Electronic bypass system

An electronic bypass system can include receiving a request to bypass a plant interlock system. A review of the request can be facilitated by a computer and, based on input from at least one reviewer, results in the request being approved or not approved. The facilitating can include: notifying the at least one reviewer of the request, storing the request and a status of the request in a database that includes bypass statuses of a plurality of plant interlock systems, and prompting the at least one reviewer to respond based on not receiving input from the at least one reviewer within a specified review time period. Based on the result of the review, the status of the request can be updated in the database to approved or not approved. A report that includes the status of the request can be generated.

BACKGROUND OF THE INVENTION

This disclosure generally relates to an electronic bypass system, and, more particularly to an electronic bypass system for facilitating and monitoring bypasses to plant interlock systems.

Manufacturing plants typically utilize several types of plant safety systems such as alarms, safety trips, interlocks, and pressure relieving systems. Plant interlock systems may be used to enforce a fixed sequence of operations, for example, during a plant start-up or shutdown process. During plant start-up, interlocks are often used to provide safety protection by requiring that certain permissible conditions exist before proceeding to a next stage of the process. Interlock systems are inserted into the process to prevent operations from departing from the fixed sequence. An interlock system is a group of devices arranged to sense an operating limit or off-limit condition, or an improper sequence of events, and is used to shut down the process or prevent the process from proceeding if any are detected. An interlock system often includes various alarms and safety trips.

Safety interlocks are also applied in locking and unlocking closing valves in a chemical plant. A closing valve provided with an interlock system may be locked in the closed position (locked closed system) or locked in an open position (locked open system). By providing closing valves with an interlock, undesired operation thereof can be prevented. It is also possible, using the locking mechanism on a number of different closing valves, to ensure a correct, predetermined sequence of closing or opening of the closing valves that may be used, for example, to prevent hazardous situations.

Safety interlocks may be bypassed temporarily for a variety of reasons, such as system maintenance. A typical interlock bypass procedure includes an operation supervisor filling in a bypass request form and handing it to a plant superintendent. The plant superintendent then reviews the request and approves the bypass for a specified time period (e.g., twenty-four hours). The approved bypass request form is then handed back to the operation supervisor who takes the appropriate action to bypass the safety interlock. This current manual method of implementing interlock bypassing is often time consuming and it is difficult to get a view of the current status of safety interlocks and bypass activities (bypasses in place, bypasses requested, etc.) across one or more plant locations.

There continues to be a need in the art for efficient methods to facilitate and monitor the bypass of safety interlocks.

SUMMARY

Disclosed herein is an electronic bypass system.

In an embodiment a method, computer program product, or a system can receive a request to bypass a plant interlock system. A review of the request can be facilitated by a computer and, based on input from at least one reviewer, results in the request being approved or not approved. The facilitating can include: notifying at least one reviewer of the request, storing the request and a status of the request in a database that includes bypass statuses of a plurality of plant interlock systems, and prompting the at least one reviewer to respond based on not receiving input from the at least one reviewer within a specified review time period. Based on the result of the review, the status of the request can be updated in the database to approved or not approved. A report that includes the status of the request can be generated.

These and other non-limiting features and characteristics are more particularly described below.

DETAILED DESCRIPTION OF THE INVENTION

An embodiment provides an electronic bypass system that can facilitate and monitor bypasses to plant interlock systems. The electronic bypass system can be used to document the approval authorities for bypass activities, to facilitate the bypass approval process, and to generate reminders to reactivate interlock systems that have been bypassed. Use of the electronic bypass system can also minimize the manual handling of paperwork and provide visibility to the status of bypass activities.

Embodiments described herein can provide online monitoring for all bypass statuses (e.g., requested, pending approval, active, normalized). Electronic bypass requests can be approved by the assigned authorized person(s) from any location using an intranet or other network to connect to the electronic bypass system. In addition, the electronic bypass system can provide automated reminders for quick and timely action. A database can also be maintained for reporting and analysis of current and previous bypass activities.

The terms “electronic bypass system” and “electronic bypass tool” are used interchangeably herein to refer to hardware and/or software for implementing embodiments described herein.

Turning now toFIG. 1, an example of an interlock system100is generally shown. As shown inFIG. 1, the interlock system100can be a control loop for a control valve106to control a flow of gas or fluid out of a container110attached to the control valve106. The control loop can include a comparator102, a controller104, the control valve106, and a measurement sensor108. The control loop can be set up to keep a process variable (PV) (e.g., fluid flow) at or close to a desired set-point value (SV). The measurement sensor108can determine a measured value (MV) of the PV. The SV and the MV of the PV can be input to the comparator102to produce an error value (“e”). In an embodiment, the value of “e” is calculated by subtracting the MV from the SV. The value of “e” can be input to the controller104, and the controller104can generate controller output (OP) based on the value of “e”. As shown in the control loop ofFIG. 1, the controller output. OP, is a control valve adjustment value which reflects an estimate of how the control valve106should be adjusted (e.g., open or shut or no movement) to maintain the PV at the desired value.

A request to bypass the interlock system100can occur, for example, when the controller104has a scheduled or unscheduled maintenance activity (e.g., a new version of computer code is being installed). The bypass can include shutting down the controller104and having an employee of the plant make adjustments to the control valve106manually. In addition, the comparator102and/or the measurement sensor108can also be shut down and bypassed during the bypass of the interlock system100shown inFIG. 1.

As used herein, the terms “plant interlock system” or “interlock system” refer to a group of devices arranged to sense an operating limit or off-limit condition, or an improper sequence of events, and is used to shut down the process or prevent the process from proceeding if any are detected. As used herein, the terms “plant interlock system bypass” or “bypass” refer to shutting off the interlock system. As used herein, the terms “normalization” and “removal of the plant interlock system bypass” refer to turning the interlock system back on.

An interlock system can automatically inhibit the operation of equipment until certain process parameters are within acceptable ranges. Process parameters can include, but are not limited to, those measured at pressure safety valves (PSVs), and those measured at safety, health and environment (SHE) critical instruments. PSVs and/or SHE critical instruments can be bypassed by taking them out of the interlock system loop through isolating them, taking them out of service or by making them unavailable. The interlock system can be normalized when the bypassed element is restored or put back into the interlock system loop.

Turning now toFIG. 2, a process flow200that can be implemented by an electronic bypass system is generally shown in accordance with an embodiment. At block202, a request to bypass a plant interlock system can be received. The request can be from a plant supervisor or other employee. The request can include information such as, but not limited to: an identifier of a plant interlock system, a date for the bypass, a number of days, and a reason for the bypass.

At block204a review of the request can be facilitated. The review can include getting input from at least one reviewer. The result of the review is that the bypass request has been approved or not approved (i.e., denied). The facilitating of the review can include notifying at least one reviewer of the request. The electronic bypass system can be customized to support different review processes based on customer requirements. For example, the review may require review by particular reviewer(s) (optionally in a particular order) based on a combination of one or more of characteristics of the plant interlock system to be bypassed (e.g., location, type of interlock system, etc.), a frequency of bypass requests having particular characteristics, and a requested duration of the bypass.

In addition, the facilitating, at block204, can include storing the request and a status of the request (e.g., pending) in a database that includes bypass statuses of a plurality of plant interlock systems. The database can be a central repository for the status of plant interlock systems. The database can include information for plant interlock systems within particular physical buildings, within geographic areas, related to particular products, and or managed by particular business units. Having a single location for storing and tracking the status of plant interlock systems can provide visibility (e.g., through database queries, reporting) into a current status of plant interlock systems. In addition, historical data can also be maintained in the database and used, for example, to identify bypass trends.

The facilitating, at block204, can further include prompting the reviewer(s) to respond based on not receiving input within a specified review time period. The specified review time period can be customized based on customer requirements and can vary based on factors such as, but not limited to, a review time specified by the requestor, a type of plant interlock system, and an urgency associated with the performing the bypass quickly.

Based on receiving input from one or more reviewers, the electronic bypass system can update an interim status of the request in the database. The electronic bypass system can also initiate a customized escalation process if input is not received from the reviewer within a specified time period. The escalation can be to notify particular employees within particular time frames.

At block206, the status of the request can be updated in the database to approved or not approved based on the result of the review.

At block208, a report that includes the status of the request can be generated. The report can include an email sent to particular employees to notify them to implement a bypass of the plant interlock system, to notify a requestor that the bypass request was not approved, or to notify an interested party (e.g., a manager, a safety engineer, etc.) of the status of the bypass request. In addition, the report can include a status of several bypass requests. The report can be generated based on contents of the database.

At block210, if the bypass request was approved, the bypass of the plant interlock system can be initiated to place the plant interlock system in a bypass state. In addition, the database can be updated to record the bypass state for the plant interlock system.

At block212, the removal of the bypass can be facilitated. The removal process can be customized (e.g., who should be notified, timeframe for notification) based on customer requirements. For example, based on a determination that the bypass has been in place longer than it was requested to be in place, a reminder can be transmitted to selected employee recipients to reactivate the plant interlock system. In addition, an escalation process that includes notifying additional employees (e.g., supervisors, managers) can be implemented based on the plant interlock system being in the bypass state for a specified time period.

Turning now toFIG. 3, an approval workflow300that can be implemented by an electronic bypass system is generally shown in accordance with an embodiment. Embodiments of the electronic bypass system can be customized to require different levels of approval for a bypass request based on how long the bypass will be in place if the request is approved. As shown inFIG. 3, supervisors302are given the authority to initiate and close interlock system bypass requests, superintendents304are given the authority to approve bypass requests that last up to twenty four hours, managers306are given the authority to approve bypass requests that last up to seven days, and the approval of general managers308can be required for bypasses that last more than seven days.FIG. 3shows one example of an approval workflow300and others can also be implemented. Other approval workflows can also take into account additional factors such as the type or location of the plant interlock system being bypassed.

Turning now toFIG. 4, an electronic bypass system approval report400is generally shown in accordance with an embodiment. In an embodiment, the approval report400is displayed on a user interface screen of a user system. The report400includes an option selection panel402where the report recipient can select different options related to bypasses in order to view different reports. The report400shown inFIG. 4also includes bypass request information404entered, for example, by the requestor of a bypass. The bypass request information404shown inFIG. 4includes, among other things, data specifying a bypass number, a site name, a plant name, an effective date, a reason of bypassing interlock, a back-up system, a duration, and a requestor name (“raised by”). The report400also includes reviewer comments406and bypass status history408to track the status of the bypass as it moves from a request to approved (or not approve) to implemented and then to normalized.

The format shown inFIG. 4can also be presented by the electronic bypass system to a user for creating a bypass request, and to a reviewer for approving the bypass request. The data entered by the requestor and reviewer are saved in the database.

Turning now toFIG. 5, an electronic bypass system status report500is generally shown in accordance with an embodiment. The report500can be generated by executing a query against the database for all bypasses within a specified time period and for a particular plant (or other location). In an embodiment, the report500is displayed on a user interface screen of a user system. Any number of reports can be generated based on the data stored in the database. The reports can be customized based on customer requirements to focus on particular locations, on particular types of machinery or plant interlock systems, on particular managers, on particular dates, on particular timeframes (length of time for review, length of time bypass is in effect), etc.

Reports can be generated by the electronic bypass system on a periodic basis (e.g., daily, weekly, monthly) and automatically sent to specified recipients. Reports can reflect electronic bypass data for specified time frames. They can include summary data for all bypasses in a particular group such as, but not limited to: an entire company, a geographic location, a group of one or more departments, and a type of process or interlock system. In an embodiment, the summary report can be displayed via a user interface screen on a user device and the summary report can be manipulated to show the detail data behind the summary data in the report. One method of outputting a generated report is via email, other methods of outputting can also be used such as text messages or printing of hard copy reports.

The electronic bypass system can alert and prevent a requestor from requesting a bypass for an active tag. A pop-up message can appear that alerts the requestor that the same bypass already exists, and the electronic bypass system can prevent the requestor from proceeding.

Turning now toFIG. 6, an email notification600of an electronic bypass system request is generally shown in accordance with an embodiment. The email notification600includes mail system heading information602, recipient and subject information604, and review request content606.

Turning now toFIG. 7, a computer system upon which an electronic bypass tool710(also referred to herein as an “electronic bypass system”) can be implemented will now be described in an exemplary embodiment. The computer system shown inFIG. 7includes a host system702and one or more user systems708. The user system708and host system702are communicatively coupled to one another via one or more networks706. The host system702can be implemented as a high-speed computer processing device (e.g., a mainframe computer) capable of handling a high volume of activities conducted by the electronic bypass tool710and the user system708with regard to the host system702. The host system702can be operated by an enterprise or organization implementing the exemplary electronic bypass tool710described herein. The host system702can operate as a web server including a web site for providing access to the electronic bypass tool710.

The host system702can also operate as an application server including one or more applications or modules for providing the electronic bypass tool710described herein. The electronic bypass tool710can include logic for performing the processing described above inFIG. 2. In an embodiment, the host system702is communicatively coupled to a storage device704, which can plant interlock system and bypass data, as well as related data used to facilitate the electronic bypass tool710.

While the storage device704is shown inFIG. 7as a separate physical device from the host system702, it will be understood that the storage device704can be integrated into the host system702as internal storage (e.g., as a hard disk drive), or accessed by the host system702via the network.

The user device708can be any type of communications device capable of sending and receiving information over a network. For example, the user device708can be a general desktop computer or laptop, or can be a wireless device, such as a smart phone or personal digital assistant. The user device708can be operated by a user of the electronic bypass tool710and/or a recipient of an output (e.g., a report) generated by the electronic bypass tool710. In an embodiment, one or more of the user devices708can be directly attached to the host system702.

The networks706can be any type of known networks in the art. For example, the networks706can be a combination of public (e.g., Internet), private (e.g., local area network, wide area network, virtual private network), and can include wireless and wire line transmission systems (e.g., satellite, cellular network, terrestrial networks, etc.).

In an embodiment, the electronic bypass tool710can be distributed across multiple processors, for example, in the host system702and one or more user devices708.

Technical effects of embodiments include providing a safety interlock electronic bypass system that can support approval and workflow processes that can be customized based on customer requirements. Embodiments can also provide a database that includes records related to plant interlock systems that are stored and backed up to avoid loss of data. Embodiments can also provide an automated notification system that utilizes electronic mail to request action from specified employees (e.g., those identified in the approval and workflow processes). In addition, embodiments can send reminders to employees when their approval time has expired and an approval (or denial) has not been received. Further, embodiments can perform an automated escalation process to higher levels of authority if a specified employee fails to take a requested action within a stipulated time period.

Set forth below are some embodiments of methods for providing an electronic bypass system, computer program products for providing an electronic bypass system, and electronic bypass systems.

A method for providing an electronic bypass system, the method comprising receiving a request to bypass a plant interlock system, and facilitating a review of the request. The facilitating is based on input from at least one reviewer and results in the request being approved or not approved. The facilitating includes: notifying at least one reviewer of the request, storing the request and a status of the request in a database that includes bypass statuses of a plurality of plant interlock systems, and prompting the at least one reviewer to respond based on not receiving input from the at least one reviewer within a specified review time period. The request and a status of the request are stored in a database that includes bypass statuses of a plurality of plant interlock systems. The at least one reviewer of the request is prompted to respond based on not receiving input from the at least one reviewer within a specified review time period. The status of the request is updated in the database to approved or not approved based on the result of the review. A report that includes the status of the request is generated.

The method of Embodiment 1, wherein the method further comprises receiving the input from the reviewer and updating an interim status of the request based on the input.

The method of any of Embodiments 1-2, wherein the method further comprises initiating placing the plant interlock system in a bypass state based on the request being approved.

The method of any of Embodiments 1-3, wherein the method further comprises transmitting a reminder to reactivate the plant interlock system.

The method of any of Embodiments 1-4, wherein the transmitting a reminder is based on the plant interlock system being in the bypass state for a specified bypass time period.

The method of any of Embodiments 1-5, wherein the method further comprises performing an escalation process based on the plant interlock system being in the bypass state for a specified bypass time period.

The method of any of Embodiments 1-6, wherein the report is generated prior to the review of the request completing and the report includes an interim status of the request.

The method of any of Embodiments 1-7, wherein the method further comprises transmitting the report to an interested party.

The method of any of Embodiments 1-8, wherein the review includes an escalation process when the input from the at least one reviewer is not received within the specified review time period.

The method of any of Embodiments 1-9, wherein there the at least one reviewer includes two or more reviewers.

The method of any of Embodiments 1-10, wherein the report further includes statuses of additional requests and is based on contents of the database.

The method of any of Embodiments 1-11, wherein the at least one reviewer of the request varies based on at least one of a type of the plant interlock system and a bypass duration associated with the request.

A computer program product for providing an electronic bypass system. The computer program product comprises a storage medium embodied with computer-readable program instructions which, when executed by a computer, cause the computer to implement any of Embodiments 1-12.

An electronic bypass system. The system comprises a computer processor and logic executable by the computer processor, the logic configured to implement any of Embodiments 1-12.

In general, the invention may alternately comprise, consist of, or consist essentially of, any appropriate components herein disclosed. The invention may additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any components, materials, ingredients, adjuvants or species used in the prior art compositions or that are otherwise not necessary to the achievement of the function and/or objectives of the present invention.