Wearable Mobile Control Devices for Process Plant Operations
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Solution Overview
Problem
Current process control systems in plants face limitations due to limited controller and device memory, communication bandwidth, and data structuring issues, leading to inefficient data archiving, inaccurate data collection, and cumbersome workflows for troubleshooting and predictive modeling.
Innovation Solution
A wearable mobile user interface device that performs control functions, providing notification, navigation, and data management within a process plant, utilizing location awareness and big data concepts to facilitate efficient operation and maintenance through seamless state transfer between devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If centralized control rooms with fixed workstations are used, then control functions can be performed, but operator mobility is limited and response time to plant issues increases
Solution Approach 1:
The control system transitions from static fixed workstations to dynamic mobile computing devices that operators can carry throughout the plant. This allows operators to move freely while maintaining access to control functions, directly resolving the contradiction between mobility and control capability.
Solution Approach 2:
The invention adds the dimension of mobility by implementing control functions on portable devices. Operators can now access the control system from any location in the plant rather than being confined to control room workstations, enabling simultaneous improvement in both response time and mobility.
2Reliability
If more data is collected and archived in the controller, then better predictive modeling and troubleshooting are achieved, but controller memory and communication bandwidth are exceeded
Solution Approach 1:
The invention extracts data archiving and historical data storage functions from the controller to external data historians and servers. This allows the controller to maintain only essential real-time data while detailed historical data is stored elsewhere, enabling better predictive modeling without overwhelming controller memory.
Solution Approach 2:
Data historians and servers act as intermediaries between the controller and the data analysis functions. They handle the bulk data storage and processing requirements, allowing the controller to focus on real-time control while still enabling comprehensive predictive modeling and troubleshooting through access to archived data.
3Reliability
If traditional wired communication infrastructure is used, then system reliability is maintained, but installation complexity and adaptability to new devices increases
Solution Approach 1:
The control system is designed with universal communication capabilities that support multiple device types and wireless protocols. Mobile computing devices, wearables, and traditional workstations can all interface with the control system through standardized communication protocols, enabling flexible device integration while maintaining system reliability.
Data Source
AI summary
Methods and apparatus for performing functions in a process plant include the use of wearable mobile user-interface (UI) devices. The wearable UI devices may perform process control functions, notification functions, commissioning functions, personal and environment safety functions, and/or guidance functions.