Patent Application
20100321153
The subject matter disclosed herein relates to an apparatus and method for performing a sequence of operational instructions, and in particular to an apparatus and method of performing a sequence of operational instructions where the operations must be performed in a sequence at different physical position/location in a desired order.
Many industries have processes that need to be performed by personnel to accomplish a task. To ensure a quality and reliability, many organizations have developed written processes that instruct the personnel on how to accomplish the task. In some application these processes need to be performed in a defined order at defined locations to avoid damaging equipment or disrupting downstream processes.
In some industries, such as the chemical, petroleum, electrical power production and electrical delivery industries, some tasks involve a complex set of instructions that must be conducted in the desired order at locations that may be physically separated by large physical distances from each other. To further complicate the task for personnel, the equipment on which they are performing tasks look identical or substantially similar to other equipment installed at the facility. If personnel become disoriented as to their position, or are not paying sufficient attention, they may perform the desired task (e.g. closing a valve or actuating a switch) at the wrong location and on the wrong equipment. In these circumstances, damage to the equipment and disruption of the processes may occur. It is estimated that across multiple process industries, in these types of situations, that 50% of errors occur due to personnel mistakenly believing that they are positioned in the right location to perform the task.
To avoid these types of errors, process industries utilize written instructions, sometimes referred to as “Operational Orders”, in combination with a system of checks and balances. For example, the equipment where tasks are performed may have locks, such as combination locks for example, that prevent actuation of the equipment without removing the lock. In these instances, the Operational Order sheet includes the combination to the lock so the personnel can access the desired equipment. In some instances, the personnel may be in contact with control center personnel that validate the personnel's actions. Despite these precautions, errors still may occur due to the sometimes repetitive nature of the Operational Orders. For example, where combination locks are used, the personnel may memorize the codes, or fail to zero-out the combination, after repeatedly performing the same procedure.
Accordingly, while existing operational process procedures are suitable for their intended purposes there remains a need for improvements, particularly in ensuring that personnel perform the desired task at the desired location in the desired sequence.
According to one aspect of the invention, an instruction and tracking apparatus is provided. The apparatus includes a positioning module, a reader module, and a display. A controller is operably coupled to the positioning module, the reader module and the display. The controller includes a processor responsive to executable computer instructions when executed on the processor for displaying a first operational sequence instruction on the display in response to receiving a first signal.
According to another aspect of the invention, an instruction and tracking apparatus is provided having an instruction unit and a key. The instruction unit comprises a positioning module, a reader module, and a display. A first controller is operably coupled to the positioning module, the reader module and the display. The first controller includes a first processor responsive to executable computer instructions when executed on the first processor for displaying a first process instruction on the display in response to receiving a first signal. The key comprising a receiver, a transmitter, and a second controller. The second controller is electrically coupled to the receiver and the transmitter. The second controller also includes a second processor and memory, the second processor being responsive to executable computer instructions when executed on the second processor for storing a sequence of codes in the memory in response to the first signal.
According to yet another aspect of the invention, a key for use with operational sequence instructions is provided. The key includes a housing and an engaging member coupled to the housing. A controller is positioned in the housing, the controller having a processor electrically coupled to memory. The processor is responsive to executable computer instructions when executed on the processor for storing a sequence of unlock codes in the memory in response to a first signal, the controller further includes a transmitter electrically coupled between the controller and the engaging member. Wherein the processor is responsive to executable computer instructions when executed on said processor for transmitting a first unlock code from the sequence of unlock codes through the engaging member when the engaging member contacts a first lock, the processor is further responsive to executable computer instructions when executed on the processor for erasing the first unlock code from the sequence of unlock codes when the first unlock code is accepted by the first lock.
According to yet another aspect of the invention, a method for performing a sequence of operational instructions is provided. The method includes the step of storing the sequence of operational instructions, the sequence of operational instructions includes a process instruction, an equipment identification data and a position where the instruction is to be performed. A first process instruction associated with a first operational instruction from said sequence of operational instructions is displayed, wherein the first operational instruction includes a first position and a first identification data. A second position is determined. An identification signal is received from a first equipment.
According to yet another aspect of the invention, a method for performing a sequence of operational instructions is provided. The method includes the steps of receiving a set of operational instructions, wherein the set of operational instructions includes a plurality of steps that are executed in order at particular locations. A plurality of unlock codes is stored in a key, wherein each of the plurality of unlock codes is associated with one of the plurality of steps. A first unlock code is transmitted from said plurality of unlock codes when the key is inserted in a first lock. The first unlock code is erased from the key if the first unlock code is accepted by the first lock. A first alarm is initiated if the first unlock code is not accepted by the first lock.
According to yet another aspect of the invention, a method for performing a sequence of operational instructions is provided. The method includes the steps of storing the sequence of operational instructions in a first memory, the sequence of operational instructions includes a process instruction, an equipment identification data and a position where the process instruction is to be performed. A plurality of unlock codes is stored in a key memory, wherein each of the plurality of unlock codes is associated with one of the sequence of operational instructions. A first process instruction associated with a first operational instruction from said sequence of operational instructions is displayed, wherein the first operational instruction includes the first process instruction, a first position and a first identification data. A second position is determined. An identification signal is received from a first equipment.
These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.
The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
Operational orders are a set of instructions that are carried out by personnel with a facility to accomplish a certain task where a series of steps are to be performed in sequence, usually at different physical locations. Operational orders are used in a variety of industries, including but not limited to chemical, pharmaceutical, petroleum, electrical power production and electrical power distribution. An exemplary facility 20 is illustrated in
Personnel typically operate from an office or work area 30. In the exemplary embodiment, the office 30 includes telecommunications devices such as a computer 32 that is coupled to receive and transmit data, such as operational orders for example, with a central control center 34. In one embodiment, the office also includes a printer 36 coupled to the computer 32 for printing the operational orders. Once an operational order is issued, either by the facility personnel or the central control center 34, the personnel proceed through the each of the steps 38A-38D on the operational order in sequence at the desired equipment 22. It should be appreciated that the operational order may include more or less steps 38. In the exemplary embodiment, the facility 20 is an electrical substation and the steps 38 are directed to the restoration of a feeder circuit fault. The steps 38 may be directed to a variety of tasks including the opening of circuit breakers, checking relays and target flags, grounding of circuits, and applying high voltage pulses. While the descriptions herein may be directed to a substation operation, the claimed invention should not be so limited and may be applied in any application where a series of tasks are performed in order.
To assist the personnel in executing the operational order, the personnel may utilize a handheld device, such as instruction unit 40 illustrated in
The unit 40 also includes a controller 54 electrically coupled to a positioning module 56 and a reader module 58. In one embodiment the position circuit 56 is a global positioning system (“GPS”) circuit that uses satellite based technology to accurately determine the position of the unit 40. However, the positioning module 56 may also be a cellular based circuit that uses cellular telecommunications antennas to triangulate a position. The positioning circuit may also be based on RFID sensors, infrared sensors, radio-frequency beacons, time-difference-of-arrival systems, ultra-wideband systems, IEEE 802.11 based systems or a hybrid of the foregoing. In another embodiment, the reader module 58 is an RFID reader that receives information from an RFID tag, such as identification device 28 for example. The reader module 58 may also be a barcode reader, or a magnetic strip reader for example.
As used herein, the term “module” means a circuit (whether integrated or otherwise), a group of such circuits, a processor(s), a processor(s) implementing software, or a combination of a circuit (whether integrated or otherwise), a group of such circuits, a processor(s) and/or a processor(s) implementing software. The term “circuit” means either a single component or a multiplicity of components, either active and/or passive, that are coupled together to provide or perform a desired function. Further, the term “scan” or “scanned” refers to the acquisition of data by the reader module 58, the acquisition of data may occur wirelessly, such as with an RFID tag, bluetooth system, or IEEE 802.11 system for example, or may include the connection of a physical medium, such as a serial, parallel, universal serial bus (USB) or Ethernet cable for example.
The reader module 58 and positioning module 56 are electrically coupled to a controller 54. The unit 40 operation is controlled by controller 54. Controller 54 is a suitable electronic device capable of accepting data and instructions, executing the instructions to process the data, and presenting the results. Controller 54 may accept instructions through user interface 46, or through other means such as but not limited to electronic data card, voice activation means, manually-operable selection and control means, radiated wavelength and electronic or electrical transfer. Therefore, controller 54 can be a microprocessor, microcomputer, a minicomputer, an optical computer, a board computer, a complex instruction set computer, an ASIC (application specific integrated circuit), a reduced instruction set computer (RISC), an analog computer, a digital computer, a molecular computer, a quantum computer, a cellular computer, a superconducting computer, a supercomputer, a solid-state computer, a single-board computer, a buffered computer, a computer network, a desktop computer, a laptop computer, a scientific computer, a cellular phone, a personal digital assistant (PDA), or a hybrid of any of the foregoing.
Controller 54 is capable of converting the analog voltage or current level into a digital signal. Alternatively, circuits, such as positioning module 56 and reader module 58 may be configured to provide a digital signal to controller 54, or an analog-to-digital (A/D) converter (not shown) maybe coupled to convert an analog signal into a digital signal for processing by controller 54. Controller 54 uses the digital signals act as input to various processes for controlling the unit. The digital signals represent one or more unit 40 data including but not limited to positioning data, equipment identification data and the like. It should be appreciated that while the controller 54, the positioning module 56, and the reader module 58 are shown and described as separate modules or components, this is for the purpose of clarity and in some embodiments, the controller 54, the positioning module 56, and the reader module 58 are integrated into a single module.
Controller 54 may be operably coupled with one or more systems or components within the facility 20 by data transmission media 60 (
In general, controller 54 accepts data from positioning module 56 and reader module 58, is given certain instructions for the purpose of comparing the data from circuits 56, 58 to predetermined operational parameters. Controller 54 provides operating signals to display 44, indicating, for example, an alarm when if the personnel scans the wrong equipment 22 for a given task. The controller 38 compares the operational parameters to predetermined variances (e.g. position of personnel to where they should be for the task to be performed) and if the predetermined variance is exceeded, generates a signal that may be used to indicate an alarm to an operator or the central control center 34. Additionally, the signal may initiate other control methods that adapt the operation of the unit 40 such as displaying a map with a path to the desired equipment 22 to compensate for the out of variance operating parameter, such as the personnel making a wrong turn for example. As will be described in more detail below, to prevent damage to the end use application, the controller 54 may initiate alarms or disable the operating order instructions in the event that the personnel attempt to perform tasks out of sequence or on the wrong equipment 22.
Referring now to
I/O controllers 70 are coupled to the user interface 46 for providing digital data between these devices and bus 74. I/O controllers 70 are also coupled to analog-to-digital (A/D) converters 76, which may receive analog data signals from circuits 56, 58.
ROM device 68 stores an application code, e.g., main functionality firmware, including initializing parameters, and boot code, for processor 62. Application code also includes program instructions as shown in
NVM device 66 is any form of non-volatile memory such as an EPROM (Erasable Programmable Read Only Memory) chip, a disk drive, or the like. Stored in NVM device 66 are various operational parameters for the application code. The various operational parameters can be input to NVM device 66 either locally, using user interface 46 or computer 32, or remotely via a local area network or a wide area network using remote computer at the central control center 34. It will be recognized that application code can be stored in NVM device 66 rather than ROM device 68.
Controller 54 includes operation control methods embodied in application code, such as those shown in
One situation that may result in errors in the execution of the operational order is when personnel memorize the combinations used on the mechanical locks 26 that secure the cabinets 24. One prior art method utilized a mechanical key system where the personnel started with the first key which then fit the desired lock. By unlocking the first cabinet, the personnel obtained a second key that was used to unlock the equipment associated with the next task. While this worked well, it was cumbersome and would only work with pre-designated processes. Where the operational order may change the order or the types of equipment, the string of mechanical keys would not function properly. Shown in
The key 78 is generally of the same size and shape as a traditional mechanical key with a handle portion 80 and a blade or engaging member 82. The handle portion 80 includes a housing 84 that is sized to contain a controller 86. The controller 86 includes a processor 88 and memory, including RAM 90, ROM 92, and NVM 94. The controller 86 may be configured to operate substantially similar to the controller 54 described herein above in that the processor 88 is responsive to executable computer instructions when executed on the processor 88. The executable computer instructions may be stored in memory 90, 92, 94. In the exemplary embodiment, the personnel insert the key 78 into a docking station (not shown) coupled to computer 32 to program the key 78 via communications module 96. The communications module 96 couples to a data transmission media that includes, but is not limited to, wired, radio and infrared signal transmission systems. In another embodiment, the key 78 may be programmed wirelessly via communications module 96 to a remote computer, such as one in the central control center 34 for example. Controller 86 is configured to provide operating signals and to receive data. As will be discussed in more detail below, in the exemplary embodiment, the controller 86 is configured to receive a sequence of unlock codes that correspond to the sequence of tasks to be performed by the personnel. In one embodiment, the controller 86 is configured to erase each unlock code in the sequence when the unlock code has been accepted by a lock.
Coupled to the processor 88 are a transmission and receiver module 98. The transmission and receiver circuit 98 is configured to transmit an unlock code to a contact on the engaging member 82 when the engaging member 82 is inserted into and contacts lock 26. The unlock code is transmitted to lock circuitry 100. If the transmitted unlock code matches the code programmed into the lock 26, the lock circuitry 100 acknowledges the unlock code and transmits an acceptance signal. The lock circuitry 100 then releases the mechanical portion (not shown) of the lock 26 to allow the cabinet 24 to open. In one embodiment, the engagement portion includes projections that engage corresponding openings in the mechanical portion of the lock 26 to allow the lock 26 to be moved into an unlocked position. In one embodiment, the controller 86 includes a visual indicator 99, such as an light emitting diode (LED) for example, that is activated when said unlock code is not accepted.
As will be discussed in more detail below, in the exemplary embodiment, the controller 86 is configured to receive a sequence of unlock codes that correspond to the sequence of tasks to be performed by the personnel. The unlock codes are an electronic equivalent to the mechanical combination code. In one embodiment, the controller 86 is configured to erase each unlock code in the sequence when the unlock code has been accepted by a lock, such that each unlock code has only a one time use. In another embodiment, the unlock codes are encrypted to prevent the unauthorized duplication or copying of the unlock codes. This provides advantages over the combination lock system and the mechanical-key system in that the unlock codes are an electronic signal which cannot be memorized by the personnel. Since a single key is used with all the cabinets 24, the inconvenience of resetting the mechanical keys is avoided. It should be appreciated that the electronic key 78 may be used by itself with a paper operational order or in combination with the instruction unit 40.
Referring now to
Once the sequence of instructions data is stored, the method 102 proceeds to block 118 where unit 40 initiates the first task, n=1. The method 102 then displays the instructions for the first task on the operational order on the display 44 of the unit 40 in block 120. The personnel then proceed to the location of the desired cabinet 24 containing the equipment 22 in block 122. In one embodiment, the unit 40 generates a graphical display mapping a path for the personnel from their current position to the position of the task to be performed, such as by using the GPS coordinates 112 to guide the personnel. The operator scans the identification device 28, such as an RFID tag for example, in block 124. Query block 126 determines whether the data from the identification device 28 matches the identification data 114. In one embodiment, the query block 126 also compares the current location of the personnel to the location data 112 to determine if the personnel are in substantially the same location as the location data 112. If either the location or identification data does not match, then the personnel are at the wrong location and the method 102 proceeds to block 128 where an alarm is initiated to alert the personnel. In one embodiment, each time the alarm is initiated, the unit 40 stores this data for later evaluation, such as for examining the effectiveness of personnel training for example. In another embodiment, the initiation of the alarm also causes an alarm to be transmitted to the central control center 34. In yet another embodiment, the unit 40 generates a graphical display mapping a path from their current position to the correct position. The method 102 then loops back to block 120 where the instruction is displayed.
If query block 126 returns a positive, meaning the personnel are at the right location, the method 102 proceeds to block 130 where the values of the combination lock for the cabinet 24 are displayed on the display 44. The personnel then complete the task in block 132 and the unit 40 erases the task and the combination information from memory in block 134. The method 102 then proceeds to query block 136 where it is determined whether the task that was just performed was the last task. If the query block returns a negative, the method 102 proceeds to block 138 where the method 102 increments to the next task in the sequence of instructions and loops back to block 120 to initiate the next task. In one embodiment, the unit 40 graphical display mapping a path from the personnel's current position to the location of the next task to be performed. If the query block 136 returns a positive, the method 102 proceeds to termination block 140 and stops.
Another method 142 for performing the operational order using the key 78 is illustrated in
With the unlock codes stored, the method 142 proceeds to block 152 where the personnel begin the first task and proceed to the location of the first task in block 154. Once the personnel arrive at the equipment 22 the personnel inserts the key 78 into the lock 26 in block 156. The key 78 transmits the unlock code associated with the step in the operational order to the lock 26 in block 158. It is determined whether the unlock code is accepted by the lock 26 in query block 160.
If query block 160 returns a negative, meaning the unlock code was not accepted. The method 142 then proceeds to the query block 162 to determine if there have been more than three unsuccessful attempts to open a lock. In the exemplary embodiment, each time an unsuccessful attempt is made, the key 78 stores the information, such as in RAM 90 for example. In one embodiment, if there have been more than three unsuccessful attempts to open locks, the method 142 proceeds to block 164 where the key 78 is deactivated and the method 142 terminates in block 166. If the query block 162 returns a negative, the method 142 proceeds to block 168 where an alarm is initiated and loops back to block 154.
If the query block 160 returns a positive, meaning that the unlock code was accepted by the lock 26, then cabinet 24 opens and the method 142 proceeds to block 170 where the personnel complete the task. Once the cabinet is unlocked, the key 78 erases the unlock code that was accepted by the lock 26 in block 172. The method 142 then proceeds to query block 174 where it is determined whether the task that was just performed was the last task in the sequence of instructions. If the query block returns a negative, the method 142 proceeds to block 176 where the method 142 increments, n=n+1, to the next task in the sequence of instructions and loops back to block 1154 to initiate the next task. If the query block 174 returns a positive, the method 142 proceeds to termination block 178 and stops.
Another method 180 for performing the operational order using both the unit 40 and the key 78 is illustrated in
The method 180 then proceeds to block 190 where the personnel initiate the first task and displays the instruction for the task in block 192. The personnel proceed to the location of the first task in block 194 where the identification device 28, such as an RFID tag for example, is scanned in block 196. The method then proceeds to query block 198 where it is determined whether the data from identification device 28 matches the identification data 114. In one embodiment, the query block 198 also compares the current location of the personnel to the location data 112 to determine if the personnel are in substantially the same location as the location data 112. If the data does not match, then the personnel are at the wrong location and the method 180 proceeds to block 200 where an alarm is initiated to alert the personnel. In one embodiment, each time the alarm is initiated, the unit 40 stores this data for later evaluation, such as for examining the effectiveness of personnel training for example. In another embodiment, the initiation of the alarm also causes an alarm to be transmitted to the central control center 34. The method 180 then loops back to block 192 where the instruction is displayed.
If the query block 198 returns a positive, the method 180 proceeds block 202 where the key 78 is inserted into the lock 26. The unlock code is transmitted to the lock 26 in block 204. Query block 206 evaluates whether the unlock code was accepted. If query block 206 returns a negative, the method 180 proceeds to query block 208 to determine if there have been more than three unsuccessful attempts to open a lock. In one embodiment, if there have been more than three unsuccessful attempts to open locks, the method 180 proceeds to block 210 where the key 78 is deactivated and the method 180 terminates in block 212. If the query block 208 returns a negative, the method 180 proceeds to block 200 where an alarm is initiated and loops back to block 192.
If the query block 206 returns a positive, the method 180 proceeds to block 214 where the personnel completes the task. The method 180 then proceeds to block 216 where the unlock code and instruction for the task are erased from the memory of unit 40 and key 78.
The method 180 then proceeds to query block 218 where it is determined whether the task that was just performed was the last task. If the query block 218 returns a negative, the method 180 proceeds to block 220 where the method 180 increments to the next task in the sequence of instructions and loops back to block 192 to initiate the next task. If the query block 218 returns a positive, the method 180 proceeds to termination block 222 and stops.
An embodiment of the method of operating the dispenser may be embodied in the form of computer-implemented processes and apparatuses for practicing those processes. The present invention may also be embodied in the form of a computer program product having computer program code containing instructions embodied in tangible media, such as floppy diskettes, CD-ROMs, hard drives, universal serial bus (USB) drives, or any other computer readable storage medium, such as random access memory (RAM), read only memory (ROM), or erasable programmable read only memory (EPROM), for example, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. The present invention may also be embodied in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits. A technical effect of the executable instructions is to provide an apparatus and a method for performing a sequence of instructions in an operational order to minimize the opportunity for personnel to make errors in the performance of the operational order.
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
