Alarm Analysis System for Real-Time Process Control Statistics
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Solution Overview
Problem
Traditional alarm management systems in process control systems are complex, costly, and do not provide real-time updates, requiring external databases and manual initiation of statistics calculations, which complicates operator decision-making and increases licensing costs.
Innovation Solution
An alarm analysis system integrated within the process control system's alarm server, capable of automatically generating real-time statistics and key performance indicators directly from stored alarms, eliminating the need for external databases and manual updates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If an external alarm management system is used to analyze alarms and provide statistics, then alarm analysis capability is improved, but device complexity and licensing costs increase
Solution Approach 1:
The patent combines the alarm management functionality with the existing process control system by integrating an alarm manager into the control computer. This merging eliminates the need for a separate external alarm management system, reducing device complexity and licensing costs while maintaining alarm analysis capability. The alarm manager receives alarms from the control system and provides statistics and reports directly within the existing system infrastructure.
2Quantity of substance
If an external database is installed with the control system to store alarms, then alarm storage capability is improved, but device complexity and installation time increase
Solution Approach 1:
The patent makes the existing process control computer serve multiple functions by enabling it to not only control the process but also manage and analyze alarms. The control computer is enhanced to function as both a control system and an alarm management system, eliminating the need for separate external database installations and reducing overall system complexity.
3Use of energy by moving object
If manual initiation of statistics calculation is used, then system resource consumption is reduced, but productivity and real-time capability deteriorate
Solution Approach 1:
The patent implements a dynamic approach where the alarm manager can automatically generate statistics and reports in real-time based on current alarm conditions, while also allowing operators to manually request specific statistics when needed. This dynamic capability enables the system to adapt between automatic real-time monitoring and on-demand analysis, improving productivity without excessive resource consumption.
4Ease of operation
If alarms are sorted into different alarm lists for different operators, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The patent segments the alarm information by creating separate alarm lists tailored to different operators' responsibilities. Each operator receives only the alarms relevant to their specific process sections, improving ease of operation. The system automatically segments and filters alarms based on operator assignments, making the interface user-friendly without requiring complex manual configuration by operators.
Data Source
AI summary
An alarm analysis system for providing statistics on alarms collected by a process control system including an alarm server receiving and storing alarms from one or more processes supervised by the control system. The alarm analysis system is run on the alarm server and the alarm analysis system is adapted to automatically produce and display the statistics in real time based on the alarms stored in the alarm server.