Computerized procedures system

• US 20070270980A1
• Filed: 10/20/2006
• Published: 11/22/2007
• Est. Priority Date: 05/19/2006
• Status: Active Grant

• Current Assignee: Westinghouse Electric Company LLC (Brookfield Asset Management Incorporated)
• Original Assignee: Westinghouse Electric Company LLC (Brookfield Asset Management Incorporated)
• Inventors: Lipner, Melvin H., Mundy, Roger A., Franusich, Michael D.
• Granted Patent: US 7,813,817 B2
• Time in Patent Office: Days
• US Class Current: 700/19
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/31455 Monitor process status
• CPC Class Codes: G05B 2219/31471 Operator can select a graphical screen at his will as help diagnostic
• CPC Class Codes: G05B 2219/35494 Online documentation, manual, procedures, operator, user guidance, assistance
• CPC Class Codes: G05B 2219/36542 Cryptography, encrypt, access, authorize with key, code, password
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

An online data driven computerized procedures system that guides an operator through a complex process facility'"'"'s operating procedures. The system monitors plant data, processes the data and then, based upon this processing, presents the status of the current procedure step and/or substep to the operator. The system supports multiple users and a single procedure definition supports several interface formats that can be tailored to the individual user. Layered security controls access privileges and revisions are version controlled. The procedures run on a server that is platform independent of the user workstations that the server interfaces with and the user interface supports diverse procedural views.

Claims

1. Apparatus for assisting an operator in the execution of procedure steps in a complex process facility to manage a complex process and other users to monitor the process, comprising.

a plurality of sensors for generating signals representative of the real-time value of a plurality of facility parameters that indicate various conditions of the process;

a server having one or more databases and computer program modules in electrical communication with said sensor signals and operable to provide a server output along a computer network that identifies the steps of a procedure applicable to the process conditions identified by the sensor signals; and

one or more workstations connected to the computer network for receiving and displaying the server output and for requesting information from the server wherein the server output comprises the text and structure of the procedure, as well as associated logic and meta data and the workstation defines the format in which the server output is presented to the operator or other user.

2. The apparatus of claim 1 wherein the one or more databases comprise:

a procedure database for storing one or more step-by-step procedures for operating the process under various conditions;

a document database for storing documents that contain background and amplification for the procedural steps stored in the procedure database; and

an authorization database for storing user names, passwords and security access levels of the operators and other users authorized to access the server.

3. The apparatus of claim 1 wherein the one or more computer modules comprise:

a data monitor module for receiving, interpreting and processing the sensor signals;

a procedure evaluator module for receiving the interpreted and processed sensor signals from the data monitor module and determining whether the entry conditions for entering the procedure have been satisfied;

a procedure state manager module for evaluating the interpreted and processed sensor signals received from the procedure evaluator module and determining the step in the process applicable to the conditions of the process indicated by the sensor signals and sequencing through the applicable procedure steps; and

a request handler module for managing and satisfying access and information requests from the one or more computer workstations by drawing on the outputs of the procedure state manager module, the document database and the authorization database to provide the server output to the one or more workstations.

4. The apparatus of claim 1 wherein the server output can accommodate any operating system platform run on the workstation.

5. The apparatus of claim 1 wherein the procedure steps are stored in the procedure database on the server in a plurality of languages including at least two workstations wherein the applicable steps of the procedure are displayed on the workstations in different languages.

6. The apparatus of claim 5 wherein the documents are stored on the document database on the server in a plurality of languages.

7. The apparatus of claim 5 wherein the workstation determines the language in which the applicable steps of the procedure are displayed.

8. The apparatus of claim 2 wherein the operator or other user, at one workstation, may have different security levels of access to the information on the server and to control the process than other users at other workstations.

9. The apparatus of claim 8 wherein in the information to be accessed and the actions permitted to be taken for each user can be controlled individually to a fine degree.

10. The apparatus of claim 8 wherein the appropriate security level of access is chosen from, e.g., rights to monitor only, rights to monitor and control the process, and rights to edit the procedural steps in the procedure database and/or the computer program modules.

11. The apparatus of claim 1 including means for uniquely identifying each accepted change or series of changes in the procedure and/or database information and archiving prior versions.

12. The apparatus of claim 1, including a plurality of workstations wherein each workstation supports diverse procedure views independent of the other workstations.

13. The apparatus of claim 1 wherein the server is a first server, further including a second server wherein the second server includes the same databases and computer program modules as the first server and is connected to a same sensor network and a same workstation network as the first server so that the second server receives any changes in the databases, computer program modules and any other information that the first server receives and the second server automatically takes over communications with the workstations if the first server fails.

14. The apparatus of claim 1 wherein one or more of the databases includes a procedures database that includes a complete definition of the procedure as a single file that comprise the entire text, structure, logic and dynamics of the procedure.

15. The apparatus of claim 1 wherein data from the sensors is time stamped and stored.

16. The apparatus of claim 15 wherein when an operator or other user from a workstation includes a sensor data update with an optional timestamp argument the server will provide an empty reply if nothing has changed since a time identified in the timestamp argument and if the timestamp argument is not included the workstation will synchronize with the current state of the server.

17. The apparatus of claim 1 including a logger that records and stores the time, the workstation address, the operator or other user and the command or other resource requested.

18. The apparatus of claim 17 wherein the logger records a detailed and time stamped log of all procedure activations and step transitions, including specific data values of entry conditions and data values for each step when the step is exited.

19. The apparatus of claim 1 wherein the format defined by a client software running on the workstation includes a windows environment in which procedure information of interest is displayed in a first window, wherein the display in the first window includes at least one tab, corresponding to procedure information not displayed in the first window, that when the tab is activated opens a second window displaying the corresponding procedure information and wherein dragging the tab in the first window displays the first and second windows concurrently.

20. The apparatus of claim 19 wherein the first window displays a step of a first procedure and the second window displays another step of a second procedure.

21. The apparatus of claim 20 wherein the first procedure and the second procedure are executed concurrently.

22. The apparatus of claim 19 wherein the tab in the first window includes an icon that provides information on a state of the corresponding procedure information.

23. The apparatus of claim 1 for executing a first procedure and a second procedure concurrently wherein the first procedure and the second procedure are run on the same or separate workstations in separate windows.