Runtime Configuration Synchronization in Process Plants
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Solution Overview
Problem
In process plants, synchronizing modified objects and their dependent objects during runtime is tedious and time-consuming, often disrupting online operations and consuming valuable bandwidth, especially when minor changes are made, as existing systems require downloading entire configurations and manually coordinating updates across multiple interconnected objects.
Innovation Solution
A synchronization system identifies dependent objects and allows engineers to select a subset for simultaneous syncing with the modified object, enabling bi-directional updates without disrupting online operations, and provides a 'sync-lite' option for minor changes to update parameters in real-time without interrupting execution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire configuration is downloaded to sync modified objects during runtime, then synchronization completeness is improved, but bandwidth consumption increases and online operations are disrupted
Solution Approach 1:
The patent segments the configuration download process by identifying and downloading only the modified objects and their dependent objects rather than the entire configuration. The system determines a set of objects to download based on the modified object and its dependencies, dividing the download task into selective portions that reduce bandwidth consumption while maintaining synchronization completeness.
2Reliability
If the entire configuration is downloaded to sync modified objects, then synchronization completeness is improved, but downtime during online operations increases
Solution Approach 1:
The patent segments the configuration download process by identifying and downloading only the modified objects and their dependent objects rather than the entire configuration. The system determines a set of objects to download based on the modified object and its dependencies, dividing the download task into selective portions that reduce downtime while maintaining synchronization completeness.
3Manufacturing precision
If manual coordination of updates across multiple interconnected objects is performed, then update accuracy is improved, but operation complexity increases
Solution Approach 1:
The patent implements self-service by automatically determining the set of objects to download based on the modified object and its dependencies. The system autonomously identifies which objects need to be synchronized without requiring manual coordination from operators, reducing operation complexity while maintaining update accuracy through automated dependency analysis.
4Productivity
If configuration changes are synced during runtime, then operational continuity is improved, but system stability may worsen due to concurrent modifications
Solution Approach 1:
The patent applies preliminary action by determining the complete set of objects to download before initiating the download process. The system identifies all modified objects and their dependencies in advance, creating a finalized list of objects to be synchronized. This preliminary determination ensures system stability by preventing concurrent modifications during the download, while still allowing runtime synchronization of the pre-determined object set.
Data Source
AI summary
Techniques for synchronizing configuration changes in a process plant allow for intelligent and efficient updates to objects and related dependent objects. Additionally, techniques for synchronizing minor configuration changes in a process plant enable real-time updates to objects during run-time. Such techniques reduce the amount of downtime for online operation of the process plant and reduce the amount of information transmitted over the process control network. Each object may correspond to a process entity and dependent objects may be referenced by or may reference the object. In some cases, when an engineer modifies an object, dependent objects with respect to the modified object that have pending modifications are identified and displayed to the engineer. The engineer then selects the dependent objects to sync with the modified object and the dependent objects and modified object are synced and executed by a corresponding device in the run-time system.