [0005] The simulation can be used in service or in situation training areas, in order to allow operators to anticipate certain situations, enabling them to react appropriately, as well as, to test and select alternatives based on the same criteria, to test why certain phenomena occur in the operations of the system under consideration, to discern which variables are most important in performance and how these variables interact, to identify bottlenecks in the process, to better understand how the system actually operates (as opposed to how it is thought to operate) and to compare alternatives and reduce the risk of decisions.
    [0006] [0006] A basic process simulator is operated without any real-time connection to a simulated process. A tracking simulator, on the other hand, has the ability to adapt its behavior to reality. A tracking simulator is a process simulator that operates in real time, in parallel with the real process and provided with a connection to the real process. More specifically, the tracking simulator receives measurements / process measurements from the real process, being able to correct its own behavior (model) by comparing the measurements of the real process with the simulator outputs. Patent document PCT / FI / 2010/050564 discloses an example of such a type of tracking simulator.
    [0007] [0007] US patent document 2008/0027704 discloses synchronized control and simulation in real time within a process facility. A simulator is operated in parallel with the current control system and the current process. The operator can articulate the simulator between two alternative operating modes: a tracking mode and a prognosis mode. In a tracking mode, the simulator can correct or update its models based on the actual process data. In the prognostic mode, the simulator performs the simulation of the process control system in relation to some future time horizon, to execute, for example, “which scenarios and if they exist”. In the prognostic mode, the simulator corresponds to a basic process simulator, operated without any real-time connection to a simulated process.
    [0008] [0008] Disturbances enter or affect the process and tend to trigger dependent controlled variables outside their desired value or setpoint condition. Typical disturbances include changes in demand for the product, or in the supply of food material. The control system must adjust the dependent variable, so that the value of the setpoint of the independent variable is maintained, despite the disturbances. If the setpoint is modified, the independent variable must be modified to adjust the controlled variable to its new desired value.
    [0009] [0009] Despite their differences, continuous process industries share essential characteristics: they maintain continuous operations at facilities that represent substantial start-up costs and time, but can be interrupted or disrupted by minor disturbances. If the product flow is interrupted or the process does not proceed optimally, the loss of productivity and loss of product can create a great financial loss. Therefore, it is important for the operator to monitor and supervise the process in real time. Control rooms are central facilities used to manage large systems, such as industrial processes. As operators of large systems are asked to more efficiently use more sophisticated control systems, with greater obligations and responsibilities, developers of control room equipment have sought to improve the operator's ability to interact effectively with their systems.
    [0010] [0010] Modern process facilities generate a large amount of data in real time that normally needs to be stored and processed efficiently for further analysis. All measurements, setpoints, controller outputs, device conditions, motor starts, alarms, operation tracking, etc., can be stored in the so-called historian database. A historian database can be integrated with other parts of a control system, such as control elements, engineering features and control rooms. Through historical data collected from the process installation with respect to time, trend graphs can be created, showing the process trends, in data, with respect to time. In modern control rooms, long historical trends are usually available to users. As all processes vary, single point measurements can be misled. Displaying historical data over time increases the understanding of the real performance of a process. Brief Description of the Invention
    [0011] [0011] An objective of the present invention is to provide an improved monitoring scheme for an industrial process. This objective of the invention is achieved by the subject matter of the attached independent claims. Preferred embodiments of the invention are disclosed in the dependent claims.
    [0012] - continuamente armazenar em um banco de dados historiador uma pluralidade de entradas reais de controle e aferições reais de processo, providas por um sistema real de automação controlador de um processo industrial; - armazenar continuamente em um banco de dados futurista uma pluralidade de entradas e aferições de processo de previsão de controle providas por um sistema virtual de automação, baseado em um modelo do processo industrial; e - exibir em uma interface gráfica de usuário, em uma única vista gráfica de tendência, a operação do passado do processo industrial até o presente momento com base nos dados do banco de dados historiador, e a operação de previsão futura do processo industrial, a partir do presente momento para frente, com base nos dados do banco de dados futurista. [0012] One aspect of the invention consists of a method of monitoring an industrial process, comprising: - continuously store in a historian database a plurality of real control inputs and real process measurements, provided by a real automation system that controls an industrial process; - continuously store in a futuristic database a plurality of inputs and measurements of the control forecasting process provided by a virtual automation system, based on an industrial process model; and - display in a graphical user interface, in a single graphical trend view, the operation of the past of the industrial process up to the present moment based on the data from the historian database, and the operation of future forecast of the industrial process, from from the present moment forward, based on data from the futuristic database.
    [0013] [0013] According to the modalities of the invention, the actual control entries and process measurements in the historian database overwrite or replace the respective control forecast process entries and measurements with the same date and time indication in the database. futuristic data in real time.
    [0014] [0014] According to the modalities of the invention, the method comprises storing future actions and / or set points and / or alarms in the futuristic database and displaying the respective trends in the graphical user interface.
    [0015] [0015] According to the modalities of the invention, the method comprises the provision of collaborative data to or from another automation system, said collaborative data including one or more of: future action, future setpoint, future trend, process measurement future, future process control, future alarm, and storage of the collaborative data in the futuristic database, using the collaborative data in the generation and display of the graphical trend visualization.
    [0016] [0016] According to the modalities of the invention, the method comprises the tracking of a state of the real automation system in the virtual automation system.
    [0017] [0017] According to the modalities of the invention, the method comprises the tracking of a process state of the actual process, in the forecast or simulation in the virtual automation system.
    [0018] [0018] According to the modalities of the invention, the method comprises the generation of control forecast inputs and process measurements in said virtual automation system, with a faster speed than a real-time speed of process inputs and measurements real control.
    [0019] [0019] According to the modalities of the invention, the method comprises the generation and display in the graphical user interface of future alarms, based on the data stored in the futuristic database.
    [0020] [0020] According to the modalities of the invention, the method displays in the graphical user interface a chronological control device, in which the user uses the chronological control device to go back in time, to analyze past events found in the historian database, and to advance in time, to analyze future events found in the futuristic database, with a desired resolution and / or desired time interval of the data.
    [0021] [0021] An additional aspect of the invention consists of a system for implementing the method according to any of the above modalities, comprising a real-time automation system connected to an industrial process, a virtual automation system capable of processing faster than in real time, a graphical user interface, a historian database and a futuristic database.
    [0022] [0022] Another aspect of the invention consists of a computer program comprising a program code for executing a method according to any of the above modalities, when said program is processed on a computer.
    [0023] [0023] Another aspect of the invention consists of a computer program comprising a program code device stored in a computer readable medium, for executing a method according to any of the above modalities, when said program product is processed in a computer. Brief Description of Drawings
    [0024] - a figura 1 é um diagrama em bloco ilustrando um sistema de acordo com uma modalidade exemplificativa da invenção; - a figura 2 é um diagrama em bloco simplificado ilustrando um exemplo de armazenamento de tags no banco de dados historiador e no banco de dados futurista; - a figura 3A ilustra uma vista de tendência exemplificativa que pode ser exibida em uma interface de operador de usuário, em conformidade com as modalidades exemplificativas da invenção; e - as figuras 3B, 3C, 3D, 3E, 3F ilustram exemplos de exibição de dados historiadores e futuristas em uma interface gráfica de usuário; - a figura 4 mostra um exemplo de um dispositivo de cronologia e zoom, exibido na interface gráfica do usuário; - a figura 5 é um diagrama em bloco ilustrando um sistema de automação virtual de acordo com uma modalidade exemplificativa da invenção; e - a figura 6 é um diagrama em bloco ilustrando ainda um sistema de acordo com outra modalidade exemplificativa da invenção. [0024] In the following, the invention will be described in greater detail by means of exemplary modalities, making reference to the attached drawings, in which: figure 1 is a block diagram illustrating a system according to an exemplary embodiment of the invention; - figure 2 is a simplified block diagram illustrating an example of storing tags in the historian database and in the futuristic database; figure 3A illustrates an exemplary trend view that can be displayed on a user operator interface, in accordance with the exemplary modalities of the invention; and - Figures 3B, 3C, 3D, 3E, 3F illustrate examples of displaying historical and futuristic data in a graphical user interface; - figure 4 shows an example of a chronology and zoom device, displayed on the graphical user interface; figure 5 is a block diagram illustrating a virtual automation system according to an exemplary embodiment of the invention; and figure 6 is a block diagram illustrating a system according to another exemplary embodiment of the invention.
    [0025] [0025] An exemplary embodiment of the invention is illustrated in figure 1. The present invention can be applied in connection with any automation system (process control system) (4) and any industrial process (2) or similar. Industrial processes (2) may include, but are not limited to, processes in a processing industry, such as a pulp and paper mill, oil refinery, petrochemical and chemical industries, or processes in power plants , etc. There are several architectures for an automation system. Thus, for example, the automation system (4) can be a Direct Digital Control system (DDC), a Distributed Control System (DCS) or a Field Control System (FCS), all well known in the technical segment. . An example of a type of decentralized automation system is Metso DNA (DNA, Dynamic Application Network) released by Metso. One unit or more central processing units of an automation system that controls the productive activity of an entire factory, such as a paper mill, is usually / are called the control operations center (control room) , which may consist of one or more computer (s) / control operations program (s), and process control computers / programs, as well as databases of an automation system. An automation system (4) can comprise a bus / process network and / or a bus / control center network, by means of which different components or process control computers are coupled together. A control center bus / network can interconnect the user interface components of the automation system (4). A control center bus / network can be a local area network, for example, based on standard Ethernet technology. A process bus / network can, in turn, interconnect process control components. A bus / process network can be based, for example, on a deterministic chip passing protocol. Process controllers can also be linked to a network of control operations centers, allowing communication between process controllers and user interfaces. However, it should be noted that there is no intention to limit the area of application of the invention to any specific implementation of an automation system (4).
    [0026] [0026] A process (2) that is controlled by an automation system (4) can typically include a large number of field devices, such as actuators, valves, pumps and sensors, in an installation area (field ). There are several alternative ways of providing an interconnection between an automation system (4) and a process (2) (for example, field devices), such as a two-conductor twisted-pair circuit (from 4 to 4 analog signal) 20 mA), HART protocol (Highway Addressable Remote Transducer), and other field buses (for example, Fieldbus and Profibus). However, it should be noted that the type or implementation of an interconnection between an automation system (4) and a process (2), for example, between a control operations center and field devices, can be based on any of the alternatives described above, or in any combination thereof, or in any other implementation. A practical installation configuration can, and typically occurs, with the inclusion of several types of automation lines or field buses in parallel, since the installation is updated and gradually extended over a long period of time.
    [0027] [0027] Process measurements y (k) can include any measurement of any desired variables or properties in a process (2), such as flow, pressure, temperature, valve position, etc. These process variables can be measured with dedicated sensors, arranged in the field of a process installation. Process controls (inputs) u (k) from an automation system (4) to a process (2) can include, but are not limited to, control inputs for field devices.
    [0028] [0028] An operator or user can monitor and control the automation system (4) through the user interface (6) of the automation system. Through the user interface, the user can monitor the displayed calibration data y (k) and process controls u (k) received from the automation system (4) and provide actions and set points for the automation system (4 ). In the exemplary modality shown in figure 1, gauging data y (k), process controls u (k) and actions and set points r (k) can be stored in databases (8) or in a portion database (8) called the historian database (8A). Historical data can include part or all of the measurements / gauges, set points, controller outputs, device conditions, motor start, alarms, operation tracking, etc., obtained from the automation system and the process during operation. The database (8) can be a database commonly referred to as a tag database, which contains data elements called tags or points. A tag can represent a single input or output value, monitored or controlled by the system (4). A tag can be “rigid” or “soft”. A rigid tag represents a current entry or exit within the system (4), while a soft tag results from logic and leveling operations applied to other points. The tags are usually stored as pairs of date and time indication values: a value and the date and time indication when it was registered or calculated. A series of value-date and time pairs provides the history of each tag. Optionally, the history database (8) can store additional meta data with tags, such as alarm information. A history database (8) can store data from an immense number of tags, for example, thousands or tens of thousands, for a long period of time (history extension), the main limiting factor being the storage capacity of the database. The collection cycle for the tags, that is, the time between the collection (sampling) of two samples can be selected by the user, for example, from approximately 0.1 second, up to days or weeks. There may be different collection cycles and / or story extensions, for example, for different tags or different users. The extent of the trend's history is limited by the available capacity of the database, for example, the hard disk space. According to an exemplary modality, the historian database can be a rounding buffer, that is, the oldest data is automatically deleted and overwritten, if the database reaches its maximum storage capacity.
    [0029] [0029] The operator's user interface (6) in a control operations center can be based on a human-machine interface (HMI), processed on the operator's console and allowing the user to monitor, supervise and control the process . The objective of the operator's user interface is an effective operation and control of factory systems, typically by means of monitors controlled by keyboard and mouse, in which a large amount of process information is graphically presented (Graphical User Interface, GUI ). The main aspects of this interface are the animated graphics with process feedback, which helps the operator to make operational decisions, for example, perform actions and modify set points to operate the process. The operator's user interface may also include data browsing and utility analysis, configuration tools and alarm monitors. When in constant operation, the operator interface displayed in the main control center can show the synthetic and functional status of the installation's system. With a simple glance, the operator will be able to know the global status of the installation system, that is, the global status of all components. If a problem occurs, the controlled component appears in error and the operator can access its detailed status, for example, by opening a screen that is specific to the supervised component. This interface can help the operator to locate the source of the problem and should suggest corrective action, if possible. In the operator's user interface, it is desired that the information displayed can be intentionally organized in a meaningful and useful way, based on clear and consistent models that are evident and recognizable to operators, putting related things together and separating non-correlated things , differentiating non-similar things and making similar things resemble each other.
    [0030] [0030] In order to provide an improved user interface environment for an operator in a process industry, according to exemplary modalities of the invention, also, control forecast inputs u '(k), process forecasting measurements y '(k) and forecasting and setpoint actions r' (k) can be provided and stored in the history database (8). The forecast data stored here is also called futuristic data, and the portion of the database (8) that stores the futuristic data is also called the futuristic database (8B). Forecasting actions and setpoints r ’(k) can be performed or set by the operator via the operator’s user interface (6). Control forecast inputs u '(k), process forecast measurements y' (k), and any other futuristic data can be generated by a virtual automation system, such as a virtual automation system that uses a process model and a simulator, or a virtual automation system based on statistical prognosis, for example, regression model and / or entropy. In other words, the historian database portion (8A) stores the process history data collected from the past operation of the industrial process to the present moment (ie, current situation in real time), while the database portion futuristic (8B) stores the predicted data of the “history” of the process, which represent the future operation of the industrial process, from the present moment (that is, current situation in real time) with respect to the future, during a desired time interval . This is schematically illustrated in figure 2, in which the tags collected from the system at the present moment, UI (now), one hour earlier in the past UI (1-h), and two hours earlier in the past UI (-2h), etc. , are stored in the historian database (8A). Similarly, futuristic tags that simulate / predict the future operation of the process one hour later in the future UI (+ 1h), two hours later in the future UI (+ 2h), five hours later in the future UI (+ 5h), etc. ., are stored in the futuristic database (8B). A later collection cycle in time, the historian data tags of the actual process will overwrite (that is, replace) the futuristic tags with the same date and time indication, as previously stored in the futuristic database (8B). With reference to the example shown in figure 2, a real process tag collected one hour later in time, that is, in time (+ 1h), will overwrite / replace the previously stored futuristic tag UI (+ 1h), having the same indication date and time (+ 1h). It should be noted that the historian database (8A) and the futuristic database (8B) can be virtual databases, and the boundary between the historian database (8A) and the futuristic database (8B) can be be defined simply based on the date and time indication, that is, date and time from the past to the present moment (now) for the historian database (8A), and indication of the date and time after the present moment for the database. futuristic data (8B). The limit, therefore, is continually shifting with real time (now). The physical configuration of the history database (8) is not important, as it may comprise a single continuous buffer database (such as a rounding buffer), a pair of a continuous historian buffer database and a bank of continuous futuristic buffer data, which can overlap with each other over time in the boundary area, a distributed database, or any other database configuration.
    [0031] [0031] Figure 3A illustrates an example of trend visualization that could be displayed in an operator user interface (6), according to the modalities principles of the present invention. In the example shown, there may be three different windows or zones: Actions (31), Stock Trends (32), and History Trends (33). In the example, the Actions window (31) can display a list of actions (310), including actions for process components (25M-100) and (25FC-100), such as pumps, and control devices (312) for establishing real time and future actions and set points r (k) and r '(k). The Actions trend window (32) can show actions graphically, as trends in a timeline, including actions from the past (historians) and trend setpoints from the past to the present (now), and forecasting actions (futurists) and setpoints from the present moment to the future. Similarly, the History trend window (33) can show history trends, including a portion of historian trend for measurements from the past (historians) y (k), and controls u (k) to the present moment (now ), and a portion of the trend forecast for prognosis measurements (futurists) y '(k) and u' (k) controls. Therefore, future trends (prognostic trends) can be displayed on the same screen (for example, on the same graph or plot) and in the same chronology as any other trend coming from the process history database. In other words, the history trends displayed in an automation system user interface can be extended to also include the trend forecasts (and with alarms and events) in the same figure with a common timeline. By having future actions and trends displayed on the screen, it becomes easier to manage a process situation, compared to a situation in which all future actions and trends have to be kept in mind, or without knowledge of future actions or trends . Also, recovery from a problematic situation will be faster, as a consequence of corrective action done in real time or established to be done in the future, will be displayed on the same screen. The operator can immediately see what has happened or what will happen in a given process situation and how the sequence of events preceded or will continue. Using the chronology and zoom functions, the operator can move back and forth in time, with the desired data resolution. The operator can “repeat” past and future events stored in the history database (8). A timeline (chronology) and a zoom device can be, for example, a graphical displacement controller, in which a cursor or an adjustment “button” can be moved along the timeline to the desired point in the past or for the future, where more detailed process data stored in the history database (8) can be displayed for analysis of the process situation. An example of such a graphical timeline and zoom device is illustrated in figure 4. Also, future alarms can be predicted and stored in the futuristic database or in an alarm list, so that the operator can obtain alarms for problematic situations that may occur in the future, if the process is continued from the present situation determined by historical data for the future, with existing and / or future actions and set points. Examples of such an alarm prognosis may include an alarm for a lack of raw material or an alarm for a waste tank when it is full, but any alarm can be predicted, depending on the specific process in question.
    [0032] [0032] Now, let's consider the trend visualization example shown in figure 3A, in more detail. Through the control cursors and the buttons “Activate”, “Remove” and “Cancel”, the operator can establish the following future actions r '(k), which are written in the futuristic database (8B), with future indications of date and time: (25M-100 will stop at time (t1); (25FC-100) will go into Local mode, at time (t2); (25FC-100) will be controlled to a level (sp1 = 100) at the time (t3); and (25FC-100) will be controlled to a level (sp1 = 50) at the time (t4); and (25FC-100) will return to a Remote mode at the instant of These future actions are also shown in the Action trend window (32). Measurements / measurements y '(k) and u' (k) prognostic controls that are calculated based on (real) and historical data future actions r '(k) and which are stored in the futuristic database (8B), are shown in the future part of the history trends, in the window (33), thus an operator user interface, according to the modalities of theinvention, can show the cumulative consequences of past and future actions through future trends, so that the operator is able to see the consequences in advance, before these actions are carried out in the real process. The actions and trends of future control can be displayed on the screen, at the same time as other historical data, the operator being continuously aware of the future consequences, without having to remember them or to articulate between a real mode and a future mode.
    [0033] [0033] It should be noted that the principles of the modalities of the invention can be applied to provide any type of futuristic graphic representation for the operator, where figure 3A illustrates only one example. As an additional example, historian and / or futuristic data can be displayed using any spelling or graphical representation of data, such as histogram-type graphs, pie charts, bar graphs, line graphs, other types of graphs, trends, etc. Historical data and futuristic data can be shown in a single window or shown in separate windows on the same screen. These separate windows of historical and futuristic data can be close together, in order to create a continuous tilt on the screen, as shown in figure 3B, or they can be located horizontally or vertically, spaced apart from each other on the screen, as shown in figure 3C. As another additional example, separate views or windows of historian and futurist data can be displayed on separate screens, as shown in figure 3D. The user may be able to selectively open and close (activate and deactivate) historian and futurist data window (s), using any control device present on the screen.
    [0034] [0034] Figure 3E illustrates an example view, in which historical and futuristic data are displayed as part of a process control view, including a graphical presentation of the process components. In the illustrated example, the historical and futuristic data from a distillation process are illustrated as united trend lines, where the historical data is illustrated in the form of a solid line and the futuristic data in the form of a dashed line. Similarly, historian and futuristic data can be displayed as part of any process control view.
    [0035] [0035] Figure 3F illustrates another example view, in which historian and futuristic data are displayed as part of a process control view, including a graphical presentation of the process components. In the illustrated example, the historical and futuristic data of a gas turbine is illustrated in a separate window, opened in a gas turbine control view, which is displayed on the screen, for example, the user clicking on a desired icon or component from the gas turbine control view. The user can close the historian and futuristic data window, for example, by clicking an appropriate icon in the window. Similarly, historian and futuristic data can be selectively displayed as part of any process control view.
    [0036] [0036] A virtual automation system (10), according to yet another exemplary embodiment of the invention, is illustrated in figure 5. The exemplary virtual automation system (10) can comprise a clone (copy) of the process control system (50), a state evaluator (52) and a simulator / predictor (54). The simulator unit process model (54) can comprise a description of simulator states (x), a list of controls and disturbances (u), a list of measurements / measurements (y), a function (f) describing the update status, a function (g) describing the state mapping (x) to perform measurements. The process model can be a discrete time model to ensure rapid simulations, but other types of models can also be used. The process model can be a non-linear model or a linear model. The state evaluator (52) can receive the measurements y (k) and controls u (k) at the time (k) (date and time indication (k)) and generate the following states x (k + 1) for the next time (k + 1) (date and time indication, k + 1), using, for example, the function (x (k + 1) = f (x (k), u (k)). The evaluator (52) may have established an evaluation gain (H), defining how the generated states are updated from the current measurements.The simulation starts from the current situation in real time (date and time indication, k = 0 The simulation can typically be performed at a higher speed, so that the prognostic trends regarding the desired time interval will be obtained and updated as soon as possible. A simulator (54) can generate future measurement merits y '(k), from state (k) and future controls u' (k) using, for example, the function y (k + 1) = g (x (k + 1)). The automation system clone (50) can receive y '(k) and future prognostic measurements actions and adjustments r '(k) for a time date (k) and generate prognosis controls u' (k + 1) for a date and time indication (k + 1). All future or prognostic data are stored in the futuristic database with the respective date and time indications. At the same time, the state of the simulator can track the state of the real process (2) and the real automation system (4). Thus, the simulation can always start from the current situation in real time, and a hot start of the simulation is possible, as the simulator is always ready for questioning analyzes. An exemplary prognostic process for a time interval from k = 0 to kmax can be illustrated using the set of functions: Repeat: x = f (x, u); y = g (x); z = F (z, y, r); u = G (z); k = k + 1; up to k> kmax.
    [0037] [0037] The parameter z (k) indicates an application status of the process control system (4). An additional exemplary embodiment for implementing the present invention is shown in figure 6. A real automation system (4) (for example, process control station - PCS) with a real control application (602) controls the real industrial process ( 2) through a real process interface (606) in a similar way to figure 1. The collected history data, that is, measurement data y (k), process controls (u) k and actions and point adjustments r (k) can be stored in a historian database (8A). A tracking simulator is provided, which models an industrial process (2) simultaneously and in parallel with the industrial process (2). The tracking simulator (602) can receive through the simulation interface (610) the same controls as those provided by an automation system (2) for the actual industrial process (2). Based on these inputs, the tracking simulator (608) with its process model (s) can provide simulated (estimated) process outputs, which represent the actual process outputs, as accurately as possible, with respect to (s) process model (s) used. In order to avoid divergence of the model (s) from the real process (2), the parameter estimation part (604) is able to correct, that is, update the parameters and the behavior (models) of the tracking simulator (608), based on the difference between the actual process outputs (2) and the tracking simulator (608).
    [0038] [0038] A virtual automation system (virtual process control system) (10) with a real control application clone can control a prognosis simulator (618) through a virtual control input / output (I / O) (614) and a simulation interface (616). The prognostic control inputs u '(k), prognostic process measurements y' (k) and prognostic action points and setpoints r '(k) can be stored in the futuristic database (8B) via the virtual process control (10). A copy (620) of the application status of the real control application (602) in the real process control system (4) must be copied for application of the control clone in the virtual process control system (10) before each simulation in order to maintain the real-time state of the virtual process control system (10) updated and in sync with the real process control system (4). In addition, a copy (622) of the tracking simulator process status (608) should be copied to the prognosis simulator (618) before each simulation, to ensure that the simulation is started from a state that is close to the actual process, if possible.
    [0039] [0039] In the modalities of the invention, there can also be communication and collaboration between different departments or unit processes in the industrial unit. A forecast obtained from a department or unit process can be valuable information for another department or unit process. Thus, when selecting one or some of future actions and setpoints r ’(k), or other futuristic data, these can be received from another department or process. Thus, for example, the virtual automation system (10) can receive the information that a new raw material dispatch will arrive at a certain date and time indication, or that the raw material will be modified, or that the product final will be dispatched in a certain time, or that an operator of another process or department will take a certain action that will affect the forecast of the process. Similarly, this collaborative information can be transferred from your own system to other systems. This collaboration will improve the accuracy of the prognosis and help to avoid unexpected process situations that result from actions in other departments or unit processes.
    [0040] [0040] The techniques described here can be implemented through various devices. So, for example, these techniques can be implemented in hardware (one or more devices), firmware (one or more devices), software (one or more modules), or combinations of them. For a firmware or software, the implementation can be done through modules (for example, procedures, functions, etc.) that perform the functions described here. Software codes may be stored in any suitable data storage medium (s) or readable / readable memory unit (s) on a processor / computer, and executed by one or more processors / computers. The data storage medium or memory unit can be implemented inside the processor / computer or externally to the processor / computer, in which case it can be communicatively coupled to the processor / computer through various devices, as is known in the art segment. In addition, the components of the systems described here can be rearranged and / or complemented by additional components, in order to facilitate the achievement of various aspects, objectives, advantages, etc., described in relation to them, and are not limited to the precise configurations established in a certain figure, as will be observed by a specialist versed in the technique.
    [0041] [0041] The description presented here and the correlated figures are only idealized to illustrate the principles of the present invention by means of examples. Various alternative modalities, variations and changes will be obvious to a specialist skilled in the art based on the present description. In addition, the present invention is not intended to be limited by the examples described herein, and may vary within the scope and spirit of the appended claims.
    权利要求:
    Claims (14)
    [0001]
    Method for monitoring an industrial process (2), comprising the steps of: control an industrial process (2) by a real automation system (4) having an operator user interface (6) allowing an operator to monitor and control the actual industrial process, the method characterized by the fact that: store in a historian database (8A) a plurality of real control inputs and real process measurements, provided by the real automation system (4); graphically display on the operator user interface (6) the operation of the industrial process (2) until the present time based on the data from the historian database (8A); provide a plurality of previous control inputs and process measurements by a virtual automation system (10) based on an industrial process model (2); store in a futuristic database (8B) the plurality of previous control inputs and process measurements provided by the virtual automation system (10); store in the futuristic database (8B) future actions and / or future set points defined by the operator and display respective graphics in the operator user interface (6); and graphically display in the operator user interface (6) the operation from the past of the industrial process to the present moment, based on data from the historian database (8A), and the forecast of the future operation of the industrial process, from the present moment onwards, based on data from the futuristic database (8B).
    [0002]
    Method, according to claim 1, characterized by the fact that new real control entries and process measurements with a certain date and time overwrite or replace the respective control forecast process entries and measurements stored with the same date and time in the futuristic database (8B).
    [0003]
    Method, according to claim 1 or 2, characterized by the fact that it comprises the steps of: provide collaborative data to or from another automation system, said collaborative data including one or more of: future action, future setpoint, future alarm, future operation, future process measurement, future process control; store the collaborative data in the futuristic database (8B); use the collaborative data in the generation and display graphs about the future operation.
    [0004]
    Method according to any one of claims 1 to 3, characterized by the fact that it comprises the tracking of a state of the real automation system (4) in the virtual automation system.
    [0005]
    Method according to any one of claims 1 to 4, characterized by the fact that it comprises the tracking of a process state of the real process (2) in the forecast or simulation in the virtual automation system (10).
    [0006]
    Method according to any one of claims 1 to 5, characterized by the fact that it comprises the generation of predictions of control inputs and process measurements in said virtual automation system (10), automatically, in the background, at a substantially greater speed than a real-time speed of the actual control inputs and process measurements.
    [0007]
    Method according to any one of claims 1 to 6, characterized by the fact that it comprises the generation of predictions of control inputs and process measurements in said virtual automation system (10), in response to changes implemented by the operator, in at least a predetermined parameter.
    [0008]
    Method according to any one of claims 1 to 7, characterized by the fact that it comprises the generation and display in the operator user interface (6) of future alarms, based on the data stored in the historian database (8B).
    [0009]
    Method according to any one of claims 1 to 8, characterized in that it comprises the display on the operator user interface (6) of a chronological control device (312), the operator using the chronological control device to go back in time to analyze past events found in the historian database (8A), and to advance in time, to analyze future events found in the futuristic database (8B) with a desired resolution and / or time interval.
    [0010]
    Method according to any one of claims 1 to 9, characterized in that it comprises the display on the operator user interface (6) of historian data and / or futuristic data with one or more of the following representations of spellings or graphical data: histogram chart, pie chart, bar chart, line chart, trends and the like.
    [0011]
    Method according to any of claims 1 to 10, characterized in that it comprises the display on the monitor of the operator of historian data and / or futuristic data in a single common window or in separate windows.
    [0012]
    Method according to any one of claims 1 to 11, characterized by the fact that the user understands that the user selectively opens and closes the historian and / or futuristic data window (s), in a process control view displayed on the operator's monitor.
    [0013]
    System characterized by the fact that it comprises a real-time automation system (4) connected to an industrial process (2), a virtual automation system (10) capable of running faster than a real-time graphical user interface (6) , a historian database (8A) and a futuristic database (8B), the system being adapted to perform the steps of the method as defined in any of claims 1 to 12.
    [0014]
    Computer-readable memory, characterized by the fact that it comprises instructions stored therein, the instructions being executable by a computer to perform the method as defined in any one of claims 1 to 12.
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    法律状态:
    2018-12-26| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2019-10-22| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|
    2020-11-03| B09A| Decision: intention to grant|
    2020-12-08| B25D| Requested change of name of applicant approved|Owner name: VALMET AUTOMATION OY (FI) |
    2020-12-29| B25G| Requested change of headquarter approved|Owner name: VALMET AUTOMATION OY (FI) |
    2021-01-12| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 11/07/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    PCT/FI2011/050648|WO2013007866A1|2011-07-11|2011-07-11|Method of monitoring an industrial process|
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