Plant Control Data Comparison for Safe Online Engineering Updates
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Solution Overview
Problem
In industrial plants, frequent changes to engineering data require online maintenance to minimize operational disruptions, but this can lead to malfunctions due to human errors and data mismatch issues between replicated and on-site control systems, especially with increasing complexity and scale.
Innovation Solution
An engineering apparatus and method that accurately identifies change points for data reflection, reducing errors by comparing data files between replicated and on-site systems, and ensuring data integrity through differential file analysis and mismatch detection before updating the on-site system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If online maintenance is performed to correct engineering data without stopping plant operation, then productivity is improved, but reliability deteriorates due to malfunctions from human errors and data mismatch
Solution Approach 1:
The patent creates a replicated control system that copies the on-site control system's configuration and engineering data. This replica serves as a safe environment for online maintenance operations, allowing engineers to modify engineering data without directly affecting the running plant. The replica is continuously synchronized with the on-site system, enabling validation of changes before application.
Solution Approach 2:
The patent performs maintenance operations in advance on the replicated control system before applying changes to the on-site system. Engineers can complete engineering work, including data correction and system modifications, in the replica environment first. Only after verifying that no malfunctions occur does the system proceed to apply changes to the actual plant control system.
2Adaptability or versatility
If engineering data is corrected frequently to adapt to changing business environments, then adaptability is improved, but reliability deteriorates due to increased risk of malfunctions
Solution Approach 1:
The replicated control system provides a dedicated environment for frequent engineering operations. Business environment changes can be accommodated by modifying engineering data in the replica system without risking the stability of the on-site system. The copy enables safe experimentation and adaptation.
Solution Approach 2:
The system continuously monitors for malfunctions in the replicated control system after engineering operations. When no malfunctions are detected, feedback confirms that changes can be safely applied to the on-site system. This feedback mechanism enables frequent adaptations while maintaining reliability through continuous validation.
3Adaptability or versatility
If the scale and complexity of control systems increase to handle larger plants, then adaptability is improved, but device complexity increases leading to more malfunctions
Solution Approach 1:
The patent divides the control system into two separate segments: the on-site control system that manages actual plant operations and the replicated control system used for engineering and validation. This segmentation isolates complexity, allowing the replica to handle complex engineering operations without directly impacting the operational system's stability.
4Loss of information
If differential files are manually extracted and transferred between systems, then data transition is achieved, but loss of information occurs due to human errors
Solution Approach 1:
The patent replaces manual mechanical operations (physical file extraction, transfer, and integration) with automated electronic processes. The engineering data determination unit automatically identifies differential files, and the transfer unit electronically transmits them between systems. This substitution eliminates human errors in data handling while maintaining efficient data transition.
Solution Approach 2:
The replicated control system and on-site control system automatically synchronize through the engineering apparatus. The system self-manages the detection, extraction, transfer, and integration of differential files without requiring manual intervention, thereby preventing human errors while maintaining operational efficiency.
Data Source
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AI summary
An engineering apparatus that is used for supporting engineering of facilities in an industrial plant according to one aspect of the present invention includes a storage storing a first data file group including first data files, the first data files including element information indicating one or a plurality of functional blocks that are constituent elements of a control logic for controlling operation of the industrial plant, a processor configured to change the element information included in the first data files, and a determiner configured to acquire a second data file group including second data files, the second data files including the changed clement information in another engineering apparatus, extract differential files including the changed element information from each of the first data file group and the second data file group, and determine whether there is mismatching between functional blocks indicated by the element information included in the differential files.