Digital Safety Locks for Remote Industrial Equipment Isolation
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Solution Overview
Problem
Traditional lockout-tagout (LOTO) procedures in industrial process plants are inconvenient and unsafe, as they require physical access to equipment, can be compromised by lost or forgotten keys, and do not account for the complex ownership and communication link relationships in modern process control systems.
Innovation Solution
A digital safety lock system that uses a processor-based digital safety lock with identification of a locking party, a digital safety lock key, and a mode or state, allowing secure isolation of field devices from run-time operations without physical presence, and enabling secure access and control in a multi-client environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional physical lockout-tagout procedures are used, then equipment can be isolated from run-time operations, but physical access to equipment is required and safety is compromised by lost or forgotten keys
Solution Approach 1:
The patent replaces the mechanical physical lockout-tagout system with a digital safety lock system implemented in software or firmware within the process controller. The digital safety lock uses electronic authentication (passwords, cryptographic keys) instead of physical keys, eliminating the need for physical access to equipment while maintaining isolation capabilities. The system stores locking party identification and authentication credentials in memory, allowing remote or contactless locking and unlocking operations.
Solution Approach 2:
The patent creates a digital replica of the physical lockout function through software-based safety locks. Multiple digital safety locks can be applied to the same process control device, each associated with a different locking party. The system maintains copies of authentication credentials and locking states in memory, enabling the locking party to lock the device without physical presence and allowing authorized parties to unlock it by providing the correct digital authentication.
2Reliability
If physical keys are used for lockout-tagout, then equipment can be secured, but access is blocked when the locking party is unavailable
Solution Approach 1:
The digital safety lock system enables self-service unlocking through automated authentication. When a party needs access to a locked process control device, they provide their authentication credentials (password, cryptographic key) to the controller, which automatically verifies them and unlocks the device if authorized. This eliminates the need to contact or physically locate the original locking party, allowing immediate access when authentication succeeds.
Solution Approach 2:
The process controller acts as an intermediary between the locking party and the equipment. The controller stores the locking party's identification and authentication credentials in its memory, creating a persistent digital record that outlives the locking party's physical presence. This intermediary storage mechanism allows any authorized party to unlock the device by presenting credentials, without needing to contact the original locking party.
3Ease of operation
If digital safety locks are implemented, then secure access is provided without physical presence, but the system complexity increases
Solution Approach 1:
The patent implements a universal digital safety lock system within the process controller that can be applied to multiple different process control devices. The same authentication mechanism and locking logic work across various device types (valves, switches, transmitters). The controller's existing processing unit and memory are utilized to implement the digital safety lock functionality, avoiding the need for separate dedicated locking hardware for each device.
Solution Approach 2:
The digital safety lock functionality is merged with the existing process control system. The authentication credentials, locking states, and safety lock logic are integrated into the controller's memory and processing unit, combining multiple functions (process control, data storage, authentication, locking) into a single unified system rather than requiring separate dedicated components.
Data Source
AI summary
A digital safety lock of a field device or other process plant equipment activates in response to receiving a request from a locking party, thereby placing the device into a locked mode. While the device is in the locked mode, only the locking party may perform maintenance activities on, or otherwise functionally control, the device. While locked, the device may provide an indication of the locking party to any other device or application attempting to access or control the locked device. Other devices, applications, and users may communicate with the locking party or locking party device to request that the device be unlocked and/or to request the corresponding digital safety lock key. Upon the device receiving the correct digital safety lock key, the digital safety lock may be deactivated, and the device may enter into an unlocked state if no other digital safety locks remain activated for the device.