Automated Field Device Commissioning via Property-Based Test Routing
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Solution Overview
Problem
The current manual commissioning process for field devices in industrial plants is labor-intensive, prone to human errors, and requires significant manpower, especially when dealing with hazardous areas and multiple check functions, which can lead to inaccurate test results and increased time consumption.
Innovation Solution
A field device commissioning system that includes a commissioning tool configured to communicate with field devices and a repository, automating check functions such as connection, range comparison, linearization, input loop, and output loop checks by retrieving properties, performing specific tests based on device type, and generating tasks automatically, reducing the need for manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual commissioning process is used for field devices, then flexibility in performing check functions is maintained, but labor intensity and human errors increase significantly
Solution Approach 1:
The commissioning system performs self-testing and self-validation by automatically executing check functions, comparing results against predefined criteria, and generating commissioning reports without requiring manual intervention for each test step, thereby eliminating human errors while maintaining operational flexibility
Solution Approach 2:
The patent replaces manual mechanical commissioning operations with an automated electronic system that uses a commissioning tool to electronically execute check functions, retrieve device properties, and automatically compare results, substituting human labor with an automated computational system
2Reliability
If multiple check functions are performed manually on each field device, then thorough testing is achieved, but time consumption and manpower requirements increase
Solution Approach 1:
The system performs preliminary actions by pre-configuring multiple check functions and their criteria in the commissioning tool before field deployment, allowing automated execution of thorough testing sequences without manual setup time for each test, thereby maintaining testing completeness while accelerating the commissioning process
Solution Approach 2:
The commissioning tool continuously executes multiple check functions in an automated sequence without interruption, retrieving device properties, performing tests, and generating reports in a continuous workflow, eliminating the start-stop nature of manual commissioning and significantly improving productivity while maintaining thoroughness
3Ease of operation
If manual communication between control room and field operators is required during testing, then coordination is possible, but constant communication increases complexity and time consumption
Solution Approach 1:
The commissioning system performs self-coordination by automatically managing the entire commissioning workflow, including device connection, property retrieval, test execution, and result reporting, without requiring human operators to coordinate each step, thereby eliminating communication complexity while maintaining operational coordination
4Productivity
If automated commissioning system is implemented, then human errors are reduced and productivity increases, but system complexity increases
Solution Approach 1:
The commissioning tool is designed as a universal multi-functional device that can perform multiple check functions (connection checks, range comparison checks, linearization checks, input/output loop checks) across different field device types using a single integrated system, reducing the need for multiple specialized tools and justifying the automation complexity through enhanced productivity and efficiency
Data Source
AI summary
A field device commissioning system includes a commissioning tool, which is configured to communicate with a field device and a repository. The commissioning tool is configured to retrieve at least one property from a field device. The commissioning tool is configured to determine, from a registration file in the repository, if the retrieved at least one property is in the registration file. When the retrieved at least one property is determined to be in the registration file, perform a first test. When the retrieved at least one property is determined to be not in the registration file, determine, from a control system loop information file in the repository, if the retrieved at least one property is for a predetermined field device. When the retrieved at least one property is determined to be for the predetermined device, perform a second test different from the first test. When the retrieved property is determined to be not for the predetermined device, perform a third test different from the first and second tests.