Method and system to resolve inconsistencies in a process control system

摘要

System for resolution of inconsistencies in process control systems, comprising: executing a first model of an entity in a controller 12, executing a second model of the entity in an execution engine 30, detecting a difference between the models, generating a prompt and receiving an operation instruction to continue or abort the process. The prompt comprises identification or display of the difference between the models of the entity. A control parameter is transmitted to a process control model and an error is generated when the parameter is not usable with a second version of a process control model. The operating instruction is from a control process or a user. The instruction to continue uses a universal, default, or previous parameter. The process is a batch process. The entity can be the phase logic module 708 used to perform a task, such as mix, transfer, or heat. Module 708 groups control modules 702-706, which can correspond to valves and pumps to move a product from one reactor, comprising filters and dyers, to another. Oversight may lead to inconsistency between equipment models known by controllers 12 and engine 30. The resolution technique of the invention reconciles the situation, reducing lost production time.