Level Field Device Validation Through Simulated Trigger Actuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for validating the operability and availability of level detecting field devices in control systems require manual intervention or extensive time, which is inefficient and not applicable to all types of controllers, especially electronic ones.
Innovation Solution
A method and system that utilize a controller to simulate the occurrence of an event trigger by actuating a movable component of the field device, allowing for remote and periodic validation of the device's operability without manual intervention, using an actuator and diagnostic module to monitor and analyze the device's response.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual validation techniques are used (visiting site to replicate liquid level rise/fall or manually manipulate field device), then field device operability can be validated, but validation time is extensive and manual intervention is required
Solution Approach 1:
The field device performs self-validation through automated diagnostic routines executed by the controller. The system validates its own operability by simulating event triggers and monitoring its response, eliminating the need for manual intervention and reducing validation time from extensive on-site procedures to rapid automated checks.
Solution Approach 2:
The controller simulates event triggers (such as liquid level changes) in advance to activate the field device before actual process conditions require it. This preliminary activation ensures the device is operational and ready, allowing validation to occur proactively rather than reactively during critical moments.
2Reliability
If liquid level is changed to engage the level detecting field device, then field device operability can be confirmed, but extensive time is required to raise or lower liquid to target level
Solution Approach 1:
The controller acts as an intermediary that simulates the effect of liquid level changes on the field device without actually changing the liquid level. By generating simulated event trigger signals, the controller activates the field device's response mechanism, allowing operability confirmation without the time-consuming physical manipulation of the process medium.
Solution Approach 2:
The physical mechanical action of raising or lowering liquid levels is replaced with electronic signal simulation. Instead of manipulating the physical process (liquid level changes), the system uses electronic event trigger signals to activate the field device, substituting mechanical/process manipulation with electronic control.
3Reliability
If manual manipulation of field device is performed to simulate tripping, then field device operability can be validated, but this method is not applicable to electronic devices that are not mechanical
Solution Approach 1:
The validation system is designed to be universal and applicable to multiple device types including both mechanical and electronic field devices. The controller generates appropriate event trigger signals that can activate various device mechanisms (mechanical switches, electronic sensors, solenoids), making the validation method versatile across different technology platforms without requiring device-specific manual manipulation techniques.
Solution Approach 2:
Manual mechanical manipulation of the field device is replaced with electronic event trigger signals generated by the controller. This substitution enables validation of electronic devices that cannot be manually manipulated, while still providing consistent operability verification across mechanical and electronic device types through a unified electronic control approach.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A system and method for validating the availability and operability of a liquid level control system in a process plant is provided. The liquid level control system comprises: a movable assembly including a bar, the bar of the movable assembly including a proximate end and a distal end; a displacer attached to the distal end of the bar; an actuator operatively connected to the movable assembly; a processor coupled to the actuator and capable of moving the displacer via the movable assembly; a sensor including an input and an output, the input of the sensor operatively coupled to the movable assembly for receiving an input signal representative of a characteristic of the displacer or an operating environment, the output of the sensor operatively coupled to the processor for providing an output signal associated with the input signal; a memory coupled to the processor;an actuating module stored on the memory, which when executed on the processor, actuates the actuator; an output device coupled to the processor; and an exhibiting module stored on the memory, which when executed on the processor, exhibits the output signal of the sensor on the output device.