Loop Test Signal Verification for Plant Pass-Fail Determination
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Solution Overview
Problem
During loop tests of plants, workers face difficulties in determining whether the plant passes or fails due to the complex interactions between field devices and monitor devices, as the test signals generated by field devices and the test result signals output by monitor devices do not directly indicate the relationship between the two, especially with various equipment and controls involved.
Innovation Solution
A verification program and apparatus that acquires test and result information, including clock time and worker information, to verify the relationship between test signals and result signals by performing predetermined operations, changes, or selections on the signals generated by field devices before they are output from monitor devices, thereby establishing a clear pass/fail determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If workers manually compare test signals and test result signals in complex plant systems with various equipment and controls, then they can perform loop tests, but they cannot accurately determine whether the plant passes or fails the test
Solution Approach 1:
The patent introduces a verification apparatus as an intermediary system between the field device and monitor device. This apparatus includes a verification unit that automatically compares test signals and test result signals, determining pass/fail status. The intermediary system handles the complexity of signal comparison and relationship verification, freeing workers from manual analysis while ensuring accurate determination of test outcomes despite complex plant system configurations.
Solution Approach 2:
The patent replaces the manual mechanical comparison process with an automated electronic verification system. The verification apparatus uses electronic signal processing and automated comparison algorithms to substitute the worker's manual signal comparison. This mechanical-to-electronic substitution enables precise automated determination of test results, overcoming the limitations of human analysis in complex signal environments.
2Adaptability or versatility
If various equipment and controls are installed between field device and monitor device, then the plant can perform complex operations, but the relationship between test signal and test result signal becomes indeterminate
Solution Approach 1:
The verification apparatus implements a feedback mechanism that automatically captures and analyzes the relationship between test signals and test result signals passing through various equipment and controls. The verification unit receives signals from both devices and systematically determines their relationship, providing feedback information about pass/fail status. This feedback system preserves signal relationship information despite the presence of multiple intermediate equipment and controls, enabling accurate verification while maintaining plant operational flexibility.
3Reliability
If workers perform manual signal comparison in complex plant systems, then they can conduct loop tests, but the determination process becomes time-consuming and error-prone
Solution Approach 1:
The verification apparatus enables self-service automated verification by systematically performing signal comparison and relationship determination without requiring worker intervention. The verification unit automatically processes test signals and test result signals, determining pass/fail status independently. This self-service capability eliminates manual comparison steps, reducing verification time and eliminating human errors while maintaining high reliability in test determination.
Data Source
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AI summary
Provided is a verification program, wherein the verification program is executed by computer and causes the computer to function as: a test information acquisition unit which acquires test information showing a test signal generated by a field device installed in a plant; a result information acquisition unit which acquires result information showing a test result signal output by a monitor device installed in the plant in response to the field device generating the test signal; and a verification unit which verifies, based on the test information and the result information, whether or not a relationship is established between the test signal and the test result signal, the relationship depending on a performed change of a signal that is generated by the field device and output from the monitor device before the signal is output from a monitor device.