Plant Loop Signal Correlation Verification for Pass-Fail Accuracy
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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 and controls between field devices and monitor devices, making it challenging to compare test signals and result signals effectively.
Innovation Solution
A recording medium with a verification program that acquires and compares test information and result information, including signal changes, equipment information, and clock time, to verify the relationship between test signals and result signals, thereby determining the pass/fail status of the loop test.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If workers manually compare test signals and result signals to determine pass/fail status, then the process requires minimal equipment, but the determination accuracy deteriorates due to complex interactions and controls between field devices and monitor devices
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 result signals, and a verification result output unit that outputs pass/fail determination. The intermediary system handles the complex signal relationship verification, relieving workers from manual analysis while maintaining determination accuracy without requiring workers to understand complex equipment interactions.
2Productivity
If workers perform manual verification of loop tests, then the equipment cost is low, but the verification efficiency deteriorates due to the time-consuming nature of manual signal comparison
Solution Approach 1:
The patent replaces the manual mechanical verification process with an automated electronic verification system. The verification apparatus automatically acquires test signals from field devices and result signals from monitor devices, performs electronic comparison operations, and outputs verification results. This substitution eliminates the time-consuming manual signal tracing and comparison work, significantly improving verification efficiency while reducing the time loss associated with manual loop test verification.
3Measurement precision
If the verification apparatus automatically compares test signals and result signals, then the determination accuracy improves, but the complexity of the verification system increases
Solution Approach 1:
The verification apparatus is segmented into distinct functional units: a test signal acquisition unit that obtains test signals from field devices, a result signal acquisition unit that obtains result signals from monitor devices, a verification unit that performs the comparison, and a verification result output unit that outputs the pass/fail determination. This segmentation allows each unit to perform a specific function, making the overall system more manageable and easier to implement while achieving accurate automatic verification through coordinated operation of these modular components.
Data Source
AI summary
Provided is a recording medium having a verification program recorded thereon, 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.