3D Plant Fault Monitoring With Multi-Sensor Remote Localization
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Solution Overview
Problem
Existing plant monitoring systems in LNG liquefaction plants require operators to physically respond to detected faults, which can lead to undetected issues in unexpected locations and inefficient response processes.
Innovation Solution
A plant-monitoring system that utilizes a network of detection elements (sound, vibration, gas, flame, smoke, and image sensors) to remotely identify fault locations and directions, allowing for remote operation and response through a processing computing unit and storage unit, enabling detailed fault analysis and remote handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If operators physically respond to detected faults by rushing to the fault location, then immediate fault handling is achieved, but operator safety is compromised and faults in unexpected locations may be missed
Solution Approach 1:
The patent creates a virtual replica of the physical plant environment through a three-dimensional model that integrates real-time data from multiple detection elements. This virtual copy allows operators to remotely observe and analyze faults without physically approaching hazardous locations, thus maintaining operator safety while ensuring comprehensive fault detection across the entire plant region.
Solution Approach 2:
The system introduces a virtual reality interface as an intermediary between the operator and the physical fault location. Instead of directly approaching the fault, operators interact with a virtual representation that provides detailed spatial and contextual information, enabling safe remote diagnosis and response while maintaining high detection reliability.
2Speed
If operators stand by in the vicinity for immediate response, then quick fault handling is enabled, but the monitoring coverage is limited to nearby areas
Solution Approach 1:
The patent transitions from two-dimensional plan monitoring to three-dimensional immersive virtual reality monitoring. This dimensional enhancement allows operators to perceive spatial relationships and fault locations throughout the entire plant volume, dramatically expanding monitoring coverage while maintaining rapid response capabilities through intuitive navigation in the virtual environment.
3Measurement precision
If detailed fault information is obtained by physical inspection at the fault location, then accurate fault analysis is achieved, but response time is increased and operator exposure to hazards occurs
Solution Approach 1:
The system performs preliminary actions by continuously collecting and integrating data from multiple detection elements (acoustic, vibration, gas, flame, smoke sensors) before a fault occurs or immediately upon detection. This pre-positioned information network provides operators with detailed fault characteristics remotely, eliminating the need for time-consuming physical inspection while maintaining high analysis precision.
4Reliability
If multiple detection elements are deployed throughout the plant, then comprehensive fault detection is achieved, but system complexity increases
Solution Approach 1:
The patent merges data from multiple heterogeneous detection elements (acoustic sensors, vibration sensors, gas detectors, flame detectors, smoke sensors) into a unified three-dimensional virtual model. This integration consolidates the complexity of managing multiple separate detection systems into a single coherent virtual reality interface, maintaining comprehensive detection coverage while simplifying operator interaction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables remote learning and detailed analysis of faults across a wide plant region, allowing for efficient and timely responses without the need for immediate operator intervention, improving fault detection and handling processes.
Implementation Method 1
a sound detector detecting volume and frequency
Implementation Method 2
a vibration detector detecting amplitude and frequency of vibration
Implementation Method 3
a gas detector detecting occurrence of gas
Implementation Method 4
a flame detector detecting occurrence of flame
Implementation Method 5
a smoke sensor detecting occurrence of smoke
Implementation Method 6
an infrared imager acquiring an image of an infrared region
Implementation Method 7
a visible imager acquiring an image of a visible region
Data Source
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AI summary
Provided are a plant-monitoring system and monitoring method that can ascertain remotely and in detail the incidence of a fault in a plant device, and perform a process in response to the incidence of the fault from a remote location. Provided are: at least one type of detection element for monitoring a subject being monitored, with at least three of the respective detection elements being provided; a detection network (10) configured of at least three detection elements being arranged inside the plant; a storage unit (30) in which detection data of each detection element are received and recorded as recorded data; and a processing computing unit (20) that receives the detection data of each detection element, determines if a fault is present by making a comparison with the recorded data, and when the incidence of a fault is recognized, specifies the fault incidence site on the basis of the detection data, and transmits the result to the prescribed corresponding department (40, 50).