Software Component Segmentation for Seamless Process Plant Upgrades
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Solution Overview
Problem
Traditional process control systems require redundant control devices for upgrades, leading to periods of unavailability and potential interruptions in plant operation, as they struggle to ensure seamless failover and efficient firmware upgrades.
Innovation Solution
The system isolates and separates control device functions into individual components, allowing for independent upgrades and state data transfer between versions, eliminating the need for redundant devices by distributing redundancy within the control system, enabling continuous operation during upgrades and faster failure recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional process control systems use redundant control devices for upgrades, then system reliability is maintained during upgrades, but hardware overhead increases and device complexity increases
Solution Approach 1:
The control device is segmented into multiple independent software components (control module, I/O module, communication module, etc.) that can be upgraded independently. Each component can be updated without requiring a complete system replacement or redundant hardware, thus maintaining reliability while reducing hardware overhead.
Solution Approach 2:
Instead of using physical redundant hardware devices, the system creates software copies or instances of control components. Multiple instances of the same component can run simultaneously, allowing for seamless failover and upgrades without additional hardware complexity.
2Reliability
If traditional process control systems use redundant control devices for upgrades, then system reliability is maintained during upgrades, but productivity decreases due to periods of unavailability
Solution Approach 1:
The system performs preliminary actions by loading and validating new software components in the background before they are needed. Upgrade components are prepared and tested in advance, allowing for seamless activation without interrupting plant operation, thus maintaining both reliability and productivity.
Solution Approach 2:
The system ensures continuous operation by maintaining active control components throughout the upgrade process. Old components continue to operate while new components are being prepared, and switching between them occurs without interruption, ensuring uninterrupted plant operation.
3Adaptability or versatility
If traditional process control systems upgrade firmware, then software functionality is improved, but device complexity increases due to synchronization requirements
Solution Approach 1:
The control system is divided into independent software modules that can be upgraded separately. Each module has its own version and can be updated independently, eliminating the need for complex synchronization across the entire system and reducing upgrade complexity.
Solution Approach 2:
The system dynamically manages multiple versions of software components simultaneously. Different components can be at different upgrade stages, and the system adapts to this dynamic state through version tracking and selective activation, simplifying the upgrade process.
4Reliability
If traditional process control systems use redundant control devices, then failover capability is provided, but hardware overhead increases
Solution Approach 1:
The system uses software copying to create virtual redundant instances of control components. Multiple copies of control modules can run on the same hardware platform, providing failover capability without requiring additional physical devices, thus reducing hardware overhead while maintaining reliability.
Solution Approach 2:
A single control device is designed to perform multiple functions simultaneously, including running multiple component instances, handling upgrades, and providing failover. This multi-functionality eliminates the need for dedicated redundant hardware while maintaining failover capability.
Data Source
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AI summary
An apparatus to upgrade software for a control device of a process control system, the apparatus comprising a first existing component (320, 310-312) to determine when a second existing component (310-312) of the software in a functioning control device (150-152) is at least one of failed, failing, or producing errors, each of the first and second existing components implementing a respective instantiation of the same software; and an upgrade module to instantiate a replacement component of the software in the functioning control device currently executing the second existing component that is at least one of failed, failing, or producing errors; and change the replacement component in the functioning control device to an active mode when a first state of the replacement component matches a second state of one of the first or second existing components.