Integrating Safety and Process Control via Field Device Status Database
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Solution Overview
Problem
Conventional commercial and industrial process control systems lack efficient coordination between safety shutdown and process control systems, leading to increased risk and unnecessary shutdowns due to lack of direct communication and redundant testing, which is time-consuming and exposes personnel to hazardous conditions.
Innovation Solution
A composite regulatory control and safety shutdown system that integrates advanced diagnostic and control modules, interactive sensor diagnostic monitors, and intelligent safety and control integrators to enable real-time communication and coordination between safety and process control systems, allowing for the delegation of functions to complementary field devices and optimizing maintenance schedules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If safety shutdown system and process control system are maintained as completely separate redundant systems, then system reliability is improved and risk of single failure is reduced, but coordination between systems deteriorates and redundant testing increases
Solution Approach 1:
The patent introduces a field device status database as an intermediary component that receives status information from both the safety shutdown system and the process control system. This database acts as a mediator that enables coordination between the two previously separate systems by storing and sharing field device status information, allowing the systems to coordinate their operations without direct coupling while maintaining their independence and reliability.
2Reliability
If safety shutdown system and process control system are maintained as completely separate systems, then system independence is improved and access control is strengthened, but communication efficiency deteriorates and unnecessary shutdowns increase
Solution Approach 1:
The field device status database serves as a communication intermediary that enables efficient information exchange between the independent safety shutdown system and process control system. By storing field device status information in a centralized database accessible to both systems, the patent maintains system independence and security while dramatically improving communication efficiency and preventing unnecessary shutdowns through better-informed decision-making.
Solution Approach 2:
The patent implements feedback mechanisms where both the safety shutdown system and process control system continuously monitor field device status information stored in the database. This feedback loop allows each system to make informed decisions based on real-time status information from the other system, improving communication efficiency while maintaining system independence through structured information exchange.
3Reliability
If redundant testing is performed on field devices, then fault detection reliability is improved, but time consumption increases and personnel exposure to hazardous conditions worsens
Solution Approach 1:
The patent merges the testing and monitoring functions of both the safety shutdown system and process control system into a coordinated approach. By sharing field device status information through the common database and coordinating their testing activities, the two systems can maintain high fault detection reliability while reducing redundant testing efforts and the associated time losses and personnel exposure to hazardous conditions.
Data Source
AI summary
An integrated monitoring, control and equipment maintenance and tracking system and method is provided for managing a plurality of field devices. The integrated and coordinated system includes the monitoring and control system that uses safety subsystem field device data and process control subsystem field device data. When a compromised field device is determined, e.g., by the safety system and/or the process control system, information about testing, maintenance, repair or replacement is conveyed to the monitoring and control system. This information is used to modify the work orders created by the equipment maintenance and tracking system processor such that the compromised field device, or a field device at a location of the compromised field device, is not subject to unnecessary or excessively redundant testing.