Process model identification in a process control system

• US 10,310,456 B2
• Filed: 04/22/2014
• Issued: 06/04/2019
• Est. Priority Date: 10/04/2005
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Caldwell, John M., Blevins, Terrence L., Wojsznis, Peter, Wojsznis, Wilhelm K.
• Primary Examiner(s): Shechtman, Sean
• Application Number:
  US14/258,527
• Publication Number:
  US 20140228979A1
• Time in Patent Office: 1,869 Days
• Field of Search: None
• CPC Class Codes: G05B 13/04 involving the use of models or simulators
• CPC Class Codes: G05B 13/048 using a predictor
• CPC Class Codes: G05B 19/0428 Safety, monitoring G05B19/0423 takes precedence
• CPC Class Codes: G05B 23/0254 based on a quantitative model, e.g. mathematical relationships between inputs and outputs; functions: observer, Kalman filter, residual calculation, Neural Networks
• CPC Class Codes: G05B 23/0272 Presentation of monitored results, e.g. selection of status reports to be displayed; Filtering information to the user

Abstract

A method of controlling and managing a process control system having a plurality of control loops includes implementing a plurality of control routines to control operation of the plurality of control loops, respectively, wherein the control routines may include at least one non-adaptive control routine. The method then collects operating condition data in connection with the operation of each control loop, and identifies a respective process model for each control loop from the respective operating condition data collected for each control loop. The identification of the respective process models may be automatic as a result of a detected process change or may be on-demand as a result of an injected parameter change. The process models are then analyzed to measure or determine the operation of the process control loops.

Claims

1. A method of implementing a process control system having a process control loop, the method comprising:

implementing, via a controller of the process control system, a control routine to control operation of the control loop;

detecting, via the controller, a trigger event associated with a change in an input or output value within the process control system; and

in response to detecting the trigger event, automatically performing the following while the process control system remains operating on-line;

collecting, via the controller or a computer processing device communicatively connected to the controller, operating condition data including current data values of one or more process variables indicative of the operation of the control loop;

generating, via the controller or the computer processing device, a process model for the control loop based on the operating condition data collected in response to the trigger event; and

analyzing, via the controller or the computer processing device, the process model to evaluate the operation of the control loop, including using the process model to determine a control loop performance index indicating a quality of performance of the control routine in controlling the control loop by (i) determining an oscillation period of the control loop, (ii) identifying a second control loop of the process control system also having the oscillation period, and (iii) identifying a process interaction between the control loop and the second control loop.

2. The method of claim 1, wherein the analyzing the process model comprises diagnosing a control problem based on the process model.

3. The method of claim 1, wherein the analyzing the process model comprises identifying a process change based on the process model.

4. The method of claim 1, wherein analyzing the process model further comprises determining a controller tuning change.

5. The method of claim 4, wherein determining a controller tuning change comprises generating, via the controller or the computer processing device, a recommendation to implement an adaptive control scheme.

6. The method of claim 4, wherein analyzing the process model further comprises simulating, using the controller or the computer processing device, the operation of the control loop based on the process model and the tuning change.

7. The method of claim 1, further comprising storing the process model in a process model history within an electronically accessible computer memory.

8. The method of claim 7, wherein analyzing the process model comprises comparing, using the controller or the computer processing device, the process model with other process models previously identified for the control loop.

9. The method of claim 1, wherein analyzing the process model comprises determining, via the controller or the computer processing device, a stability of the control loop.

10. The method of claim 1, wherein analyzing the process model comprises determining, via the controller or the computer processing device, an abnormal condition associated with the control loop.

11. The method of claim 1, wherein analyzing the process model comprises determining, via the controller or the computer processing device, a source of a control problem within the control loop.

12. The method of claim 1, wherein analyzing the process model includes generating, via the controller or the computer processing device, a performance report for the control loop.

13. The method of claim 1, further including enabling a user, via the computer processing device, to approve of the identified process model prior to analyzing the process model.

14. The method of claim 1, wherein generating the process model for the control loop based on the operating condition data includes determining, via the controller or the computer processing device, a quality measurement of the identified process model.

15. The method of claim 1, further including generating, via the controller or the computer processing device, a recommendation for altering the control loop.