METHODS AND APPARATUS TO UPGRADE AND PROVIDE CONTROL REDUNDANCY IN PROCESS PLANTS

• US 20090076628A1
• Filed: 09/18/2007
• Published: 03/19/2009
• Est. Priority Date: 09/18/2007
• Status: Abandoned Application

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Smith, David Mark, Tetmeyer, Kyle, Law, Gary, Hieb, Brandon, Denison, David R., Sherriff, Godfrey R.
• Application Number:
  US11/857,250
• Publication Number:
  US 20090076628A1
• Time in Patent Office: Days
• US Class Current: 700/3
• CPC Class Codes: G05B 19/4184 characterised by fault tolerance, reliability of production system
• CPC Class Codes: G05B 2219/13153 Modification, change of program in real time
• CPC Class Codes: G05B 2219/24187 Redundant processors run identical programs
• CPC Class Codes: G05B 2219/24188 Redundant processors run different programs
• CPC Class Codes: G05B 2219/31026 Diagnostic controller coupled to field and to redundant process controllers
• CPC Class Codes: G05B 2219/31418 NC program management, support, storage, distribution, version, update
• CPC Class Codes: G05B 2219/33332 Each processor can execute all programs
• CPC Class Codes: G05B 2219/34482 Redundancy, processors watch each other for correctness
• CPC Class Codes: G05B 2219/34488 One computer, controller replaces other, backup computer
• CPC Class Codes: G06F 8/656 while running
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

Methods and apparatus to upgrade and provide control redundancy in process plants are disclosed. An example disclosed method to upgrade software for a control device of a process control system comprises instantiating a replacement component of the software, copying state data from an existing component to the replacement component, and changing the replacement component to an active mode when a first state of the replacement component matches a second state of the existing component.

Claims

1. A method to upgrade software for a control device of a process control system, the method comprising:

instantiating a replacement component of the software;

copying state data from an existing component to the replacement component; and

changing the replacement component to an active mode when a first state of the replacement component matches a second state of the existing component.

4. A method as defined in claim 1, wherein a first control application comprises the replacement component while a second control application continues to comprise the existing component.

6. A method as defined in claim 1, wherein the replacement component is instantiated as a redundant module for the existing component.

8. A method as defined in claim 1, wherein an inter-process communication is used to copy the state data.

10. A method as defined in claim 1, further comprising:

verifying that the first state matches the second state; and

copying additional state data when the first state and the second state do not match.

11. A method as defined in claim 1, further comprising performing a test of the replacement component before changing the replacement component to the active mode.

12. A method as defined in claim 1, wherein the software upgrade occurs without a loss of control time of the process control system.

13. A method as defined in claim 1, wherein the replacement component comprises a sub-system of a control application, and wherein other sub-systems of the control application are not upgraded.

15. A method as defined in claim 1, wherein the replacement component comprises a hot fix.

2. (canceled)

3. (canceled)

5. A method as defined in claim 3, further comprising reverting the first control application reverts back to using the existing component.

7. (canceled)

9. (canceled)

14. (canceled)

16. An article of manufacture storing machine readable instructions which, when executed, cause a machine to upgrade software for a control device of a process control system by:

instantiating a replacement component of the software;

copying state data from an existing component to the replacement component; and

changing the replacement component to an active mode when a first state of the replacement component matches a second state of the existing component.

19. An article of manufacture as defined in claim 16, wherein a first control application comprises the replacement component while a second control application continues to comprise the existing component.

20. An article of manufacture as defined in claim 16, wherein the machine readable instructions, when executed, cause the machine to instantiate the replacement component as a redundant module for the existing component.

17. (canceled)

18. (canceled)

21. (canceled)

22. (canceled)

23. (canceled)

24. (canceled)

25. (canceled)

26. (canceled)

27. (canceled)

28. A method to provide control redundancy for a process plant control system, the method comprising:

providing a control input to a first instance of control software sub-system and to a second instance of the control software sub-system, the first and second instances to process the control input substantially in parallel; and

providing either an output of the first instance or an output of the second instance to a process plant field device.

29. A method as defined in claim 28, wherein the first and second instances are executed via different control devices.

31. A method as defined in claim 29, wherein the different control devices are each an active controller for at least one control application.

32. A method as defined in claim 29, further comprising selecting which control devices execute the first and second instances based on processing loads of the control devices.

33. A method as defined in claim 29, further comprising changing over time which control devices execute the first and second instances.

36. A method as defined in claim 28, wherein the first instance is a master and determines which output is provided to the process plant field device.

37. A method as defined in claim 28, further comprising:

providing the control input to a third instance of control software sub-system;

collecting outputs of the first, second and third instances; and

performing voting to determine which output is provided to the process plant field device.

38. A method as defined in claim 28, further comprising:

providing the control input to a third instance of control software sub-system; and

exchanging outputs of the first, second and third instances, wherein the first, second and third instances perform voting to determine which instance is to provide its output to the process plant field device.

30. (canceled)

34. (canceled)

35. (canceled)

39. An article of manufacture storing machine readable instructions which, when executed, cause a machine to provide control redundancy for a process plant control system by:

providing a control input to a first instance of control software sub-system and to a second instance of the control software sub-system, the first and second instances to process the control input substantially in parallel; and

providing either an output of the first instance or an output of the second instance to a process plant field device.

48. An article of manufacture as defined in claim 39, wherein the machine readable instructions, when executed, cause the machine to:

provide the control input to a third instance of control software sub-system;

collect outputs of the first, second and third instances; and

perform voting to determine which output is provided to the process plant field device.

49. An article of manufacture as defined in claim 39, wherein the machine readable instructions, when executed, cause the machine to:

provide the control input to a third instance of control software sub-system; and

exchange outputs of the first, second and third instances, wherein the first, second and third instances perform voting to determine which instance is to provide its output to the process plant field device.

40. (canceled)

42. An article of manufacture as defined in claim 40, wherein the different control devices are each an active controller for at least one control application.

41. (canceled)

43. (canceled)

44. (canceled)

45. (canceled)

46. (canceled)

47. (canceled)