Abstract: Computer-implemented methods and systems construct a calibrated operation-centric first-principles model suitable for online deployment to monitor, predict, and control real-time plant operations. The methods and systems identify a plant-wide first-principles model configured for offline use and select a modeled operating unit contained in the plant-wide model. The methods and systems convert the plant-wide model to an operation-centric first-principles model of the selected modeled operating unit. The methods and systems recalibrate the operation-centric model to function using real-time measurements collected by physical instruments of the operating unit at the plant. The recalibration may include reconciling flow and temperature, estimating feed compositions, and tuning liquid and vapor traffic flow in the model. The methods and systems deploy the operation-centric model to calculate KPIs (Key Performance Indicators) using real-time measurements.

Abstract: Embodiments are directed to computer methods and systems that construct a calibrated operation-centric first-principles model suitable for online deployment to monitor, predict, and control real-time plant operations. The methods and systems identify a plant-wide first-principles model configured for offline use and select a modeled operating unit contained in the plant-wide model. The methods and systems convert the plant-wide model to an operation-centric first-principles model of the selected modeled operating unit. The methods and systems recalibrate the operation-centric model to function using real-time measurements collected by physical instruments of the operating unit at the plant. The recalibration may include reconciling flow and temperature, estimating feed compositions, and tuning liquid and vapor traffic flow in the model.