Layered Process Data Distribution for Secure Mobile Plant Access
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Solution Overview
Problem
Existing distributed process control systems lack the ability for real-time, secure access to process data outside the plant premises, limiting situational awareness and causing discontinuities during shift changes, which can impact product quality, efficiency, safety, and compliance.
Innovation Solution
A system that securely disseminates process data from a process control node to remote computing devices via a mobile server, allowing real-time communication and access to process data, alarms, and notifications on mobile devices, while maintaining network security through a layered architecture and secure data transmission protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If process control data is made accessible outside the plant premises, then real-time situational awareness is improved, but network security is compromised
Solution Approach 1:
The patent introduces multiple intermediary components including a data highway, gateway server, and web server that act as secure buffers between the process control system and external networks. These intermediaries enable remote access to process data while maintaining network security by preventing direct connections to the control system.
Solution Approach 2:
The network architecture is segmented into multiple isolated layers: the process control network, the data highway network, and the external network. This segmentation allows process data to be accessed remotely while maintaining security boundaries that prevent unauthorized access to the control system.
2Ease of operation
If centralized hardware devices are used for process monitoring, then data security is maintained, but real-time remote access is limited
Solution Approach 1:
The web server acts as an intermediary that converts process control data into web-compatible formats accessible by mobile devices, enabling remote access without requiring physical presence in control rooms and eliminating response delays during shift changes.
Solution Approach 2:
The patent replaces the mechanical requirement of physical presence at centralized hardware devices with electronic web-based access through mobile devices, allowing operators to monitor and respond to process conditions from any location in real-time.
3Ease of operation
If direct network connection is provided to mobile devices, then ease of access is improved, but system complexity increases
Solution Approach 1:
The web server provides a universal interface using standard web protocols that can be accessed by any mobile device with a web browser, eliminating the need for device-specific applications or complex custom network configurations while maintaining ease of access.
4Loss of information
If process data is transmitted to external networks, then operational awareness is improved, but data transmission security is compromised
Solution Approach 1:
The data transmission path is segmented into isolated network zones with controlled data flow. Process data is transmitted through multiple secure layers (data highway, gateway server, web server) with unidirectional communication that prevents external networks from accessing or corrupting the control system while maintaining information availability.
Data Source
AI summary
A system for securely disseminating information relating to a process control plant includes a process control node and a controller that is coupled to a plurality of process control devices. The process control node includes a communicator module operable to transmit, via a first network, information of the process plant received from the controller. The system also includes a data services module operable to receive from the communicator module, via the first network, the information of the process plant and to transmit some or all of that information via a second network, and a mobile server, coupled to the second network and to a third network, and operable to receive data from the data services module. The mobile server is operable to communicate with a plurality of mobile computing devices via the third network.