BIG DATA IN PROCESS CONTROL SYSTEMS

• US 20140250153A1
• Filed: 03/04/2013
• Published: 09/04/2014
• Est. Priority Date: 03/04/2013
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Nixon, Mark J., Blevins, Terrence, Christensen, Daniel Dean, Muston, Paul Richard, Beoughter, Ken
• Granted Patent: US 9,558,220 B2
• Time in Patent Office: Days
• US Class Current: 707/812
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 19/042 using digital processors G05B19/05 takes precedence
• CPC Class Codes: G05B 2219/15052 Communication processor, link interface
• CPC Class Codes: G05B 23/0208 characterized by the configuration of the monitoring system
• CPC Class Codes: G06F 16/22 Indexing; Data structures therefor; Storage structures

Abstract

A big data network or system for a process control system or plant includes a big data apparatus including a data storage area configured to store, using a common data schema, multiple types of process data and/or plant data (such as configuration and real-time data) that is used in, generated by or received by the process control system, and one or more data receiver computing devices to receive the data from multiple nodes or devices. The data may be cached and time-stamped at the nodes and streamed to the big data apparatus for storage. The process control system big data system provides services and/or data analyses to automatically or manually discover prescriptive and/or predictive knowledge, and to determine, based on the discovered knowledge, changes and/or additions to the process control system and to the set of services and/or analyses to optimize the process control system or plant.

Claims

1. A system for supporting big data in a process control plant, comprising:

a unitary, logical data storage area including one or more data storage devices configured to store, using a common format, data corresponding to at least one of the process plant or a process that is controlled in the process plant, the data including multiple types of data, and a set of types of data including configuration data, continuous data, and event data corresponding to the process; and

one or more data receiver computing devices configured to receive the data from one or more other devices and to cause the data to be stored in the unitary, logical data storage area.

2. The system of claim 1, wherein the data includes time series data.

3. The system of claim 2, wherein a data entry of the time series data stored in the unitary, logical data storage area includes a content and a timestamp, the timestamp being indicative of a time of generation of the content of the data entry.

4. The system of claim 1, wherein the unitary, logical data storage area is further configured to store metadata corresponding to the data.

5. The system of claim 4, wherein the data is stored using a common structured format, and wherein the metadata is stored using an unstructured format.

6. The system of claim 1, wherein the data further includes at least one of:

data indicative of a health of a machine included in the process plant,

data indicative of a health of a particular piece of equipment included in the process plant,

data indicative of a health of a particular device included in the process plant, or

data corresponding to a parameter related to safety of the process plant.

7. The system of claim 1, wherein the data further includes at least one of:

data describing a user input entered at one of the one or more other devices;

data describing a communication network of the process plant;

data received from a computing system external to the process plant;

or

data received from another process plant.

8. The system of claim 7, wherein the data describing the communication network of the process plant comprises data describing at least one of a performance, a resource, or a configuration of the communication network.

9. The system of claim 1, wherein the one or more data storage devices are included in at least one of:

a data bank, a RAID storage system, a cloud data storage system, a distributed file system, or other mass data storage system.

10. The system of claim 1, wherein at least the portion of the data is streamed using a streaming service hosted by at least one of the one or more other devices, and wherein the unitary, logical data storage area or at least one of the one or more data receiver computing devices is a subscriber to the streaming service.

11. The system of claim 1, wherein the one or more other devices includes:

a field device and a controller that are communicatively coupled to control a process in the process plant, and

at least one of a user interface device or a network management device.

12. The system of claim 1, wherein all data generated at and received by at least one of the one or more other devices is caused to be stored at the unitary, logical data storage area.

13. The system of claim 1, wherein the system further comprises a set of request servicer computing devices configured to perform one or more services using at least a portion of the data stored in the unitary, logical data storage area, the one or more services including a computational analysis.

14. The system of claim 13, wherein at least one data receiver computing device and least one request servicer computing device are an integral computing device.

15. The system of claim 13, wherein at least one of the request servicer computing devices is further configured to determine, based on an execution of the computational analysis, a change to a configured entity included in the process plant.

16. The system of claim 15, wherein the at least one of the request servicer computing devices is further configured to at least one of:

(i) present the determined change at a user interface, or (ii) automatically apply the change to the configured entity.

17. The system of claim 13, wherein the one or more services further include a service to generate a set of definitions corresponding to a set of entities that are able to be instantiated in a runtime environment of the process plant.

18. The system of claim 17, wherein the set of entities includes at least one of:

a configurable device, a diagnostic application, a display view application, a control model, or a control application.

19. The system of claim 17, wherein the set of definitions is generated in an offline environment of the process plant, and wherein the system further comprises a set of scripts to transform at least one definition included in the set of definitions, and to load the transformed at least one definition into the runtime environment of the process plant.

20. The system of claim 19, wherein the at least one definition is generated in the offline environment in response to a user input.

21. The system of claim 19, wherein the at least one definition is generated in the offline environment automatically.

22. The system of claim 13, wherein at least one of the one or more services is a web service.

23. A method for supporting big data in a process control plant, comprising:

receiving, at one or more data receiver computing devices, data corresponding to at least one of the process control plant or a process controlled by the process control plant; and

causing the received data to be stored, using a common format, in a unitary, logical data storage area, the unitary, logical data storage area including one or more data storage devices configured to store multiple types of data using a common format, and a set of types of data including configuration data, continuous data, and event data corresponding to the process.

24. The method of claim 23, wherein receiving the data comprises receiving at least a portion of the data using a streaming service.

25. The method of claim 24, further comprising subscribing to the streaming service.

26. The method of claim 23, wherein receiving the data comprises receiving the data from one or more other devices included in the process plant, the one or more other devices including a controller in communicative connection with a field device to control the process.

27. The method of claim 23, further comprising causing a service to be performed using at least a portion of the data stored in the unitary, logical data storage area.

28. The method of claim 27, wherein causing the service to be performed comprises causing a computational analysis to be performed.

29. The method of claim 28, wherein causing the computational analysis to be performed comprises causing the computational analysis to be performed in response to a user request.

30. The method of claim 28, wherein causing the computational analysis to be performed comprises causing the computational analysis to be selected and performed automatically by the system.

31. The method of claim 28, wherein the at least a portion of the data stored in the unitary, logical data storage area is a first set of data, and the method further comprises generating a second set of data based on an execution of the computational analysis on the first set of data.

32. The method of claim 31, further comprising storing the second set of data in the unitary, logical data storage area.

33. The method of claim 32, wherein storing the second set of data comprises storing at least one of:

a display component definition, a binding definition, a process model definition, a data definition, a data relationship, or a definition of another computational analysis.

34. A process control system, comprising:

a controller configured to control a process in the process control system;

a field device communicatively connected to the controller, the field device configured to perform a physical function to control the process in the process control system, and the field device configured to transmit to or receive from the controller real-time data corresponding to the physical function; and

a process control system big data apparatus, the process control system big data apparatus including;

a unitary, logical data storage area including one or more data storage devices configured to store, using a common format, the real-time data and configuration data corresponding to the controller; and

one or more data receiver computing devices to receive the real-time data and to cause the received data to be stored in the unitary, logical data storage area;

wherein the controller is a first node of a process control system big data network, and the process control system big data apparatus is a second node of the process control system big data network.

35. The process control system of claim 34, wherein the process control system big data network includes at least one of a wired communication network or a wireless communication network.

36. The process control system of claim 34, wherein the process control system big data network is at least partially an ad-hoc network.

37. The control system of claim 35, wherein the process control system big data network is a first communication network, and wherein the field device is communicatively connected to the controller via a second communication network different than the first communication network.

38. The process control system of claim 34, wherein the process control system big data network further includes one or more other nodes, the one or more other nodes including at least one of:

a user interface device, a gateway device, an access point, a routing device, a network management device, or an input/output (I/O) card coupled to the controller or to another controller.

39. The process control system of claim 34, wherein the controller is configured to cache the real-time data, and wherein an indication of an identity of the real-time data is excluded from the configuration data corresponding to the controller.

40. The process control system of claim 34, further comprising a process control system big data user interface configured to enable a user, via a user interface device, to perform at least one user action from a set of user actions including:

view at least a portion of the data stored in the unitary, logical data storage area;

request a service to be performed, the service requiring the at least the portion of the data stored in the unitary, logical data storage area;

view a result of a performance of the service;

configure an entity included in the process control system;

cause a configured entity to be instantiated in the process control system; and

configure an additional service,

wherein the user interface device is a third node of the process control system big data network.

41. The process control system of claim 40, wherein the process control system big data user interface is configured to authenticate at least one of the user, the user interface device, or an access application running on the user interface device, and wherein one or more user actions included in the set of user actions is made available to the user for selection based on the authentication.