Quality control system and method for construction, commissioning, and other initiation of a process plant

• US 20060087402A1
• Filed: 10/22/2004
• Published: 04/27/2006
• Est. Priority Date: 10/22/2004
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Manning, Anthony J., Martyna, Chuck
• Granted Patent: US 8,645,092 B2
• Time in Patent Office: Days
• US Class Current: 340/3.100
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/24012 Use camera of handheld device, head mounted display
• CPC Class Codes: G05B 2219/32196 Store audit, history of inspection, control and workpiece data into database
• CPC Class Codes: G05B 2219/36159 Detachable or portable programming unit, display, pc, pda
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

Disclosed herein are a system and method useful for providing quality control services in connection with a project for initiation of a process plant having field devices disposed at respective field sites in the process plant. Quality control data is generated at the field sites with a portable computer in response to quality control task information provided via a user interface of the portable computer. The quality control data is transmitted to a host computer having a database with project history information, and stored in the database through integration of the quality control data with the project history information. The quality control data may be generated via check lists downloaded from the host computer to the portable computer, where the check lists specify tasks customized for the respective field site. Recordation of the quality control data via the check lists may include entering deficiency information. The initiation project may include commissioning of the process plant, and the project history information in the database may be made available for subsequent preventative maintenance or other work during operation of the process plant.

Claims

1. A method for providing quality control services in connection with a project for initiation of a process plant wherein field devices are disposed at respective field sites in the process plant, the method comprising the steps of:

generating quality control data at the field sites with a portable computer in response to quality control task information provided via a user interface of the portable computer;

transmitting the quality control data to a host computer having a database with project history information; and

storing the quality control data in the database by integrating the quality control data with the project history information in the database.

2. The method of claim 1, further comprising the step of storing the quality control task information in a memory of the portable computer to enable quality control work at the field sites.

3. The method of claim 2, wherein the quality control task information comprises a check list for each respective field device, and wherein the check list is stored in the memory of the portable computer in association with equipment specification data for each respective field device.

4. The method of claim 3, wherein the generating step comprises the step of entering comment data via the user interface for storage in the memory of the portable computer in connection with a task specified in the respective check list.

5. The method of claim 3, wherein the generating step comprises the step of modifying the equipment specification data stored in the memory of the portable computer upon visual inspection of the field device.

6. The method of claim 3, further comprising the step of using the portable computer to select a respective field device by searching the memory of the portable computer based on one or more project criteria selected from the group consisting of plant, system, subsystem, equipment type, and equipment tag name.

7. The method of claim 3, wherein the generating step comprises the steps of selecting a task from the check list for a respective field device and entering deficiency information associated with the task via the user interface for storage in the memory of the portable computer.

8. The method of claim 3, wherein the generating step comprises the step of entering, via the user interface for storage in the memory of the portable computer, an indication that each task shown in the check list for a respective field device has been completed such that the quality control data comprises a signoff indication for the respective field device.

9. The method of claim 1, wherein the quality control data comprises a digital image of the respective field device such that the generating step comprises the step of storing the digital image recorded by a digital camera of the portable computer in a memory of the portable computer.

10. The method of claim 9, wherein the digital image recording step is performed in connection with a quality control problem such that the quality control data further comprises textual description of the quality control problem.

11. The method of claim 1, wherein the storing step comprises the step of synchronizing the quality control data with the project history information such that the quality control data overwrites portions of the project history information for a respective field device.

12. The method of claim 11, wherein the synchronizing step comprises the step of exporting deficiency information stored in the database in association with respective field devices to a memory of the portable computer such that the deficiency information becomes a portion of the quality control task information available for display via the user interface of the portable computer.

13. The method of claim 11, wherein the synchronizing step is implemented in accordance with rules specifying conditions under which the quality control data may overwrite portions of the project history information for a respective field device.

14. The method of claim 1, wherein the project comprises a commissioning project such that the project history information comprises commissioning history information, and wherein the method further comprises the step of utilizing the commissioning history information in a preventative maintenance system used during subsequent operation of the process plant.

15. The method of claim 1, wherein the transmitting step comprises the step of establishing communication between the portable computer and the host computer via an Internet connection.

16. A method of using a portable computer to facilitate quality control in connection with a project for initiation of a process plant having a field device disposed at a field site in the process plant, the method comprising the steps of:

displaying a quality control check list on a user interface of the portable computer at the field site;

recording quality control data at the field site via the user interface by storing the quality control data in a memory of the portable computer; and

,

transmitting the quality control data from the portable computer to a host computer for quality control in connection with the project.

17. The method of claim 16, further comprising the step of storing the quality control check list in the memory of the portable computer in association with equipment specification data for the field device.

18. The method of claim 17, wherein the recording step comprises the step of modifying the equipment specification data stored in the memory of the portable computer upon inspection of the field device.

19. The method of claim 16, further comprising the step of entering search criteria via the user interface to search the memory of the portable computer to select the field device wherein the search criteria are selected from the group consisting of plant, system, subsystem, equipment type, and equipment tag name.

20. The method of claim 16, wherein the recording step comprises the steps of entering deficiency information associated with the field device via the user interface for storage in the memory of the portable computer.

21. The method of claim 16, wherein the recording step comprises the step of entering, via the user interface for storage in the memory of the portable computer, an indication that each task shown in the quality control check list has been completed such that the quality control data comprises a signoff indication for the field device.

22. The method of claim 16, wherein the quality control data comprises a digital image of the field device such that the recording step comprises the step of actuating a digital camera of the portable computer.

23. The method of claim 16, further comprising the step of storing the quality control data in a memory of the host computer by integrating the quality control data into a project history database.

24. The method of claim 23, wherein the storing step comprises the step of synchronizing the quality control data with the project history database such that the quality control data overwrites a portion of the project history database associated with the field device.

25. The method of claim 24, wherein the synchronizing step is implemented in accordance with rules specifying conditions under which the quality control data may overwrite portions of the project history database associated with the field device

26. The method of claim 24, wherein the synchronizing step comprises the step of exporting deficiency information stored in the project history database in association with the field device to the memory of the portable computer such that the deficiency information is available for display via the user interface of the portable computer in connection with the quality control check list.

27. The method of claim 23, wherein the project comprises a commissioning project such that the project history information comprises commissioning history information, and wherein the method further comprises the step of utilizing the commissioning history information in a preventative maintenance system used during subsequent operation of the process plant.

28. The method of claim 16, wherein the transmitting step comprises the step of establishing communication between the portable computer and the host computer via an Internet connection.

29. A portable computer for quality control in connection with a project for initiation of a process plant having field equipment at a field site, the portable computer comprising:

a user interface suitable for operation at the field site;

a processor communicatively coupled to the user interface;

a memory communicatively coupled to the processor;

a data collection routine stored in the memory and adapted for execution by the processor to display via the user interface a quality control check list for the field equipment and to store in the memory quality control data entered via the user interface and in accordance with the quality control check list; and

,

a data transmission routine stored in the memory and adapted for execution by the processor to deliver the quality control data from the memory for recordation in connection with the project.

30. The portable computer of claim 29, wherein the data transmission routine is further adapted to retrieve equipment specification data associated with the field equipment in connection with the quality control check list.

31. The portable computer of claim 29, further comprising a communications port for wireless transmission of the quality control check list to another portable computer at the field site.

32. The portable computer of claim 29, wherein the user interface comprises a digital camera such that the quality control data comprises a digital image.

33. The portable computer of claim 29, further comprising a wireless communication transceiver such that the quality control data is delivered via an Internet connection.

34. The portable computer of claim 29, wherein the data collection routine provides via the user interface a prompt for check list signoff such that the quality control data comprises a signoff indication that the quality control check list has been fully completed.

35. The portable computer of claim 29, wherein the data collection routine provides via the user interface a form for entering deficiency information indicative of a problem encountered during action taken in accordance with the quality control check list.

36. The portable computer of claim 35, further comprising an audio recorder communicatively coupled to the processor such that the data collection routine provides via the user interface an option to record audio clips as the deficiency information.

37. A system for quality control in connection with a project for initiation of a process plant having field equipment at field sites in the process plant, the quality control system comprising:

a host computer having a project history database; and

,

a portable computer configured for communication with the host computer and having a user interface, a processor coupled to the user interface, and a memory coupled to the processor for execution of a quality control routine stored in the memory;

wherein the quality control routine comprises a data synchronization routine to download, from the project history database to the memory, respective quality control check lists and equipment specification data for the field equipment and a data collection routine to record in the memory quality control data entered via the user interface in accordance with the quality control check lists.

38. The system of claim 37, wherein the data synchronization routine uploads the quality control data from the memory to the project history database.

39. The system of claim 37, wherein the project comprises commissioning of the process plant such that the project history database comprises commissioning history information.

40. The system of claim 37, wherein the data collection routine comprises a deficiency recordation routine to enter, via the user interface, deficiency information associated with a task specified in the quality control check list.

41. The system of claim 37, wherein the deficiency recordation routine provides an opportunity to enter, via the user interface, an indication that the task has been completed.

42. The system of claim 41, wherein the host computer comprises a database management routine to generate reports from information set forth in the project history database, and wherein the reports include a deficiency management report derived from the deficiency information and indication entered via the deficiency recordation routine.

43. The system of claim 37, wherein the portable computer comprises a transceiver such that the host computer and portable computer communicate via an Internet connection.