APL Field Interface with Safe Power Distribution in Hazardous Areas
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing field devices in process plants face high investment costs and inefficiencies when upgrading to Advanced Physical Layer (APL) technology, which is necessary for safe data transmission in explosion-prone areas, and existing solutions like Power over Ethernet are not economically viable for complete plant upgrades.
Innovation Solution
A field device with a power distributing data switching device that includes a primary connection for high power consumption and multiple secondary connections for low power data communication, housed in a dust- and water-proof enclosure with a protective bridge for safe power and data transfer, allowing for cost-effective and safe operation in explosion-prone environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If APL technology is used for data transmission in explosion-prone areas, then safety and data transmission capability are improved, but investment costs and device complexity increase
Solution Approach 1:
The field device is segmented into multiple independent connection interfaces: a first connection for high-power APL communication and second connections for low-power intrinsically safe devices. This segmentation allows the complex APL technology to be isolated to specific components while keeping other parts simple and safe.
Solution Approach 2:
A power distribution unit acts as an intermediary between the APL connection and intrinsically safe devices. This mediator distributes power from the high-power APL interface to multiple low-power safe interfaces, enabling safe operation in hazardous areas while maintaining access to high-power APL technology.
2Ease of operation
If Power over Ethernet technology is used to supply power and data, then ease of operation and data transmission speed are improved, but power density and suitability for explosion-prone areas worsen
Solution Approach 1:
Different connection interfaces provide different power densities tailored to their specific needs: the APL connection provides high power density for devices requiring more energy, while intrinsically safe connections provide low power density suitable for hazardous areas. Each interface has optimized local characteristics for its intended application.
3Power
If multiple field devices are connected with individual power supply cables, then power distribution capability is improved, but device complexity and installation effort increase
Solution Approach 1:
Multiple intrinsically safe field devices are merged into a single field device through the power distribution unit. This allows multiple devices to share a common APL connection while maintaining individual low-power safe connections, reducing overall installation complexity and cable requirements.
Solution Approach 2:
The field device incorporates multiple functions: it serves as both an APL communication node and a power distribution hub for multiple intrinsically safe devices. This multi-functionality reduces the need for separate dedicated devices for each function, simplifying the overall system architecture.
Data Source
AI summary
A field device for a process plant, may include a power distributing data switch having an electrical primary connection to consume power at a first power level higher than 10W, and at least two electrical secondary connections for combined data communication and power transfer at a second power level of lower than 10W per secondary connection. The field device may also include a housing to accommodate electrical components safe from dust and/or water, which forms a first housing compartment fitted for pressure proof enclosure of electrical components in an environment with explosive or flammable atmosphere and which accommodates the primary connection. The secondary connections may be arranged outside a pressure proof enclosure and outside the first housing compartment. The device may include a protective bridge to isolate leads out of the first housing compartment to connect the primary connection to the secondary connections.