Modular Process Plant Monitoring with Multi-Level KPI Alarm Views
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Solution Overview
Problem
Modular process plants require improved visualization and easier identification of malfunctions due to frequent reconfigurations and the inability of existing systems to display key performance indicators (KPIs) and efficiently trace alarm causes in complex industrial settings.
Innovation Solution
A method for monitoring modular process plants that uses multiple zooming levels on an operator screen to display aggregated KPIs, process modules, and control objects, with alarm aggregation and visualization to reduce information overload and facilitate quick identification of malfunctions, allowing operators to switch between levels for detailed information and overview.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If detailed information about all control objects is displayed on the operator screen, then operators can access comprehensive data, but information overload occurs making it difficult to locate malfunctions
Solution Approach 1:
The operator screen is divided into multiple zooming levels that segment information hierarchically. Level 1 displays aggregated KPIs for the entire plant, Level 2 segments by process modules, Level 3 segments by control objects within modules, and Level 4 provides detailed control object information. This segmentation allows operators to access comprehensive data when needed while maintaining a clean overview at higher levels.
Solution Approach 2:
The system adds a temporal dimension to information display by showing historical trends of KPIs alongside current values. This allows operators to understand not just the current state but also the evolution of parameters over time, providing context for malfunction analysis without cluttering the interface with excessive static data.
2Ease of operation
If aggregated KPIs are displayed at high level, then overview is improved, but detailed information about specific control objects becomes inaccessible
Solution Approach 1:
The operator interface is designed as a dynamic, multi-level zooming system where operators can navigate between aggregation levels in real-time. The system dynamically adjusts the level of detail displayed based on the operator's zoom level, maintaining an clean overview at Level 1 while allowing instant access to detailed control object data at Level 4 through sequential zooming operations.
3Loss of information
If multiple alarm signals are displayed simultaneously, then complete alarm information is provided, but it becomes difficult to trace the root cause of malfunctions
Solution Approach 1:
Alarm signals are nested hierarchically across the four zooming levels. Level 1 shows aggregated alarm status for the entire plant, Level 2 nests alarms by process module, Level 3 nests by control object, and Level 4 provides detailed alarm information. This nested structure allows operators to trace alarm propagation from the root cause upward through the system hierarchy, displaying complete alarm information in an organized, traceable manner.
4Adaptability or versatility
If traditional display screens are used for modular process plants, then existing systems can be utilized, but they cannot efficiently handle frequent reconfigurations and KPI visualization
Solution Approach 1:
The operator interface is designed as a universal system that can display and adapt to any modular process plant configuration. The four-level zooming structure is agnostic to specific plant layouts or configurations, allowing the same interface framework to handle frequent reconfigurations. KPI visualization is integrated at each zooming level, making the system versatile for different operational contexts while maintaining ease of use.
Data Source
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AI summary
A Method of monitoring a modular process plant complex (1) comprising a plurality of interconnected process modules (PM1.1 to PM 3.N) each of which includes a plurality of interconnected physical control objects (4), wherein the physical control objects (4) and their interconnections inside a physical process module (PM1.1 to PM 3.N) are displayed together with associated control parameters as stylized control objects on an operator screen display (10) in different zooming levels (ZL1 to ZL4), is characterized in that in a first zooming level (ZL1) with least detail information, diagrams of aggregated key performance indicators (12.1.1 to 12.3.3) of the plant complex (1) are displayed on said operator screen display (10), said aggregated key performance indicators (12) being aggregations of associated key performance indicators (14) of physical process modules (PM1.1 to PM3.N) which are located in different plant areas (PA1.1 to PA3.3), in a second zooming level (ZL2) diagrams of said key performance indicators (14) are displayed together with stylized images of the associated plant areas (PA1.1 to PA 3.3) on said operator display screen (10), in a third zooming level (ZL3), the process modules (PM1.1 to PM3.N) associated to a plant area (PA1.1 to PA 3.3) of said second zooming level (ZL2) and the physical control objects (4) included in each of said process modules (PM1.1 to PM 3.N) are displayed as stylized process modules (PM1.1 to PM3.N) and stylized control objects (4) in a stylized view of said plant area (PA1.1 to PA 3.3), and in a fourth zooming level (ZL4), one or more physical control objects (4) included in a process module (PM1.1 to PM 3.N) of said third zooming level (ZL3) are displayed together with the associated control parameters and interconnections as stylized control objects (4) on the operator screen display (10).