System to manually initiate an emergency shutdown test and collect diagnostic data in a process control environment

• US 20020145515A1
• Filed: 04/05/2002
• Published: 10/10/2002
• Est. Priority Date: 04/05/2001
• Status: Active Grant

• Current Assignee: Saudi Arabian Oil Company (Government of Saudi Arabia)
• Original Assignee: Fisher Controls International LLC (Emerson Electric Company)
• Inventors: Snowbarger, Jimmie L., Ali, Riyaz M.
• Granted Patent: US 7,079,021 B2
• Time in Patent Office: Days
• US Class Current: 340/514
• CPC Class Codes: G05B 19/0428 Safety, monitoring G05B19/0423 takes precedence
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/24037 Switch on pin of microprocessor for test
• CPC Class Codes: G05B 23/0256 injecting test signals and analyzing monitored process response, e.g. injecting the test signal while interrupting the normal operation of the monitored system; superimposing the test signal onto a control signal during normal operation of the monitored system
• CPC Class Codes: G05B 9/02 electric
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning
• CPC Class Codes: Y10T 137/0396 Involving pressure control
• CPC Class Codes: Y10T 137/0441 Repairing, securing, replacing, or servicing pipe joint, valve, or tank
• CPC Class Codes: Y10T 137/0753 Control by change of position or inertia of system

Abstract

An emergency shutdown test, wherein the emergency shutdown test system includes an emergency shutdown device controller and sensors to provide data to the controller. The emergency shutdown device controller has a processor, a memory coupled to the processor and an auxiliary input couple to the processor, wherein an emergency shutdown test is stored in the memory, and the auxiliary input is adapted to receive a binary signal and sensor data.

A first routine is stored in the memory and is adapted to be executed on the processor to cause the emergency shutdown test to be performed in response to the receipt of the binary signal at the auxiliary input. The memory is also adapted to store a second routine, wherein the second routine is adapted to be executed on the processor to cause sensor data to be recorded in the memory during the emergency shutdown test. The processor compares a plurality of predetermined limits to the received sensor data to determine if the valve is fully operational or if possible problems exist.

Claims

1. An emergency shutdown test system comprising:

an emergency shutdown device controller having;

a processor;

a memory coupled to the processor, wherein an emergency shutdown test procedure is stored in the memory;

an auxiliary input coupled to the processor and adapted to receive a binary signal;

a first routine stored in the memory and adapted to be executed on the processor to cause the emergency shutdown test procedure to be performed in response to the receipt of the binary signal at the auxiliary input; and

a second routine stored in the memory and adapted to be executed on the processor to acquire data from a sensor and to cause the data to be stored in the memory, during the emergency shutdown test.

2. The emergency shutdown test system of claim 1, further including a communication unit, wherein the communication unit is coupled to the processor and communicates with a portable communication unit.

3. The emergency shutdown test system of claim 1, wherein the first routine is further adapted to prevent the activation of the emergency shutdown test unless an auxiliary-input-type is activated.

4. The emergency shutdown test system of claim 1, wherein the first and second routines comprise valve specific, configurable scripts.

5. The emergency shutdown test system of claim 1, wherein the emergency shutdown device comprises an emergency shutdown valve.

6. The emergency shutdown test system of claim 5, wherein the second routine is further adapted to cause a valve plug setpoint to be compared to an actual valve stem position of the emergency shutdown valve.

7. The emergency shutdown test system of claim 5, wherein the emergency shutdown test procedure includes a partial stroke test for the emergency shutdown valve.

8. The emergency shutdown test system of claim 5, wherein the second routine stored in the memory is further adapted to automatically cause the processor to acquire data from a sensor when a valve plug of the valve moves.

9. The emergency shutdown test system of claim 5, wherein the emergency shutdown device controller further includes an analog-to-digital (“

A/D”

) converter to convert an analog input from a sensor to digital data for utilization by the processor.

10. The emergency shutdown test system of claim 9, wherein the analog input converted by the A/D converter includes an analog input selected from the group of analog inputs consisting of:

valve stem travel, line pressure, loop current, and binary signal generation.

11. The emergency shutdown test system of claim 1, wherein the second routine is further adapted to cause a plurality of inputs that are coupled to the processor to be monitored, during the emergency shutdown test procedure, for one of several conditions that would cause the emergency shutdown test to be aborted.

12. The emergency shutdown test system of claim 11, wherein the data acquired from the sensor is compared with a predetermined limit.

13. The emergency shutdown test system of claim 11, wherein the conditions are selected from a group of conditions consisting of:

minimum partial stroke pressure, travel deviation, and valve stuck.

15. The control device test system of claim 14, wherein the first routine is further adapted to cause the auxiliary input to be monitored for a binary signal having a predetermined time duration.

16. The control device test system of claim 14, wherein the first and second routines comprise valve specific, configurable scripts.

17. The control device test system of claim 14, wherein the control device comprises an emergency shutdown valve.

18. The control device test system of claim 17, wherein the second routine is further adapted to compare a predetermined limit to a valve stem position of the emergency shutdown valve, and create an alarm if the comparison is greater than a predetermined threshold.

19. The control device test system of claim 14, wherein the second routine is further adapted to monitor a plurality of sensor inputs during the control device test, and to acquire and compare data from the sensor inputs to a plurality of predetermined limits, and to indicate an alarm condition, and if appropriate, to cause the control device test to be aborted.

20. The control device test system of claim 14, wherein the device controller further includes an analog-to-digital (“

A/D”

) converter to convert an analog input signal from a sensor to a digital value for usage by the processor.

21. The control device test system of claim 20, wherein the analog input measured by the A/D converter includes an analog input selected from a group of sensor inputs consisting of:

valve stem travel, line pressure, and loop current.

14. A control device test system comprising:

a device controller having;

a processor;

a memory coupled to the processor, wherein a control device test is stored in the memory;

an auxiliary input coupled to the processor and adapted to receive a binary signal;

a first routine stored in the memory and adapted to be executed on the processor to cause the control device test to be performed in response to the receipt of the binary signal at the auxiliary input; and

a second routine stored in the memory and adapted to be executed on the processor to cause data to be acquired from a sensor and recorded in the memory during the control device test; and

a communication unit, coupled to the processor, to transfer the data to a user.

22. A method of conducting an emergency shutdown test on an emergency shutdown valve, comprising:

storing an emergency shutdown test script in a memory of a controller;

storing at least one predetermined limit in the memory of the controller;

activating a switch to perform the emergency shutdown test, wherein a processor is responsive to the switch activation;

acquiring sensor data from a sensor and storing the sensor data in the memory;

comparing the sensor data to the at least one predetermined limit and creating alarms if the difference between the sensor data and the at least one predetermined limit is greater than a predetermined threshold.

23. The method of claim 22, further comprising aborting the emergency shutdown test if an alarm is created.

24. The method of claim 22, further comprising transferring the sensor data to a portable communication unit.

25. The method of claim 22, wherein the step of comparing the sensor data includes comparing a valve plug setpoint to an actual valve stem position.

26. The method of claim 22, wherein the step of storing the emergency shutdown test script includes storing a partial stroke test for the emergency shutdown valve.

27. The method of claim 22, further comprising converting an analog input from a sensor to digital data for utilization by a processor of the controller.

28. The method of claim 22, further comprising causing a plurality of inputs that are coupled to a processor of the controller to be monitored for one of several conditions that would cause the emergency shutdown test to be aborted.