Equipment condition and performance monitoring using comprehensive process model based upon mass and energy conservation

A computer-based system for processing signals representative of a process effected by one or more units of equipment in operative communication through one or more resource flows therebetween, said system comprising:

• a first sensor for measuring a flow rate of a first of said resource flows in order to generate a first measured resource flow signal;
• a second sensor for measuring a flow rate of a second of said resource flows in order to generate a second measured resource flow signal;
• a model generation module operative to formulate a model of said process based upon conservation of a process parameter characterizing said first and second resource flows, said model including at least a first maintenance parameter;
• and
• a reconciliation module operative to adjust a first value of said first measured resource flow signal, a second value of said second measured resource flow signal, and said first maintenance parameter such that said process parameter is conserved consistent with said model.

A method of processing signals representative of operation of a process involving one or more mass flows between a plurality of units of equipment, said method comprising:

• measuring flow rates of at least first and second of said mass flows in order to generate respective first and second measured mass flow signals;
• measuring first and second energies associated with said first and second mass flows in order to generate respective first and second measured energy signals;
• formulating a model of said process based upon mass and energy balance of said first and second resource flows;
• and
• adjusting values of said first and second measured mass flow signals and said first and second measured energy signals such that said mass and energy balance is conserved consistent with said model.

A method for controlling operation of a plant process effected by one or more units of equipment in fluid communication through one or more mass flows, said method comprising:

• creating, using a graphical user interface, a sequence representative of a mathematical model of said plant process based upon conservation of mass and energy, said sequence including a plurality of tasks defining functions to be performed in controlling said plant process;
• measuring a flow rate of a first of said mass flows in order to generate a first measured mass flow signal;
• measuring a flow rate of a second of said mass flows in order to generate a second measured mass flow signal;
• modifying a first value of said first measured mass flow signal by a first offset, a second value of said second measured mass flow signal by a second offset, and a first maintenance parameter of said mathematical model by a third offset;
• and
• adjusting said first of said mass flows in accordance with said first offset.

A method for monitoring condition of equipment used to effect a process, said method comprising:

• formulating a model of said process, said model including at least a first maintenance parameter;
• and
• adjusting a value of said first parameter such that a predicted value of a process parameter of said process is reconciled with a measured value of said process parameter derived from measurements of characteristics of said process;
• and
• monitoring changes in said value of said first maintenance parameter over time wherein changes in said value are indicative of changes in said condition of said equipment.

A method for monitoring condition of a plurality of units of equipment used to effect a process involving one or more resource flows, said method comprising:

• measuring flow rates of at least first and second of said resource flows in order to generate respective first and second measured resource flows;
• formulating a model of said process, said model including a plurality of nonlinear equipment models corresponding to said plurality of units of equipment wherein at least a first of said nonlinear equipment models includes a first maintenance parameter;
• adjusting a value of at least said first maintenance parameter such that predictions of said flow rates are reconciled with said first and second measured resource flows;
• and
• monitoring changes in said value of said first maintenance parameter over time in order to enable detection of changes in condition of at least one of said plurality of units of equipment.