Modular reaction control system for live monitoring of long-term and/or multi-channel reactions
A method of live monitoring of long-term and/or multi-channel reactions may include: controlling a chemical reaction apparatus via a modular control system, collecting reaction data via the digital and analog input ports, logging the reaction data via a data logging module configured to transmit the reaction data to a remote data server for data storage, periodically querying a remote interlock server for an emergency stop instruction via an emergency stop controller, inputting the emergency stop instruction into the remote interlock server via a remote user interface, executing, in response to receiving the emergency stop instruction, one or more emergency stop actions. The modular control system may include: a digital control module in electrical communication with digital input and output ports; an analog control module in electrical communication with analog input and output ports; and a pneumatic control module in pneumatic communication with pneumatic output ports.
1 . A method of live monitoring of long-term and/or multi-channel reactions, the method comprising:
controlling a chemical reaction apparatus via a modular control system, the modular control system comprising:
a digital control module in electrical communication with digital input and output ports;
an analog control module in electrical communication with analog input and output ports;
a pneumatic control module in pneumatic communication with pneumatic output ports;
collecting reaction data via the digital and analog input ports;
logging the reaction data via a data logging module configured to transmit the reaction data to a remote data server for data storage;
periodically querying, via an emergency stop controller, a remote interlock server for the presence of an emergency stop instruction received from a remote human user, wherein the modular control system is configured such that:
if the emergency stop instruction is not detected on the remote interlock server by the modular control system, then the modular control system continues to control the chemical reaction apparatus as normal; and
if the emergency stop instruction is detected on the remote interlock server by the modular control system, then the modular control system executes one or more emergency stop actions;
inputting the emergency stop instruction into a remote user interface via the remote human user, the human user being located remotely from the chemical reaction apparatus;
transmitting the emergency stop instruction from the remote user interface to the remote interlock server;
storing the emergency stop instruction on the remote interlock server;
detecting, via the modular control system, the presence of the emergency stop instruction on the remote interlock server; and
executing, in response to the detecting of the emergency stop instruction, the one or more emergency stop actions.
2 . The method of claim 1 , wherein the one or more emergency stop actions comprise actuating a valve and/or de-energizing a heating element.
3 . The method of claim 1 , wherein the remote data server is a cloud-based server.
4 . The method of claim 1 , wherein the remote interlock server is a cloud-based server.
5 . The method of claim 1 , comprising maintaining power to the modular control system via an uninterruptable power supply.
6 . The method of claim 1 , comprising automatically responding to one or more predetermined safety events via a field programmable gate array.
7 . The method of claim 6 , wherein the one or more predetermined safety events comprise at least one of the following:
sensing of a toxic gas, sensing a high pressure alert, and/or sensing a high temperature alert.
8 . The method of claim 1 comprising inputting process parameters via a touchscreen panel adapted to display a process flow diagram, wherein the process flow diagram displays real time data and process conditions.
9 . The method of claim 1 , wherein the data logging module is configured to log data correlated to one or more of the following: gas sensor alarms, flow rates, gas chromatography output, pressure, temperature, and/or valve state.
10 . The method of claim 8 , wherein the process flow diagram is user-configurable, the method further comprising configuring the process flow diagram.
11 . The method of claim 1 , wherein the remote data server and the remote interlock servers are different servers.
12 . The method of claim 1 , wherein the modular control system comprises a remote alarm module, the method further comprising providing notification of an alarm event to the remote human user via the remote alarm module.
13 . The method of claim 12 , wherein the notification of the alarm event comprises sending an SMS alarm alert to a remote device of the remote human user.
14 . The method of claim 12 , wherein the notification of the alarm event comprises sending an email alarm alert to a remote device of the remote human user.
15 . The method of claim 12 , wherein the chemical reaction apparatus is controlled by the remote human user from a location remote of the chemical reaction apparatus.