Life Cycle Management System for Intelligent Electronic Devices

• US 20090204458A1
• Filed: 01/12/2009
• Published: 08/13/2009
• Est. Priority Date: 07/11/2006
• Status: Active Grant

• Current Assignee: ABB Schweiz AG (ABB Limited)
• Original Assignee: ABB Research Ltd. (ABB Ltd.)
• Inventors: Wiese, Wilhelm, Khan, Ahmad Hasan
• Granted Patent: US 8,443,355 B2
• Time in Patent Office: Days
• US Class Current: 705/7
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: Y04S 10/50 Systems or methods supporting the power network operation or management, involving a certain degree of interaction with the load-side end user applications

Abstract

This invention relates to the Life Cycle Management System for distributed Intelligent Electronic Devices (IED) starting from the design phase to the end of service phase. Hence, it caters to the needs from installation via engineering, installation/commissioning phases, until asset management and remote service support of the devices during the operational phase The increasing decentralization of the involved components via networks, especially via the Internet, is a key criterion and needs to be addressed by the life cycle management. The added value for the customer grows disproportionately with the degree of integration of multiple independent software components into a complex and often highly distributed control system. The architecture of today'"'"'s control systems must be sufficiently flexible to allow customers to regard their plant components from various locations. Additionally, the stability, security and maintainability of such a system is strongly dependent on the homogeneity and interoperability of all involved components.

Claims

1. A method of managing a life cycle of a plurality of Intelligent Electronic Devices (IEDs), also referred to as assets, in a process plant which in their life cycle go through

a. An Engineering phase

b. An Installation/commissioning phase

c. An Operational phase

For an end-user comprising the steps of:

a. Creating a Device Integration Aspect Object by collecting data such as engineering design data documentation during the engineering phase of the IED'"'"'s development or the plant setup, plant configuration data relating to the set up of the IED or the process plant applicable to the installation/commissioning phase, data from maintenance management software that are integrated with the IED or the process plant applicable to the operational phase and diagnostic data about the health of the device in the process plant applicable to the operational phase;

b. utilizing the Device Integration Aspect Object, in a Life Cycle Management System (LCMS) for managing information from different phases in the lifecycle of the IED or the process plant;

c. performing homogenization and version control checks to help the end user optimize the life of the IED applicable to both the installation/commissioning and operational phases;

d. performing Asset Management, to prolong the life of the asset applicable to the operational phase;

e. supporting a plurality of formats and standards across documentation, maintenance data, diagnostic tools, network protocols, control protocols, Operating System platforms and programming environments to manage the life cycle, applicable to all the phases;

f. performing life cycle management in a location-independent fashion.

2. The method of claim 1, wherein the step of collecting engineering design data includes information from data sheets pertaining to the IEDs in the process plant, DD/EDD/Capability source files and device specific DTMs.

3. The method of claim 1, wherein the step of collecting installation and commissioning data includes information from manuals, maintenance and spare parts manuals, project specific documents and lists detailing interchangeable IEDs with their operating procedures.

4. The method of claim 1, wherein the step of collecting data provides for format independent aggregation of different documents.

5. The method of claim 1, wherein the step of collecting engineering design data includes the step of using a communication format based on a markup language.

6. The method of claim 1, wherein the step of collecting plant configuration data includes the step of collecting data pertaining to a plurality of bus networks that might be used to interconnect various IEDs in the process plant, the topology of said networks, the IEDs they are used to connect, unique parameters of these IEDs and calibration details about a Network Capable Application Processor (NCAP) adhering to the ISO/EEC standard.

7. The method of claim 1, wherein the step of collecting diagnostic data about the health of the IED in the process plant, also referred to as assets, includes the step of collecting data pertaining to asset operational status, an asset diagnostic alarm, an asset condition report, an asset performance trend report, an asset maintenance status, and asset remote servicing recommendation and operator notes for asset usage constraints.

8. The method of claim 1, wherein the step of performing LCMS in a location-independent fashion includes the step of providing a connectivity application.

9. The method of claim 1, wherein the step utilizing a Device Integration Aspect Object, in a Life Cycle Management System (LCMS) for managing information from different phases in the lifecycle of the IED or the process plant comprises the steps of:

a. Populating the Device Integration Aspect Objects;

b. Accessing the Device Integration Aspect Objects during the course of managing the life cycle.

10. The method of claim 9, wherein the step of populating the Device Integration Aspect Objects includes the steps of collecting information about various Aspects of the device, which are perspectives on the device under one or more categories.

11. The method of claim 9, wherein the step of populating the Device Integration Aspect Objects includes the steps of collecting information about various Aspects of the device such as:

a. Field Device/Sensor definition Aspect;

b. Field Bus/Sensor Network Management Aspect;

c. Device/Sensor Health Monitoring and Diagnostics Aspects and

d. Documentation Aspect.

12. The method of claim 1, wherein the step of collecting plant configuration data accumulates the data into a Definition Aspect and a Network Management Aspect.

13. The method of claim 11, where the Field Bus/Sensor Network Management Aspect contains information including:

i. Field Bus/Sensor Network Topology Definition and Management;

ii. Network Capable Application Processor Definition and Management;

iii. Smart Transducer Interface Module Definition and Management;

iv. Network Topology overview-Status of Devices/Sensors/Modules/Processors/Device/Sensor Management Aspect;

v. Modification of Parameters unique to the Device/Sensor;

vi. Perform As-found/As-left calibration checks for the Device;

vii. Perform Device calibration;

viii. Perform Device/Sensor characterization and

ix. Device Management Event Log Reports.

14. The method of claim 11, where the Device/Sensor Health Monitoring and Diagnostics Aspect contains information including:

i. Asset operational status;

ii. Asset Diagnostic Alarm;

iii. Asset Condition Document;

iv. Asset Performance Trend;

v. Asset condition Reporting;

vi. Asset Maintenance Status;

vii. Asset Remote servicing Recommendations and

viii. Operator notes for Asset usage constraints.

15. The method of claim 11, where the Documentation Aspect contains information including:

i. Data sheet;

ii. DD/EDD/Device Capability source files;

iii. Device Specific DTM;

iv. Installation &

Commissioning Manual;

v. Maintenance &

Spare Parts Manual;

vi. Project specific documents (Instrument specification, Installation &

Impulse piping diagram, Loop wiring diagram etc.,) and

vii. List, source of Plug &

Play Devices that can replace the Device in use;

operating procedures for interchanging the devices.

16. The method of claim 1, wherein the step of collecting data includes the step of converting documentation reversibly from a set of proprietary formats to a standard format.

37. The method of claim 1, wherein the method is carried out by a computer program product containing software code means loadable into the internal memory of a computer in a computerized system.

39. A computer program product containing according to claim 37, embodied on a computer readable medium.

17. A Life Cycle Management System to control the Intelligent Electronic Devices (IEDs) in a process plant including a plurality of IEDs that are connected by networks and device-specific protocols, a plurality of computers including communication devices communicating with said computers, computer networks and IEDs, said Life Cycle Management System comprising:

a. a data-store for storing information relating to the LCMS;

a software object for incorporating information about different Aspects of a device, a plurality of connected computers performing Life Cycle Management;

b. data aggregation means to populate said software object, hereby referred to as a Device Integration Aspect Object;

c. version control means to ensure compatibility of installed components

d. asset management/optimization means to maximize the life of an asset/device;

e. means to support a plurality of formats and standards across documentation, maintenance data, diagnostic tools, network protocols, control protocols, Operating System platforms and programming environments;

f. location-independent communication means to communicate with the customer as well as device vendors and other parties that assist in maintenance or those that assist in providing information on the various stages in the lifecycle of the product.

18. A Life Cycle Management System according to claim 17, wherein the version control means facilitates the import of only those pre-configured Device Integration Aspect Objects from the libraries which passed the check for version compatibility

19. A Life Cycle Management System according to claim 17, wherein the version control means has the capability to import device description source files like DD/EDD/CFF and to manage and validate them within the version control system.

20. A Life Cycle Management System according to claim 17, wherein the version control means possesses the capability to build DTMs from device description source files and to include these DTM into the version management.

21. A Life Cycle Management System according to claim 17, wherein the version control means has the capability to build Device Integration Aspect Objects with Device Type Managers (DTM) which are supplied by 3rd party vendors without jeopardizing the stability of the control system by unknown software components.

22. A Life Cycle Management System according to claim 17, wherein the version control means further comprises testing means comprising testing tools in the LCMS to test and validate the target FDT frame application before installing any DTMs.

23. A Life Cycle Management System according to claim 17, wherein the location-independent communication means provides a connectivity application that allows connecting and managing IEDs via the Internet.

24. A Life Cycle Management System according to claim 17, wherein data aggregation means includes gathering different engineering sub systems with the corresponding engineering documents and support systems including

a. Document Managers for document Administration;

b. Library Assistants;

c. Reuse Assistants;

d. Cross-reference tools and

e. Document Import/Export.

25. A Life Cycle Management System of claim 17 wherein a distributed software system executing Life Cycle Management implements a control and management strategy for the Intelligent Electronic Devices (IEDs) in the plant, the control strategy incorporating information from Device Integration Aspect Objects and Asset monitors, placed in the plant which report the status of the asset/device, along with incorporating information from other maintenance management tools, said software system executing Life Cycle Management being capable of accommodating a variety of maintenance tools and standards, data formats, documentation formats and communication formats.

26. A Life Cycle Management System of claim 25 wherein the distributed software system is capable of communicating information to device-vendors and customers through a connectivity application.

27. A Life Cycle Management System of claim 25 wherein the distributed software system is capable of communicating information to device-vendors and accept their diagnosis and integrate that diagnosis while managing the life of the asset/device.

28. A Life Cycle Management System according to claim 17, said system controlling a process plant comprising a plurality of Intelligent Electronic Devices (IEDs) that are connected by networks implementing different protocols such as ProfiBus, Device Net, Foundation Field Bus (for the Process Industries), Inter Bus S, Control Net and CAN Open (for the Discrete Manufacturing Industries) and HART.

29. A Life Cycle Management System according to claim 17, with means to ensure the exchangeability of process data, like limits, alarm values or “

units, between the IEDs and Control module logic and function block structure confirming to, IEC-61149, BBC61131-3 and EEC 61804-2.

30. A Life Cycle Management System according to claim 17, with means to ensure that the control system provides a homogeneous and holistic audit trail system.

31. A Life Cycle Management System according to claim 17, with homogeneous visual handling and navigation means for accessing Device Integration Aspect Objects and their aspects in Plant/Functional/Location Structures.

32. A Life Cycle Management System according to claim 17, with known authentication methods used to provide secure access to the Life Cycle Management System and all of its components, for all the parties requiring such access.

33. A Life Cycle Management System according to claim 17, with storage means to store IED attributes (static and dynamic) that can be accessed by enterprise wide users with Simple Object Access Protocol.

34. A Life Cycle Management System according to claim 17, with redundancy means including a Redundant Array of Independent Disks.

35. A Life Cycle Management System according to claim 17, with scalability means incorporating a clustered strategy, for the application of the solution to a large processing complex.

36. A Life Cycle Management System according to claim 17, with a highly available Life Cycle Management Server without a connected control system to provide the life cycle management service for distributed systems via the Internet.

38. (canceled)

40. A computer implemented web-centric Life Cycle Management System (LCMS) implemented using client/server technology for providing a Life Cycle Management mechanism for process plants with complex and diverse internal layouts, having a number of Intelligent Electronic Devices (IEDs), the LCMS providing an asset management system that takes input about the IEDs aggregated in one or a plurality of software objects, called a Device Integration Aspect Object, combining this information with device or asset performance status or condition reports obtained from either of the process plant or other enterprise software which might be integrated with the process plant for purposes of maintenance, to provide a holistic life cycle management system which extends the on-stream availability of the IEDs, further providing version control to ensure stability of the IEDs within the LCMS and location-independent device health monitoring and repair by device vendors and location-independent asset management and control to the customer who owns the process plant.

41. A LCMS of claim 40, wherein the Intelligent Electronic Devices (IEDs) in the process plant, device vendors, display devices for the customer and other maintenance management software communicate with the LCMS using a standard interface, said interface being customized for programs, vendors, data exchange and tools.

42. A LCMS of claim 40, wherein the asset management system improves the availability of the intelligent electronic devices or assets, by using a combination of information present in the Device Integration Aspect Object and the asset monitor input from the process plant.

43. (canceled)

44. A computer implemented web-centric Life Cycle Management System (LCMS) implemented using client/server technology for providing a Life Cycle Management mechanism for process plants with complex and diverse internal layouts, having a number of Intelligent Electronic Devices (IEDs), the LCMS providing an asset management system that takes input about the IEDs aggregated in one or a plurality of software objects, called a Device Integration Aspect Object, combining this information with device or asset performance status or condition reports obtained from either of the process plant or other enterprise software which might be integrated with the process plant for purposes of maintenance, to provide a holistic life cycle management system which extends the on-stream availability of the IEDs, further providing version control to ensure stability of the IEDs within the LCMS and location-independent device health monitoring and repair by device vendors and location-independent asset management and control to the customer who owns the process plant, which performs the method of managing a life cycle of a plurality of Intelligent Electronic Devices (IEDs), also referred to as assets, in a process plant which in their life cycle go through

a. An Engineering phase

b. An Installation/commissioning phase

c. An Operational phase

For an end-user comprising the steps of:

a. Creating a Device Integration Aspect Object by collecting data such as engineering design data documentation during the engineering phase of the IED'"'"'s development or the plant setup, plant configuration data relating to the set up of the IED or the process plant applicable to the installation/commissioning phase, data from maintenance management software that are integrated with the IED or the process plant applicable to the operational phase and diagnostic data about the health of the device in the process plant applicable to the operational phase;

b. utilizing the Device Integration Aspect Object, in a Life Cycle Management System (LCMS) for managing information from different phases in the lifecycle of the IED or the process plant;

c. performing homogenization and version control checks to help the end user optimize the life of the IED applicable to both the installation/commissioning and operational phases;

d. performing Asset Management, to prolong the life of the asset applicable to the operational phase;

e. supporting a plurality of formats and standards across documentation, maintenance data, diagnostic tools, network protocols, control protocols, Operating System platforms and programming environments to manage the life cycle, applicable to all the phases;

f. performing life cycle management in a location-independent fashion.