Apparatus and method for calculating asset capability using model predictive control and/or industrial process optimization

1 . A system, comprising:

one or more processors;

a memory; and

one or more programs stored in the memory, the one or more programs comprising instructions configured to:

receive an optimization request to optimize an industrial process that produces an industrial process product; and

in response to the optimization request for the industrial process:

obtain asset modeling data from one or more asset performance management systems for an asset associated with the industrial process;

adjust one or more real-time operating limits for the industrial process based at least in part on the asset modeling data obtained from the one or more asset performance management systems, wherein adjusting the one or more real-time operating limits comprises computing, by the one or more asset performance management systems, one or more real-time operating limits that define feasible operating capacity of the asset for the optimization;

estimate a feasibility optimization region based on the adjusted one or more real-time operating limits obtained from the one or more asset performance management systems, wherein the adjusted one or more real-time operating limits define the feasibility optimization region to operate the asset within asset constraints in real-time;

transmit a control signal configured based at least in part on the one or more real-time operating limits to a controller configured for optimization associated with the industrial process that produces the industrial process product; and

receive by the controller, the control signal configured based at least in part on the one or more real-time operating limits to optimize the asset associated with the industrial process to produce the industrial process product.

2 . The system of claim 1 , the one or more programs further comprising instructions configured to:

modify one or more proxy limits for the industrial process based on the asset modeling data obtained from the one or more asset performance management systems.

3 . The system of claim 1 , the one or more programs further comprising instructions configured to:

configure the control signal based on a comparison between the adjusted one or more real-time operating limits and multivariate control criteria for the industrial process.

4 . The system of claim 1 , the one or more programs further comprising instructions configured to:

obtain asset operational data from one or more asset performance management systems for the asset associated with the industrial process; and

adjust the one or more real-time operating limits for the industrial process based at least in part on the asset operational data obtained from the one or more asset performance management systems.

5 . The system of claim 1 , the one or more programs further comprising instructions configured to:

obtain asset model configuration data from one or more asset performance management systems for the asset associated with the industrial process; and

adjust the one or more real-time operating limits for the industrial process based at least in part on the asset model configuration data obtained from the one or more asset performance management systems.

6 . The system of claim 1 , the one or more programs further comprising instructions configured to:

obtain asset model output data from one or more asset performance management systems for the asset associated with the industrial process; and

adjust the one or more real-time operating limits for the industrial process based at least in part on the asset model output data obtained from the one or more asset performance management systems.

7 . The system of claim 1 , the one or more programs further comprising instructions configured to:

obtain first-principles model data from one or more asset performance management systems for the asset associated with the industrial process; and

adjust the one or more real-time operating limits for the industrial process based at least in part on the first-principles model data obtained from the one or more asset performance management systems.

8 . The system of claim 1 , the one or more programs further comprising instructions configured to:

obtain data-driven model data from a regression model configured for the asset associated with the industrial process; and

adjust the one or more real-time operating limits for the industrial process based at least in part on the data-driven model data obtained from the one or more asset performance management systems.

9 . The system of claim 1 , the one or more programs further comprising instructions configured to:

obtain data-driven model data from a neural network model configured for the asset associated with the industrial process; and

adjust the one or more real-time operating limits for the industrial process based at least in part on the data-driven model data obtained from the one or more asset performance management systems.

10 . A method, comprising:

at a device with one or more processors and a memory:

receiving an optimization request to optimize an industrial process that produces an industrial process product; and

in response to the optimization request for the industrial process:

obtaining asset modeling data from one or more asset performance management systems for an asset associated with the industrial process;

adjusting one or more real-time operating limits for the industrial process based at least in part on the asset modeling data obtained from the one or more asset performance management systems, wherein adjusting the one or more real-time operating limits comprises computing, by the one or more asset performance management systems, one or more real-time operating limits that define feasible operating capacity of the asset for the optimization;

estimating a feasibility optimization region based on the adjusted one or more real-time operating limits obtained from the one or more asset performance management systems, wherein the adjusted one or more real-time operating limits define the feasibility optimization region to operate the asset within asset constraints in real-time;

transmitting a control signal configured based at least in part on the one or more real-time operating limits to a controller configured for optimization associated with the industrial process that produces the industrial process product; and

receiving by the controller, the control signal configured based at least in part on the one or more real-time operating limits to optimize the asset associated with the industrial process to produce the industrial process product.

11 . The method of claim 10 , the adjusting the one or more real-time operating limits for the industrial process comprising modifying one or more proxy limits for the industrial process based on the asset modeling data obtained from the one or more asset performance management systems.

12 . The method of claim 10 , further comprising:

configuring the control signal based on a comparison between the adjusted one or more real-time operating limits and optimization criteria for the industrial process.

13 . The method of claim 10 , further comprising:

configuring the control signal based on a comparison between the adjusted one or more real-time operating limits and multivariate control criteria for the industrial process.

14 . The method of claim 10 , further comprising in response to the optimization request for the industrial process:

obtaining asset operational data from one or more asset performance management systems for the asset associated with the industrial process; and

adjusting the one or more real-time operating limits for the industrial process based at least in part on the asset operational data obtained from the one or more asset performance management systems.

15 . The method of claim 10 , further comprising in response to the optimization request for the industrial process:

obtaining asset model configuration data from one or more asset performance management systems for the asset associated with the industrial process; and

adjusting the one or more real-time operating limits for the industrial process based at least in part on the asset model configuration data obtained from the one or more asset performance management systems.

16 . The method of claim 10 , further comprising in response to the optimization request for the industrial process:

obtaining asset model output data from one or more asset performance management systems for the asset associated with the industrial process; and

adjusting the one or more real-time operating limits for the industrial process based at least in part on the asset model output data obtained from the one or more asset performance management systems.

17 . The method of claim 10 , further comprising in response to the optimization request for the industrial process:

obtaining first-principles model data from one or more asset performance management systems for the asset associated with the industrial process; and

adjusting the one or more real-time operating limits for the industrial process based at least in part on the first-principles model data obtained from the one or more asset performance management systems.

18 . The method of claim 10 , further comprising in response to the optimization request for the industrial process:

obtaining data-driven model data from a regression model configured for the asset associated with the industrial process; and

adjusting the one or more real-time operating limits for the industrial process based at least in part on the data-driven model data obtained from the one or more asset performance management systems.

19 . The method of claim 10 , further comprising in response to the optimization request for the industrial process:

obtaining data-driven model data from a neural network model configured for the asset associated with the industrial process; and

adjusting the one or more real-time operating limits for the industrial process based at least in part on the data-driven model data obtained from the one or more asset performance management systems.

20 . A non-transitory computer-readable storage medium comprising one or more programs for execution by one or more processors of a device, the one or more programs including instructions which, when executed by the one or more processors, cause the device to:

receive an optimization request to optimize an industrial process that produces an industrial process product; and

in response to the optimization request for the industrial process:

obtain asset modeling data from one or more asset performance management systems for an asset associated with the industrial process;

adjust one or more real-time operating limits for the industrial process based at least in part on the asset modeling data obtained from the one or more asset performance management systems, wherein adjusting the one or more real-time operating limits comprises computing, by the one or more asset performance management systems, one or more real-time operating limits that define feasible operating capacity of the asset for the optimization;

estimate a feasibility optimization region based on the adjusted one or more real-time operating limits obtained from the one or more asset performance management systems, wherein the adjusted one or more real-time operating limits define the feasibility optimization region to operate the asset within asset constraints in real-time;

transmit a control signal configured based at least in part on the one or more real-time operating limits to a controller configured for optimization associated with the industrial process that produces the industrial process product; and

receive by the controller, the control signal configured based at least in part on the one or more real-time operating limits to optimize the asset associated with the industrial process to produce the industrial process product.