Fusion of process performance monitoring with process equipment monitoring and control

• US 20020077711A1
• Filed: 09/17/2001
• Published: 06/20/2002
• Est. Priority Date: 02/22/1999
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Schleiss, Trevor D., Nixon, Mark J., Keyes, Marion A. IV, Belvins, Terrence L., Gudaz, John A.
• Granted Patent: US 7,206,646 B2
• Time in Patent Office: Days
• US Class Current: 700/51
• CPC Class Codes: C10G 11/187 Controlling or regulating
• 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 process control system uses a data collection and distribution system and an asset utilization suite to collect data or information pertaining to the assets of a process plant from various sources or functional areas of the plant including, for example, the process control functional areas, the maintenance functional areas and the process performance monitoring functional areas. This data and information is manipulated in a coordinated manner by the data collection and distribution system and is redistributed to other applications where this it is used to perform overall better or more optimal control, maintenance and business activities. Information or data may be collected by maintenance functions pertaining to the health, variability, performance or utilization of a device, loop, unit, area, etc. and this information may then be sent to and displayed to a process operator or maintenance person to inform that person of a current or future problem. A user interface is provided that enables users to access and manipulate the expert engine to optimize plant operation or cause optimization of plant operation, to get information about the operation of the plant, etc. Furthermore, applications, such as work order generation applications may automatically generate work orders, parts or supplies orders, etc. based on events occurring within the plant.

Claims

1. A process control system within a plant including:

process equipment monitoring devices that collect equipment data;

process control monitoring devices that collect process control data;

process models adapted to perform process performance monitoring to generate process performance data; and

a computer system that implements a software routine that uses two or more of the equipment data, the process control data and the process performance data to perform a function within the plant.

2. The process control system of claim 1, wherein the function within the plant is a diagnostic function and the software routine is a diagnostic routine that combines two or more of the equipment data, the process control data and the process performance data to perform a diagnostic function.

3. The process control system of claim 2, wherein the software routine includes two or more of a process control diagnostic routine, an equipment monitoring diagnostic routine and a process performance diagnostic routine.

4. The process control system of claim 3, wherein the software routine includes two or more of a process control model , an equipment model and a performance monitoring model.

5. The process control system of claim 2, wherein the diagnostic routine includes a predictive routine that predicts a condition in the future based on two or more of the equipment data, the process control data and the process performance data.

6. The process control system of claim 2, further including a recommendation software routine which makes recommendations to a user in response to a diagnostic decision made by the diagnostic routine.

7. The process control system of claim 2, further including an action software routine which implements one of a control action or a process action based on a diagnostic decision made by the diagnostic routine.

8. The process control system of claim 2, further including an order generating routine which automatically generates an order based on a diagnostic decision made by the diagnostic routine.

9. The process control system of claim 8, wherein the order generating routine generates a work order ordering work to be performed within the plant.

10. The process control system of claim 8, wherein the order generating routine generates a part order ordering one or more parts needed for the plant.

11. The process control system of claim 2, wherein the diagnostic routine performs backtracking based on two or more of the process control data, the equipment data and the process performance data.

12. The process control system of claim 1, wherein the function is a viewing function and the software routine is adapted to create and display a display screen via a display terminal using two or more of the collected equipment data, the process control data and process performance data.

13. The process control system of claim 12, wherein the software routine includes an index creation routine that creates indexes associated with process control components or with equipment components or process performance components and wherein the software routine creates a view of the process control plant displaying the indexes.

14. The process control system of claim 12, wherein the software routine displays process two or more of a process control alarm, an equipment alarm and a process performance alarm together on a display screen.

15. The process control system of claim 1, further including one or more data reconciliation applications which process the collected equipment data or the collected process control data or the process performance data.

16. The process control system of claim 15, wherein the equipment data or the process control data or the process performance data is compressed.

17. The process control system of claim 1, wherein the software routine is distributed among two or more computers within the plant.

19. The method of claim 18, wherein the further function within the plant is a diagnostic function and the step of using two or more of the equipment data and the process control data and the process performance data includes the step of combining two or more of the equipment data and the process control data and process performance data to perform a diagnostic function.

20. The method of claim 19, wherein the step of combining two or more of the equipment data and the process control data and the process performance data includes the steps of using two or more of a process control diagnostic routine to process the process control data, an equipment monitoring diagnostic routine to process the equipment data and a process performance monitoring routine to process the process performance data.

21. The method of claim 20, wherein the step of combining two or more of the equipment data and the process control data and the process performance data includes the step of using two or more of equipment models, process control models and process performance models.

22. The method of claim 19, wherein the step of combining two or more of the equipment data and the process control data and the process performance data includes the step of predicting a condition in the future based on two or more of the equipment data and the process control data and the process performance data.

23. The method of claim 19, further including the step of recommending one or more actions to a user in response to a diagnostic decision made during the step of combining two or more of the equipment data and the process control data and the process performance data.

24. The method of claim 19, further including the step of implementing one of a control action or a process action based on a diagnostic decision made during the step of combining two or more of the equipment data and the process control data and the process performance data.

25. The method of claim 19, further including automatically generating an order based on a diagnostic decision made during the step of combining two or more of the equipment data and the process control data and the process performance data.

26. The method of claim 25, wherein the order generating step generates a work order ordering work to be performed within the plant.

27. The method of claim 25, wherein the order generating step generates a part order ordering one or more parts needed for the plant.

28. The method of claim 19, wherein the step of combining two or more of the equipment data and the process control data and the process performance data includes the step of performing backtracking based on two or more of the equipment data and the process control data and the process performance data.

29. The method of claim 18, wherein the function is a viewing function and the step of using two or more of the equipment data and the process control data and the process performance data includes the step of creating a display screen using two or more of the collected equipment data and the process control data and the process performance data.

30. The method of claim 29, wherein the step of using two or more of the equipment data and the process control data and the process performance data includes the step of creating one or more indexes associated with process control components or with equipment components or with process performance components and wherein the step of creating a display screen includes the step of creating a view of the process control plant displaying the one or more indexes.

31. The method of claim 29, wherein step of creating a display screen includes the step of displaying two or more of a process control alarm, an equipment alarm and a process performance alarm together on the display screen.

32. The method of claim 18, further including the step of processing the collected equipment data or the collected process control data or the process performance data prior to the step of using two or more of the equipment data and the process control data and the process performance data.

33. The method of claim 18, further including the step of compressing at least a portion of the process control data or the equipment data or the process performance data.

35. The process control system of claim 34, wherein the multiple different source types includes two or more of hand held collection devices, laboratory chemical and physical measurement sources, direct on-line input sources and remote sources.

36. The process control system of claim 34, wherein the process control system is distributed across a geographically distributed network.

37. The process control system of claim 36 wherein at least one of the communication networks is a shared communication channel comprising one of the internet or a satellite communication network.

38. The process control system of claim 36 wherein the data collection routines collect data via a physical medium comprising one of wired, wireless, coaxial cable, telephone modem, fiber optic, optical, meteor burst, satellite medium using one of a Fieldbus, IEEE 802.3, blue tooth, X.25 or X.400 communication protocol.

39. The process control system of claim 34 wherein the data collection routines operate independently and communicate with each other via the one or more communication networks.

40. The process control system of claim 34 wherein each of the data collection routines includes a data processing routine that reconciles, verifies, validates and formats the collected data in a consistent format.

41. The process control system of claim 34, wherein the data collection routines send the collected data to a control system using one of the controllers and one of the user interfaces and wherein the condition monitoring routine reconciles, verifies, validates and formats the collected data in a consistent format.

42. The process control system of claim 41, wherein the condition monitoring routine is stored and executed on a subassembly processor associated with the control system.

43. The process control system of claim 42, wherein the subassembly processor is connected directly to the user interface and the controller of the control system via a system bus.

44. The process control system of claim 42, wherein the controller includes an input/output system adapted to connect the controller of the control system to process control equipment and wherein the subassembly processor is integrated with the controller input/output system.

45. The process control system of claim 44, wherein the data collection routines include a compression routine that compress the collected data.

46. The process control system of claim 45, wherein the compression routine uses a compression technique comprising one of wavelet signal representation, Fourier, Hadamard transformation and communication of the coefficients, exception processing, and swinging door data compression.

48. The process control system of claim 47, wherein the display routine displays the equipment and process control strategy configuration information and the condition monitoring information in multiple levels, including a high level presenting information pertaining to different elements of the equipment and process control strategy and one or more lower levels providing more information about individual elements within the high level including condition monitoring information.

49. The process control system of claim 48, wherein the display routine enables a user to go from a higher level layer to a lower level layer by selecting an element within a screen depicting the higher level layer.

18. A method of operating a process control system within a plant including the steps of:

collecting equipment data related to the status of equipment within the plant;

collecting process control data related to the status of process control activities within the plant;

collecting process performance data relating to the performance of the process; and

using two or more of the equipment data, the process control data and the process performance data to perform a further function within the plant.

34. A process control system comprising:

multiple process control devices;

one or more controllers;

one or more user interfaces;

one or more data collection routines implemented on processing devices that collect process control data, equipment data and process performance data; and

a condition monitoring routine communicatively connected to the data collection routines to accept and process the process control data, the equipment data and the process performance data collected by the data collection routines to perform condition monitoring within the process control system;

wherein the process control devices, controllers and user interfaces are communicatively connected via one or more communication networks and wherein the data collection routines are configured to transparently accept data from multiple different source types within the process control system.

47. A process control system comprising:

multiple process control devices;

one or more controllers;

one or more user interfaces;

a communication network that interconnects the one or more controllers and the one or more user interfaces;

a database that stores equipment and process control strategy configuration information pertaining to the configuration of the process control system;

one or more data collection routines implemented on processing devices that collect process control data, equipment data and process performance data;

a condition monitoring routine communicatively connected to the one of more data collection routines to accept and process the process control data, the equipment data and the process performance data collected by the data collection routines to perform condition monitoring within the process control system; and

a display routine that displays the equipment and process control strategy configuration information associated with the process control system as stored in the database along with condition monitoring information pertaining to or generated by the condition monitoring routine, via the one or more user interfaces.