Cloud APC Management System for Remote Diagnostics
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Solution Overview
Problem
Advanced process control (APC) engineering is a complex and time-consuming task, exacerbated by a scarcity of APC engineers and the need for efficient maintenance and diagnostics in industrial process control systems, where existing model files lack maintenance history, leading to inefficiencies and redundant problem-solving efforts.
Innovation Solution
A cloud computing system is implemented to separate APC control and management responsibilities, with the APC management computer performing iterative step tests, generating process models, and transmitting them to the APC control computer, while maintaining records for asset health and diagnostics, enabling remote capabilities and centralized control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If APC engineers perform on-site maintenance and diagnostics, then they can directly assess and resolve system issues, but travel time increases and engineer availability decreases
Solution Approach 1:
The patent creates a virtual copy of the APC system by collecting and transmitting process data, controller outputs, and system responses to a remote location. This digital replica allows engineers to perform diagnostics and step tests remotely, obtaining the same diagnostic information as on-site without requiring physical travel to the facility.
Solution Approach 2:
The patent introduces communication devices and data transmission systems as intermediaries between the APC system and the engineer. These intermediaries transmit process data, controller responses, and diagnostic information over networks, enabling remote interaction with the system while maintaining diagnostic accuracy without requiring engineer presence at the physical location.
2Device complexity
If APC control and management functions are integrated, then system operation is simplified, but maintenance history and diagnostic capabilities are lost
Solution Approach 1:
The patent segments the APC system into distinct functional components: the control computer that executes control algorithms, the management computer that handles diagnostics and data collection, and the communication devices that transmit data between them. This segmentation allows maintenance history and diagnostic information to be preserved in the management computer while the control computer focuses on real-time control operations.
Solution Approach 2:
The patent introduces communication devices as intermediaries that connect the control computer and management computer. These intermediaries enable the management computer to access and analyze maintenance history and process data from the control computer without interfering with control operations, thus preserving diagnostic capabilities while maintaining operational simplicity.
3Loss of time
If engineers work remotely using data transmission, then travel time is reduced, but secure data transfer requirements increase
Solution Approach 1:
The patent employs communication devices as secure intermediaries that transmit data between the APC system and remote engineers. These intermediaries implement secure data transfer protocols, encrypting sensitive process data, controller outputs, and diagnostic information during transmission over networks, thus enabling remote work while maintaining data security and integrity.
Data Source
AI summary
A system and method for performing management and diagnostic functions in a cloud computing system for advanced process control (APC). A cloud based APC management computer retrieves operating process data from an APC control computer and performs an iterative step test on the APC system. The iterative step test modifies at least one test parameter 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 at least one process variable from the iterative step test and generates at least one process model based on the process variable. The APC management computer transmits the process model to the APC control computer.