Controller, manager, plant control system, and data processing method

• US 10,025,283 B2
• Filed: 01/22/2015
• Issued: 07/17/2018
• Est. Priority Date: 01/28/2014
• Status: Active Grant

• Current Assignee: Yokogawa Electric Corporation
• Original Assignee: Yokogawa Electric Corporation
• Inventors: Hasegawa, Kenji, Sakai, Masahiro
• Primary Examiner(s): DAO, TUAN C.
• Application Number:
  US14/602,320
• Publication Number:
  US 20150212506A1
• Time in Patent Office: 1,272 Days
• Field of Search: None
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 19/0426 Programming the control sequence
• CPC Class Codes: G05B 2219/42001 Statistical process control spc
• CPC Class Codes: G16H 40/67 for remote operation
• CPC Class Codes: G16H 50/30 for calculating health indices; for individual health risk assessment
• CPC Class Codes: G16H 70/00 ICT specially adapted for the handling or processing of medical references

Abstract

A controller includes a calculator configured to receive process data necessary for controlling a plant and vital data indicating a state of a plant worker, the process data being received from a field device, the vital data being received from the plant worker, the calculator calculating first index data and second index data, the first index data indicating a gap between a current one of the process data and a previous one of the process data which is received when the plant is in a normal state, the second index data indicating a gap between a current one of the vital data and a previous one of the vital data which is received when the plant is in the normal state, and a determiner configured to determine health of the plant by using the first index data and the second index data which are calculated by the calculator.

Claims

1. A controller comprising:

a hardware calculator or calculator stored in a memory configured to receive process data necessary for controlling a plant and vital data indicating biological information of a plant worker, the process data being received from a field device, the vital data being received from the plant worker, the calculator calculating first index data and second index data, the first index data indicating a gap between a current one of the process data and a previous one of the process data which is received when the plant is in a normal state, the second index data indicating a gap between a current one of the vital data and a previous one of the vital data which is received when the plant is in the normal state;

a determiner configured to determine health of the plant by using the first index data and the second index data which are calculated by the calculator, the health of the plant including an abnormal state, an unstable state, and a normal state,

wherein the determiner is configured to determine the health of the plant based on a magnitude relation between the first index data and a first threshold value set to the first index data and a magnitude relation between the second index data and a second threshold value set to the second index data,

wherein the determiner determines that the plant is in the abnormal state in a case where the first index data exceeds a first threshold value,

wherein the determiner determines that the plant is in the unstable state in a case where the first index data does not exceed the first threshold value and the second index data exceeds a second threshold value, and

wherein the determiner determines that the plant is in the normal state in a case where the first index data does not exceed the first threshold value and the second index data does not exceed the second threshold value.

2. The controller according to claim 1, further comprising storage configured to store first backup data and second backup data, the first backup data being data of an abnormal part of the first index data and the second index data, the second backup data being data indicating an abnormality frequency of the first index data and the second index data,

wherein the determiner is configured to perform a preliminary determination by using at least one of the first backup data and the second backup data before the determiner determines the health of the plant by using the first index data and the second index data.

3. The controller according to claim 2, further comprising a display configured to display a determination result of the health of the plant, which is determined by using the first index data and the second index data, and a determination result of the preliminary determination, which is determined by using the first backup data and the second backup data.

4. The controller according to claim 3, wherein the display is configured to display a radar chart of which axes indicate the first index data, the second index data, and the preliminary determination result.

5. The controller according to claim 4, wherein the display is configured to display the radar chart with a first line connecting upper allowable limits on the axes and a second line connecting lower allowable limits on the axes.

6. The controller according to claim 1, further comprising a display configured to display a determination result of the determiner.

7. The controller according to claim 1, wherein the calculator is configured to receive location data from the plant worker, the location data indicating a location of the plant worker.

8. The controller according to claim 7, wherein the determiner is configured to determine the health of the plant by using the process data, the vital data, and the location data.

17. A plant control system comprising:

a field device configured to be installed in a plant and perform at least one of a measurement and a control which are necessary for controlling the plant;

a controller, according to claim 1, configured to control the plant by transmitting the process data to the field device and receiving the process data from the field device; and

a manager configured to manage a state of the plant by collecting the field data from the field device, said manager comprising;

a calculator configured to receive field data indicating a state of a field device installed in a plant and vital data indicating biological information of a plant worker, the field data being received from the field device, the vital data being received from the plant worker, the calculator calculating first index data and second index data, the first index data indicating a gap between a current one of the field data and a previous one of the field data which is received when the plant is in a normal state, the second index data indicating a gap between a current one of the vital data and a previous one of the vital data which is received when the plant is in the normal state; and

a determiner configured to determine health of the plant by using the first index data and the second index data which are calculated by the calculator, the health of the plant including an abnormal state, an unstable state, and a normal state,

wherein the determiner is configured to determine the health of the plant based on a magnitude relation between the first index data and a first threshold value set to the first index data and a magnitude relation between the second index data and a second threshold value set to the second index data,

wherein the determiner determines that the plant is in the abnormal state in a case where the first index data exceeds a first threshold value,

wherein the determiner determines that the plant is in the unstable state in a case where the first index data does not exceed the first threshold value and the second index data exceeds a second threshold value, and

wherein the determiner determines that the plant is in the normal state in a case where the first index data does not exceed the first threshold value and the second index data does not exceed the second threshold value.

9. A manager comprising:

a hardware calculator or calculator stored in memory configured to receive field data indicating a state of a field device installed in a plant and vital data indicating biological information of a plant worker, the field data being received from the field device, the vital data being received from the plant worker, the calculator calculating first index data and second index data, the first index data indicating a gap between a current one of the field data and a previous one of the field data which is received when the plant is in a normal state, the second index data indicating a gap between a current one of the vital data and a previous one of the vital data which is received when the plant is in the normal state;

a determiner configured to determine health of the plant by using the first index data and the second index data which are calculated by the calculator, the health of the plant including an abnormal state, an unstable state, and a normal state,

wherein the determiner is configured to determine the health of the plant based on a magnitude relation between the first index data and a first threshold value set to the first index data and a magnitude relation between the second index data and a second threshold value set to the second index data,

wherein the determiner determines that the plant is in the abnormal state in a case where the first index data exceeds a first threshold value,

wherein the determiner determines that the plant is in the unstable state in a case where the first index data does not exceed the first threshold value and the second index data exceeds a second threshold value, and

wherein the determiner determines that the plant is in the normal state in a case where the first index data does not exceed the first threshold value and the second index data does not exceed the second threshold value.

10. The manager according to claim 9, further comprising storage configured to store first backup data and second backup data, the first backup data being data of an abnormal part of the first index data and the second index data, the second backup data being data indicating an abnormality frequency of the first index data and the second index data,

wherein the determiner is configured to perform a preliminary determination by using at least one of the first backup data and the second backup data before the determiner determines the health of the plant by using the first index data and the second index data.

11. The manager according to claim 10, further comprising a display configured to display a determination result of the health of the plant, which is determined by using the first index data and the second index data, and a determination result of the preliminary determination, which is determined by using the first backup data and the second backup data.

12. The manager according to claim 11, wherein the display is configured to display a radar chart of which axes indicate the first index data, the second index data, and the preliminary determination result.

13. The manager according to claim 12, wherein the display is configured to display the radar chart with a first line connecting upper allowable limits on the axes and a second line connecting lower allowable limits on the axes.

14. The manager according to claim 9, further comprising a display configured to display a determination result of the determiner.

15. The manager according to claim 9, wherein the calculator is configured to receive location data from the plant worker, the location data indicating a location of the plant worker.

16. The manager according to claim 15, wherein the determiner is configured to determine the health of the plant by using the field data, the vital data, and the location data.

18. A data processing method comprising:

receiving process data which is necessary for controlling a plant from a field device installed in the plant;

receiving vital data which is biological information of a plant worker from the plant worker;

calculating first index data and second index data, the first index data indicating a gap between a current one of the process data and a previous one of the process data which is received when the plant is in a normal state, the second index data indicating a gap between a current one of the vital data and a previous one of the vital data which is received when the plant is in a normal state;

determining health of the plant by using the first index data and the second index data, the health of the plant including an abnormal state, an unstable state, and a normal state;

determining the health of the plant based on a magnitude relation between the first index data and a first threshold value set to the first index data and a magnitude relation between the second index data and a second threshold value set to the second index data;

determining that the plant is in the abnormal state in a case where the first index data exceeds a first threshold value;

determining that the plant is in the unstable state in a case where the first index data does not exceed the first threshold value and the second index data exceeds a second threshold value; and

determining that the plant is in the normal state in a case where the first index data does not exceed the first threshold value and the second index data does not exceed the second threshold value.