Actuation Fluid Shut-Off for Fail-Safe Process Control
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Solution Overview
Problem
Process engineering systems face security risks due to increasing hacker attacks, which can compromise the control and regulation of complex processes, potentially leading to damage if unauthorized access gains control of actuation units.
Innovation Solution
The method involves using externally controlled actuation units that assume a safe state by reducing the supply of operating fluid, employing a shut-off or pressure reducing device in the supply line to quickly and effectively bring multiple actuation units into a fail-safe position, preventing damage from hacker attacks or malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If electronically controlled actuating units are used to control process parameters, then control precision and automation are improved, but vulnerability to hacker attacks and cyber threats increases
Solution Approach 1:
The system divides the actuation control into two independent parts: an electronic control unit for normal operation and a mechanically operated manual override device for emergency situations. This segmentation isolates the electronic system from potential cyber threats while maintaining automation benefits during normal operation.
Solution Approach 2:
A manual override device with mechanical connection to the actuating unit serves as an intermediary that can physically disrupt the operation of electronically controlled actuators. This mechanical intermediary provides a non-electronic means to bring actuators to a safe state, bypassing vulnerable electronic control systems.
2Device complexity
If multiple actuating units are controlled through a common supply line, then system complexity is reduced, but the ability to individually control each actuator is compromised
Solution Approach 1:
The manual override device is designed with multiple independent operating elements (such as multiple valves or control mechanisms) that can individually affect different actuators. This allows selective control of individual actuators while maintaining the common supply line architecture, achieving both simplicity and versatility.
Solution Approach 2:
The manual override device serves multiple functions: it can control individual actuators selectively, control multiple actuators simultaneously, and provide a mechanical backup to electronic control. This multi-functionality allows a single device to handle various control scenarios without increasing system complexity.
3Reliability
If actuating units are designed to assume safe state upon fluid supply failure, then safety is improved, but control flexibility is reduced
Solution Approach 1:
The manual override device acts as an intermediary that can actively manipulate the fluid supply to actuators, enabling controlled transitions to safe states rather than passive failure-based transitions. This maintains safety while adding active control flexibility.
Solution Approach 2:
The manual override device allows operators to proactively bring actuators to safe states before actual failures occur, or to prepare the system for potential failures. This preliminary action capability enhances both safety and control flexibility by allowing planned safety transitions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for rapid and secure transition of process engineering systems into a safe state, minimizing damage by actively reducing the operating fluid supply, thereby ensuring system safety even in large and complex systems.
Implementation Method 1
externally controlled, for example electronically or electrically, actuating units are used to control and/or regulate and/or monitor process parameters by means of a pressurized operating fluid
Implementation Method 2
Several actuating units are now supplied with operating fluid via a supply line connecting a common supply unit to the actuators
Data Source
Figure 1~2
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AI summary
The invention relates to a method for operating a process engineering system (100) in which actuation units (140) which are externally driven and are operated using actuators by means of a pressurized operating fluid (e) are used to control and/or regulate and/or monitor process parameters (a, b, c) and are each configured to assume a safe state in the absence of a sufficient supply of the operating fluid (e), wherein a plurality of the actuation units (140) are supplied with the operating fluid (e) via a supply line (135) between a common supply unit (130) and the plurality of actuation units (140), and wherein the supply of the operating fluid (e) to the plurality of actuation units (140) is actively reduced if necessary at least to such an extent that said actuation units each assume the safe state, and to an actuation system (120) and a process engineering system (100).