Background collection of diagnostic data from field instrumentation devices

• US 10,120,350 B2
• Filed: 03/11/2013
• Issued: 11/06/2018
• Est. Priority Date: 03/11/2013
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Dicaire, Andre A., Schleiss, Trevor D.
• Primary Examiner(s): Buhr, M.N. Von
• Application Number:
  US13/793,374
• Publication Number:
  US 20140257529A1
• Time in Patent Office: 2,066 Days
• Field of Search: 700 17, 700 21, 700 28, 700 52, 700 79, 700 83
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 23/0267 Fault communication, e.g. human machine interface [HMI]

Abstract

In a method and system, a device tag allows automatic configuration of a process control system to download and cache device diagnostic data associated with one or more process control field devices. The device diagnostic data are downloaded and cached using bandwidth not otherwise required for real-time process control communications. The device diagnostic data may be polled asynchronously and/or according to a low priority, background task. The device diagnostic data include one or more non-static parameter values. The cached parameter values may be used in display routines, control routines, or any routine for which the update frequency is sufficient. Each cached parameter value may also have associated with it a status.

Claims

1. A method for controlling a process in a plant, the method comprising:

communicatively coupling a field device to a process controller via an input/output device, wherein;

(i) the process controller is a device located in the plant and configured to;

(a) receive measurements of process parameters, and (b) generate control signals for controlling the process based on a process control routine and the measurements of process parameters;

(ii) the field device is a device located in the plant and configured to;

(a) measure the measured process parameters, or (b) actuate in response to receiving the control signals; and

(iii) the input/output device is a device located in the plant and configured to;

(a) route the measured process parameters received from the field device to the process controller via a backplane to which the process controller is connected, and (b) route the control signals received from the process controller via the backplane to the field device;

obtaining a device tag for the field device;

configuring the input/output device according to the device tag to;

(i) cause the input/output device to perform prioritized operations including a low priority retrieval of a value of a dynamic device diagnostic parameter for the field device, such that real-time process control communications performed by the input/output device receive priority over the low priority retrieval;

(ii) cache the value of the dynamic device diagnostic parameter; and

(iii) provide one or more applications access to the cached value of the dynamic device diagnostic parameter;

retrieving, by the input/output device, the value of the dynamic device diagnostic parameter for the field device before the one or more applications have requested access to the value of the dynamic device diagnostic parameter;

caching the value of the dynamic device diagnostic parameter before the one or more applications have requested the value of the dynamic device diagnostic parameter; and

providing the cached value of the dynamic device diagnostic parameter to the one or more applications.

2. The method according to claim 1, wherein obtaining a device tag for the field device comprises retrieving device tag from the field device.

3. The method according to claim 1, wherein obtaining a device tag for the field device comprises receiving in a configuration application a selection of a device tag to associate with the field device.

4. The method according to claim 1, wherein retrieving the value of the dynamic device diagnostic parameter comprises retrieving a value of at least one of the group consisting of:

a calibration state;

a calibration due date;

a device state;

an alert status;

an alarm status;

a device health status;

a measured process parameter;

an input of a function block; and

an output of a function block.

5. The method according to claim 4, wherein retrieving a value of an output of a function block comprises retrieving a value of an output of a statistical processing module (SPM) block.

6. The method according to claim 1, wherein retrieving the value of the dynamic device diagnostic parameter comprises polling the dynamic device diagnostic parameter utilizing bandwidth not otherwise required for real-time process control communications.

7. The method according to claim 1, wherein retrieving the value of the dynamic device diagnostic parameter comprises polling the dynamic device diagnostic parameter according to an asynchronous call.

8. The method according to claim 1, wherein retrieving the value of the dynamic device diagnostic parameter device comprises polling the dynamic device diagnostic parameter according to a low priority, background task.

9. The method according to claim 1, wherein caching the value of the dynamic device diagnostic parameter further comprises:

determining a data status for each of one or more cached values of the dynamic device diagnostic parameter; and

storing the determined data status as associated with the corresponding cached value of the dynamic diagnostic data parameter.

10. The method according to claim 9, wherein determining a data status comprises:

determining a time elapsed since the cached value of the dynamic device diagnostic parameter was retrieved;

comparing the time elapsed to a predetermined threshold value;

determining that the data status is good if the time elapsed is less than the predetermined threshold value; and

determining that the data status is bad if (1) the time elapsed is greater than the predetermined threshold value or (2) an active communication alert exists for the field device from which the value of the dynamic device diagnostic parameter was retrieved.

11. The method according to claim 10, wherein the predetermined threshold value to which the elapsed time for a first one of the one or more cached values of the dynamic device diagnostic parameter is compared is different from the predetermined threshold value to which the elapsed time for a second one of the one or more cached values of the dynamic device diagnostic parameter is compared.

12. The method according to claim 1, wherein caching the value of the dynamic device diagnostic parameter comprises caching the value of the dynamic device diagnostic parameter in a memory device of the input/output device.

13. The method according to claim 1, wherein providing the cached value of the dynamic device diagnostic parameter to the one or more applications comprises providing the cached value of the dynamic device diagnostic parameter to at least one of the group consisting of:

a device detail display;

an alarm display; and

a device faceplate.

14. The method according to claim 1, wherein providing the cached value of the dynamic device diagnostic parameter to the one or more applications comprises providing the value of the dynamic device diagnostic parameter to a control routine.

15. The method according to claim 1, wherein the one or more applications includes a maintenance display and an operator control display, the maintenance display and the operator control display each including a cached value of the dynamic device diagnostic parameter and the method further comprising:

identifying a problem with the process in using maintenance display; and

fixing the problem with the process using the operator control display.

16. A process control system comprising:

a process controller located in a plant and executing one or more process control routines to control a process, the process controller configured to;

(a) receive measurements of process parameters for the process, and (b) generate control signals for controlling the process based on the process control routines and the measurements of process parameters;

an input/output device communicatively coupled to the process controller;

a plurality of field devices communicatively coupled to the input/output device via a bus and, via the input/output device, to the process controller, at least one of the plurality of field devices generating a value of a dynamic device diagnostic parameter, the at least one of the plurality of field devices configured to;

(a) measure the measured process parameters, or (b) actuate in response to receiving the control signals;

wherein the input/output device is configured to;

(a) route the measured process parameters received from the at least one of the plurality of field devices to the process controller via a backplane to which the process controller is connected, and (b) route the control signals received from the process controller via the backplane to the field device;

a device tag associated with the at least one field device; and

one or more memory devices storing;

(a) data for configuring the input/output device to perform prioritized operations including a low priority retrieval of the value of the dynamic device diagnostic parameter, such that real-time process control communications performed by the input/output device receive priority over the low priority retrieval;

(b) a first routine operable to cause the input/output device to;

(i) retrieve the value of the dynamic device diagnostic parameter generated by the at least one field device, and

(ii) cache the value of the dynamic device diagnostic parameter retrieved from the at least one field device before the value of the dynamic device diagnostic parameter is used to perform a process control function; and

(c) a second routine operable to read the stored value of the dynamic device diagnostic parameter from the cache and perform the process control function using the value of the dynamic device diagnostic parameter.

17. The process control system according to claim 16, wherein the device tag for the at least one field device is stored in a memory device disposed within the at least one field device.

18. The process control system according to claim 16, wherein the device tag is stored in a configuration database and associated with the at least one field device according to an input received via a configuration application.

19. The process control system according to claim 16, wherein the dynamic device diagnostic parameter is one of the group consisting of:

a calibration state;

a calibration due date;

a device state;

an alert status;

an alarm status;

a device health status;

a measured process parameter;

an input of a function block; and

an output of a function block.

20. The process control system according to claim 19, wherein the dynamic device diagnostic parameter is the output of a function block and the output of the function block comprises the output of a statistical processing module (SPM) block.

21. The process control system according to claim 16, wherein the first routine is operable to retrieve the value of the dynamic device diagnostic parameter by polling the at least one field device using bandwidth not otherwise required for real-time process control communications.

22. The process control system according to claim 16, wherein:

one or more values of the dynamic device diagnostic parameter are cached, each of the data values associated with a corresponding value of the dynamic device diagnostic parameter; and

a data status corresponding to each of the one or more values of the dynamic device diagnostic parameter is stored.

23. The process control system according to claim 22, wherein the data status is determined according to a comparison of a time elapsed since the corresponding value of the dynamic device diagnostic parameter was retrieved to a predetermined threshold value.

24. The process control system according to claim 23, wherein the predetermined threshold value to which the elapsed time for a first one of the one or more cached values of the dynamic device diagnostic parameter is compared is different from the predetermined threshold value to which the elapsed time for a second one of the one or more cached values of the dynamic device diagnostic parameter is compared.

25. The process control system according to claim 16, wherein the value of the dynamic device diagnostic parameter is cached on a memory device of the input/output device.

26. The process control system according to claim 16, wherein the second routine is a device detail display routine, an alarm display routine, or a device faceplate display routine.

27. The process control system according to claim 16, wherein the second routine is a control routine.

28. The process control system according to claim 16, wherein the second routine is a maintenance display routine that includes the value of the dynamic device diagnostic parameter stored in the cache and further comprising:

an operator control display routine that includes a user interface component dynamically linked to the one or more process control routines to control the operation of the process via user interaction with the user interface component, such that a problem with the process identified in the maintenance display routine is fixed using the accessible operator control display routine.

29. The process control system according to claim 16, wherein the first routine is an asynchronous polling routine.

30. The process control system according to claim 16, wherein the first routine is a low priority, background task.