METHODS AND APPARATUS TO MANAGE TESTING OF A PROCESS CONTROL SYSTEM

• US 20110054643A1
• Filed: 08/26/2009
• Published: 03/03/2011
• Est. Priority Date: 08/26/2009
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Sherriff, Godfrey R., Nixon, Mark, Law, Gary Keith
• Granted Patent: US 9,874,870 B2
• Time in Patent Office: Days
• US Class Current: 700/79
• 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: G06F 11/3636 by tracing the execution of the program

Abstract

Example methods and apparatus to manage testing of a process control system are disclosed. A disclosed example method includes generating a test application from a process control routine, the test application including at least one test that is to be performed within a time period, monitoring an operation of the process control routine, determining if the operation of the process control routine during the time period includes an execution of a portion of the process control routine that is substantially similar to the at least one test, and updating the test application by indicating that the at least one test has been performed within the time period.

Claims

1. A method to manage testing of a process control system, the method comprising:

generating a test application from a process control routine, the test application including at least one test that is to be performed within a time period;

monitoring an operation of the process control routine;

determining if the operation of the process control routine during the time period includes an execution of a portion of the process control routine that is substantially similar to the at least one test; and

updating the test application by indicating that the at least one test has been performed within the time period.

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

determining if the execution of the portion of the process control routine includes a proper mitigation of an issue that is associated with the at least one test; and

upon determining if the execution of the portion of the process control routine includes the proper mitigation, indicating that the at least one test is to be preformed within a second time period, the second time period occurring after the first time period.

3. A method as defined in claim 2, wherein the proper mitigation includes a specified process control response to correct the issue within the process control system.

4. A method as defined in claim 2, further comprising:

upon determining the proper mitigation, time-stamping the at least one test; and

storing to a test record at least one of the proper mitigation, the time-stamp of the at least one test, or the at least one test.

5. A method as defined in claim 1, wherein generating the test application from the process control routine includes at least one of:

determining at least one test limit based on at least one parameter within the process control routine;

ordering a sequence of the at least one test based on an order of instructions within the process control routine;

or

ordering the sequence of the at least one test based on a type of a function within the process control routine.

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

receiving a modification to the process control routine;

modifying the test application based on the modification; and

storing the modified test application as another version of the test application.

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

generating a test plan from the test application including the at least one test;

prompting an operator to execute the at least one test included within the test plan;

receiving at least one of data associated with the test plan or data associated with the test application;

determining if the received data corresponds to a proper mitigation of the at least one test; and

updating the test plan to indicate the at least one test is verified for the time period.

8. A method as defined in claim 7, further comprising:

prompting the operator for an identification value;

receiving the identification value;

accessing a database of personnel training records;

determining if a training record corresponding to the identification value includes an indication the operator is allowed to perform the test plan; and

allowing the operator to execute the test plan.

9. A method as defined in claim 7, further comprising:

combining results of the test plan with the test application to create a test record for the first time period;

time-stamping the test record with the time the at least one test was completed;

determining if the at least one test associated with the test application has been completed within the time period; and

generating an indication that the at least one test has not been completed within the time period.

10. An apparatus to manage testing of a process control system, the apparatus comprising:

a routine monitor to monitor an operation of a process control routine;

a test application comparer to determine if the operation of the process control routine during a time period includes an execution of a portion of the process control routine that is substantially similar to at least one test that is included within a test application, wherein the at least one test is to be performed within the time period; and

a test application modifier to update the test application in response to determining that the at least one test has been performed within the time period.

11. An apparatus as defined in claim 10, further comprising a test application generator to generate the test application from the process control routine.

12. An apparatus as defined in claim 11, wherein the test application generator generates the test application from the process control routine by at least one of:

determining at least one test limit based on at least one parameter within the process control routine;

ordering a sequence of the at least one test based on an order of instructions within the process control routine;

or

ordering the sequence of the at least one test based on a type of a function within the process control routine.

13. An apparatus as defined in claim 11, wherein the test application generator is to generate a test plan from the test application including the at least one test.

14. An apparatus as defined in claim 13, further comprising:

a test application processor to;

prompt an operator to execute the at least one test included within the test plan;

prompt the operator for an identification value; and

receive the identification value; and

a test execution verifier to receive at least one of data associated with the test plan or data associated with the test application.

15. An apparatus as defined in claim 14, wherein the test application comparer is to:

determine if the received data corresponds to a proper mitigation of the at least one test;

access a database of personnel training records;

determine if a training record corresponding to the identification value includes an indication the operator is allowed to perform the test plan;

allow the operator to execute the test plan;

combine results of the test plan with the test application to create a test record for the first time period; and

determine if the at least one test associated with the test application has been completed within the time period.

16. An apparatus as defined in claim 15, wherein the test application modifier is to:

update the test plan to indicate the at least one test is verified for the time period; and

time-stamp the test record with the time the at least one test was completed.

17. An apparatus as defined in claim 16, wherein the test application comparer is to generate an indication that the at least one test has not been completed within the time period.

18. An apparatus as defined in claim 10, wherein the test application comparer is to determine if the execution of the portion of the process control routine includes a proper mitigation of an issue that is associated with the at least one test.

19. An apparatus as defined in claim 18, wherein upon the test application comparer determining if the execution of the portion of the process control routine includes the proper mitigation, the test application modifier is to at least one of:

indicate that the at least one test is to be preformed within a second time period, the second time period occurring after the first time period;

time-stamp the at least one test;

or

store to a test record at least one of the proper mitigation, the time-stamp of the at least one test, or the at least one test.

20. An apparatus as defined in claim 18, wherein the test application comparer is to determine the proper mitigation by determining if the proper mitigation includes a specified process control response to correct the issue within the process control system.

21. An apparatus as defined in claim 10, wherein the test application modifier is to:

receive a modification to the process control routine;

modify the test application based on the modification; and

store the modified test application as another version of the test application.

22. A machine-accessible medium having instructions stored thereon that, when executed, cause a machine to:

generate a test application from a process control routine, the test application including at least one test that is to be performed within a time period;

monitor an operation of the process control routine;

determine if the operation of the process control routine during the time period includes an execution of a portion of the process control routine that is substantially similar to the at least one test; and

update the test application by indicating that the at least one test has been performed within the time period.

23. A machine-accessible medium as defined in claim 22, wherein the machine-accessible instructions, when executed, cause the machine to:

determine if the execution of the portion of the process control routine includes a proper mitigation of an issue that is associated with the at least one test; and

upon determining if the execution of the portion of the process control routine includes the proper mitigation, indicate that the at least one test is to be preformed within a second time period, the second time period occurring after the first time period.

24. A machine-accessible medium as defined in claim 23, wherein the machine-accessible instructions, when executed, cause the machine to determine if the proper mitigation includes a specified process control response to correct the issue within the process control system.

25. A machine-accessible medium as defined in claim 23, wherein the machine-accessible instructions, when executed, cause the machine to:

upon determining the proper mitigation, time-stamp the at least one test; and

store to a test record at least one of the proper mitigation, the time-stamp of the at least one test, or the at least one test.

26. A machine-accessible medium as defined in claim 22, wherein the machine-accessible instructions, when executed, cause the machine to generate the test application from the process control routine by at least one of:

determining at least one test limit based on at least one parameter within the process control routine;

ordering a sequence of the at least one test based on an order of instructions within the process control routine;

or

ordering the sequence of the at least one test based on a type of a function within the process control routine.

27. A machine-accessible medium as defined in claim 22, wherein the machine-accessible instructions, when executed, cause the machine to:

receive a modification to the process control routine;

modify the test application based on the modification; and

store the modified test application as another version of the test application.

28. A machine-accessible medium as defined in claim 22, wherein the machine-accessible instructions, when executed, cause the machine to:

generate a test plan from the test application including the at least one test;

prompt an operator to execute the at least one test included within the test plan;

receive at least one of data associated with the test plan or data associated with the test application;

determine if the received data corresponds to a proper mitigation of the at least one test; and

update the test plan to indicate the at least one test is verified for the time period.

29. A machine-accessible medium as defined in claim 28, wherein the machine-accessible instructions, when executed, cause the machine to:

prompt the operator for an identification value;

receive the identification value;

access a database of personnel training records;

determine if a training record corresponding to the identification value includes an indication the operator is allowed to perform the test plan; and

allow the operator to execute the test plan.

30. A machine-accessible medium as defined in claim 28, wherein the machine-accessible instructions, when executed, cause the machine to:

combine results of the test plan with the test application to create a test record for the first time period;

time-stamp the test record with the time the at least one test was completed;

determine if the at least one test associated with the test application has been completed within the time period; and

generate an indication that the at least one test has not been completed within the time period.