Seppo Sierla

Mohammad Azangoo, Joonas Salmi, Iivo Yrjölä et al.

Making an updated and as-built model plays an important role in the life-cycle of a process plant. In particular, Digital Twin models must be precise to guarantee the efficiency and reliability of the systems. Data-driven models can simulate the latest behavior of the sub-systems by considering uncertainties and life-cycle related changes. This paper presents a step-by-step concept for hybrid Digital Twin models of process plants using an early implemented prototype as an example. It will detail the steps for updating the first-principles model and Digital Twin of a brownfield process system using data-driven models of the process equipment. The challenges for generation of an as-built hybrid Digital Twin will also be discussed. With the help of process history data to teach Machine Learning models, the implemented Digital Twin can be continually improved over time and this work in progress can be further optimized.

Thimal Kempitiya, Seppo Sierla, Daswin De Silva et al.

The global ambitions of a carbon-neutral society necessitate a stable and robust smart grid that capitalises on frequency reserves of renewable energy. Frequency reserves are resources that adjust power production or consumption in real time to react to a power grid frequency deviation. Revenue generation motivates the availability of these resources for managing such deviations. However, limited research has been conducted on data-driven decisions and optimal bidding strategies for trading such capacities in multiple frequency reserves markets. We address this limitation by making the following research contributions. Firstly, a generalised model is designed based on an extensive study of critical characteristics of global frequency reserves markets. Secondly, three bidding strategies are proposed, based on this market model, to capitalise on price peaks in multi-stage markets. Two strategies are proposed for non-reschedulable loads, in which case the bidding strategy aims to select the market with the highest anticipated price, and the third bidding strategy focuses on rescheduling loads to hours on which highest reserve market prices are anticipated. The third research contribution is an Artificial Intelligence (AI) based bidding optimization framework that implements these three strategies, with novel uncertainty metrics that supplement data-driven price prediction. Finally, the framework is evaluated empirically using a case study of multiple frequency reserves markets in Finland. The results from this evaluation confirm the effectiveness of the proposed bidding strategies and the AI-based bidding optimization framework in terms of cumulative revenue generation, leading to an increased availability of frequency reserves.

Seppo Sierla, Mohammad Azangoo, Alexander Fay et al.

Ongoing standardization in Industry 4.0 supports tool vendor neutral representations of Piping and Instrumentation diagrams as well as 3D pipe routing. However, a complete digital plant model requires combining these two representations. 3D pipe routing information is essential for building any accurate first-principles process simulation model. Piping and instrumentation diagrams are the primary source for control loops. In order to automatically integrate these information sources to a unified digital plant model, it is necessary to develop algorithms for identifying corresponding elements such as tanks and pumps from piping and instrumentation diagrams and 3D CAD models. One approach is to raise these two information sources to a common level of abstraction and to match them at this level of abstraction. Graph matching is a potential technique for this purpose. This article focuses on automatic generation of the graphs as a prerequisite to graph matching. Algorithms for this purpose are proposed and validated with a case study. The paper concludes with a discussion of further research needed to reprocess the generated graphs in order to enable effective matching.

Seppo Sierla, Ville Kyrki, Pekka Aarnio et al.

This paper proposes a new concept in which a digital twin derived from a digital product description will automatically perform assembly planning and orchestrate the production resources in a manufacturing cell. Thus the manufacturing cell has generic services with minimal assumptions about what kind of product will be assembled, while the digital product description is designed collaboratively between the designer at an OEM and automated services at potential manufacturers. This has several advantages. Firstly, the resulting versatile manufacturing facility can handle a broad variety of products with minimal or no reconfiguration effort, so it can cost-effectively offer its services to a large number of OEMs. Secondly, a solution is presented to the problem of performing concurrent product design and assembly planning over the organizational boundary. Thirdly, the product design at the OEM is not constrained to the capabilities of specific manufacturing facilities. The concept is presented in general terms in UML and an implementation is provided in a 3D simulation environment using Automation Markup Language for digital product descriptions. Finally, two case studies are presented and applications in a real industrial context are discussed.

Miia Rantala, Hannu Niemistö, Tommi Karhela et al.

This article investigates how graph matching can be applied to process plant design data in order to support the reuse of previous designs. A literature review of existing graph matching algorithms is performed, and a group of algorithms is chosen for further testing. A use case from early phase plant design is presented. A methodology for addressing the use case is proposed, including graph simplification algorithms and node similarity measures, so that existing graph matching algorithms can be applied in the process plant domain. The proposed methodology is evaluated empirically on an industrial case consisting of design data from several pulp and paper plants.

Eero Siivola, Seppo Sierla, Hannu Niemistö et al.

The emergence of the Industrial Internet results in an increasing number of complicated temporal interdependencies between automation systems and the processes to be controlled. There is a need for verification methods that scale better than formal verification methods and which are more exact than testing. Simulation-based runtime verification is proposed as such a method, and an application of Metric temporal logic is presented as a contribution. The practical scalability of the proposed approach is validated against a production process designed by an industrial partner, resulting in the discovery of requirement violations.