APC Process Model Updating Through Remote Step-Test Diagnostics
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Solution Overview
Problem
Advanced process control (APC) engineering requires efficient management and diagnostic capabilities, particularly due to a scarcity of APC engineers and the need for remote operations, as existing systems lack centralized maintenance records and secure data transfer, leading to inefficiencies in problem-solving and resource utilization.
Innovation Solution
The system separates APC control and management responsibilities, pushing control layer capabilities to a lower level with operator functions at a higher level, incorporating maintenance records and asset health data, and utilizing a computer program product with modules for data collection, step testing, and secure communication to enhance diagnostics and maintenance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If APC engineers perform on-site diagnostics and maintenance, then problem-solving effectiveness is improved, but travel time and resource utilization efficiency deteriorate
Solution Approach 1:
The system creates a virtual copy of the APC engineer's diagnostic and maintenance capabilities through remote access functionality. The virtualized environment allows engineers to access and diagnose APC systems from any location, eliminating the need for physical travel while maintaining full diagnostic effectiveness through replicated system access.
Solution Approach 2:
A centralized virtualization platform serves as an intermediary between APC engineers and distributed APC control systems. This platform enables remote connection and diagnostics by mediating the interaction between the engineer's workstation and the target APC system, allowing effective problem-solving without physical presence.
2Adaptability or versatility
If APC control and management functions are distributed at unit level, then system autonomy is improved, but maintenance efficiency and manpower utilization deteriorate
Solution Approach 1:
The system merges multiple distributed APC control systems into a unified virtualized environment. By consolidating access to multiple APC systems through a single centralized platform, the system maintains the autonomy of individual control units while enabling efficient centralized management and diagnostics across all units.
Solution Approach 2:
The virtualization platform provides universal access capabilities that work across different APC control systems and locations. A single engineer account can access multiple diverse APC systems through the platform, making the maintenance tool universally applicable and significantly improving manpower utilization efficiency.
3Loss of information
If maintenance history and diagnostic data are stored locally at each APC system, then data availability is improved, but data security and centralized management capability deteriorate
Solution Approach 1:
The system extracts maintenance history and diagnostic data from local APC systems and stores them in a centralized secure repository. This extraction maintains data availability for diagnostics while improving security through centralized access control and protection mechanisms that are more robust than local storage capabilities.
Solution Approach 2:
The system implements feedback loops where diagnostic data flows from APC systems to the centralized platform for analysis, and maintenance history feeds back to inform future diagnostics. This centralized feedback mechanism ensures data security while maintaining full availability for engineering analysis and decision-making.
Data Source
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AI summary
A system and method for performing management and diagnostic functions in an advanced process control (APC) system (100). An APC management computer (112) retrieves (606) operating process data (444) from an APC control computer (150, 152) and performs an iterative step test (608) on the APC system. The iterative step test modifies at least one test parameter (448) of the operating process data and identifies changes to a set of remaining parameters of the operating process data resulting from modification of the test parameter. The APC management computer determines (610) at least one process variable (443) from the iterative step test and generates (614) at least one process model (352, 354, 356) based on the process variable. The APC management computer transmits (620) the process model to the APC control computer.