Predictive Troubleshooting for Batch Plant Abnormal Operations
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Solution Overview
Problem
Current industrial processes lack the ability to automatically predict and prevent abnormal situations in batch operations, leading to increased downtime and reduced batch throughput, as operators rely on manual recording and analysis of issues, which is time-consuming and inefficient.
Innovation Solution
A system that enables rapid two-way communication between operators and sensors, using a processor to detect abnormal conditions by comparing signal data against operational limits, providing visual notifications and context menus for responses, and logging comments and recommended actions for future reference, allowing for data-driven predictive analytics and quick troubleshooting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If operators manually record and analyze abnormal conditions on paper sheets, then data integrity compliance is maintained, but the time required to troubleshoot abnormal conditions increases and batch throughput decreases
Solution Approach 1:
The patent replaces the mechanical paper-based recording system with an electronic computer-based system. Operators use computer terminals to electronically record abnormal conditions, comments, and recommended actions, eliminating manual paper handling while maintaining data integrity through structured electronic databases and validation protocols.
Solution Approach 2:
The system creates electronic copies of abnormal condition data, comments, and recommended actions in a centralized database. These digital records can be instantly retrieved, analyzed, and shared across multiple workstations, enabling rapid troubleshooting without the physical constraints of paper documentation.
2Reliability
If the system provides comprehensive information and historical data analysis, then predictive capabilities improve, but the device complexity increases
Solution Approach 1:
The system is segmented into modular functional components: data acquisition modules at individual workstations, a centralized database server, analytical processing modules, and user interface components. This segmentation allows the complex predictive functionality to be built from manageable, independent modules that can be developed, maintained, and scaled separately.
3Productivity
If electronic recording system is implemented, then data accessibility and analysis capability improve, but initial system complexity and implementation requirements increase
Solution Approach 1:
The electronic system is designed to be self-servicing where operators naturally input data during normal operations without requiring separate dedicated recording sessions. The system automatically timestamps, stores, and organizes data as it is entered, reducing the need for additional manual processing steps and minimizing implementation complexity.
Data Source
AI summary
A system and method are provided for recording and then displaying comments containing recommended actions to take in response to abnormal conditions arising during process operations. The comments can be ranked by an operator based on their success in remedying abnormal conditions with the highest ranked actions displayed first.