Data Rectification System Evaluation And Improvement Based On Simulation

In process enterprise integrated automation system, especially in petro-chemical industry, MES (Manufacturing Execution System) plays a closed-loop-control role in plant control, operation and management through collecting, processing, transforming, transferring data which is generated in the manufacturing process. MES is the information integration link between PCS (Process Control System) and ERP (Enterprise Resource Planning). In real world applications, manufacturing data collection is the base of other MES functions. A successful MES depends on process measurement data accuracy and integrity.Data reconciliation(DR) technology can solve manufacturing data measurement in-balance and in-completeness. DR technology uses measurement time and special redundancy information to find and delete the gross errors in raw data, reduce the random errors influence on data measurement and estimate the un-measured variables. Data balance module which was developed based on DR principle and technique is one of core modules in MES software. Because no true process data value can be gained directly through the measurement, the DB industry application effectiveness evaluation just can depend on experience judgments in a long time and lack theory evidence. Manufacturing process simulation data generated from integral plant model can support the effectiveness evaluation of DB scientifically—using simulation true value according to the field MES level demands to generate manufacturing simulation data which contains the error set by tester, then using DR module to rectify the process data and the comparison result between rectified data and true valued shows the DR module evaluation result. This article designs and develops an intelligent plant data reconciliation simulation evaluation platform based on the demands proposed previously and study further on such as component tracing and component-flow data reconciliation after the evaluation result analysis.The main contents of this article and innovation points are as follows:1) DR technology applications current situation in engineering and its main challenge are discussed and analyzed (especially about SMES-Sinopec MES). 2) According to the problems emerged in DR engineering application, DR system evaluation method based on simulation is proposed. Main evaluation method is as follow:field data, collect model-true value simulation, manufacturing data simulation contained error, SMES data reconciliation, comparison between DR result and true value, evaluation result.3) According to the process industry DR demands on simulation platform, Intelligent Plant Data Reconciliation Simulation Evaluation Platform is designed and developed.4) Process measurement simulation data generated by Evaluation Platform are used to evaluate SMES3.0 Data Balance module. According to the evaluation result, improvement suggestions are proposed and components, component-flow application in data reconciliation are discussed.