Rapid process model identification and generation

A method of simulating the operation of a process, comprising:

• collecting process data related to a process variable and a manipulated variable within the process;
• determining a ramp rate associated with the process variable after a change in the manipulated variable from the collected process data;
• generating a process model for the process using the determined ramp rate;
• simulating the operation of the process using the process model prior to the process being controlled to reach steady state in response to the change in the manipulated variable.

A method of controlling a process being controlled by a process controller using a set of control parameters, comprising:

• collecting process data related to a process variable and a manipulated variable within the process;
• determining a ramp rate associated with the process variable after a change in the manipulated variable from the collected process data before the process is controlled to reach steady state in response to the change in the manipulated variable;
• generating a process model for the process using the determined ramp rate;
• using the process model to determine anew set of control parameters for the process controller prior to the process being controlled to reach steady state in response to the change in the manipulated variable;
• and
• providing the new set of control parameters to the process controller prior to the process being controlled to reach steady state in response to the change in the manipulated variable.

A process model generation system, comprising:

• a processor;
• a first routine stored on a computer readable medium that operates on the processor to collect process data related to a process variable and a manipulated variable within an on-line process;
• a second routine stored on the computer readable medium that operates on the processor to determine a ramp rate associated with the process variable after a change in the manipulated variable over a time period that is shorter than the process response time associated with the process;
• and
• a third routine stored on the computer readable medium that generates a process model for the process using the determined ramp rate.

A process modeling system for use with a process, comprising:

• a data collection unit that collects process data related to a process variable and a manipulated variable within the process;
• a deadtime unit that determines, from the collected process data, a deadtime associated with the process;
• a ramp unit that determines a ramp rate associated with the process variable after a change in the manipulated variable from the collected process data generated within a particular time period related to the determined deadtime, wherein the particular time period is shorter than the process response time associated with the process;
• and
• a modeling unit that generates a process model for the process using the determined ramp rate.