Process Transmitter Accuracy via Reference Equation Comparison
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Solution Overview
Problem
Industrial process control systems face challenges in accurately evaluating the accuracy of process conditions calculated by process transmitter electronics, which are limited by their hardware capabilities and require complex calculations that are often simplified, leading to a need for more expedient and accurate assessment methods.
Innovation Solution
The system generates a process condition reference equation signal and an approximation equation signal, allowing for comparison and adjustment of approximation coefficients to improve accuracy, enabling on-line and off-line evaluations of process conditions using both real-time and simulated data, and transmitting adjusted coefficients to transmitter electronics for improved calculations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex calculations are performed by transmitter electronics to accurately assess process conditions, then measurement precision is improved, but device complexity and power consumption increase beyond what is available in low-power transmitter hardware
Solution Approach 1:
The system divides the computational task into two segments: the transmitter electronics perform simplified algorithm-based calculations with limited power, while a separate control room computer performs the complex reference equation calculations. This segmentation allows each component to operate within its capabilities, resolving the contradiction between measurement precision and device complexity.
Solution Approach 2:
The control room computer acts as an intermediary that receives process variable data from the transmitter, performs the complex reference equation calculations, and compares results with the transmitter's algorithm-based calculations. This intermediary enables accurate assessment without requiring the transmitter itself to perform complex calculations.
2Use of energy by moving object
If algorithm-based calculations are used in transmitter electronics to reduce power consumption, then use of energy is improved, but measurement precision deteriorates due to simplified calculations
Solution Approach 1:
The system implements feedback by comparing the transmitter's algorithm-based calculation results with the control room's reference equation calculation results. This feedback mechanism allows the system to assess the accuracy of the simplified calculations and make adjustments, thereby maintaining measurement precision while using low-power algorithm-based calculations in the transmitter.
Solution Approach 2:
The control room computer performs the complex reference equation calculations in advance (off-line) to establish accurate reference values. This preliminary action enables the transmitter to use simplified algorithms during operation with the knowledge that accuracy can be assessed and corrected through comparison with pre-calculated reference values.
3Measurement precision
If manual computation of complex equations is required to evaluate accuracy, then measurement precision can be assessed, but loss of time increases due to manual analysis requirements
Solution Approach 1:
The control room computer automatically performs the reference equation calculations and compares them with the transmitter's algorithm-based calculations without requiring manual user computation. The system self-evaluates the accuracy of the computational analysis by generating an accuracy output signal, eliminating the time-consuming manual analysis step while maintaining precision assessment.
Data Source
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AI summary
Methods and systems for assessing transmitter electronics in an industrial process control system comprise generating a process condition reference equation signal, a process condition approximation equation signal, and an accuracy output signal. The process condition reference equation signal is generated using a process condition reference equation and process control inputs. The process condition approximation equation signal is generated using a process condition approximation equation that approximates the reference equation using the process control inputs, and approximation equation coefficients based on the approximation equation and the process control inputs. The approximation equation signal is compared to the reference equation signal at a control room workstation such that the industrial process control system can be adjusted. In one embodiment, the approximation equation coefficients are adjusted and transmitted to process transmitter electronics over a control network. In another embodiment, a parameter of the industrial process control system, such as a primary element or transmitter, is adjusted.