DISTRIBUTED INDUSTRIAL PERFORMANCE MONITORING AND ANALYTICS
First Claim
1. A method for providing early fault detection in a process plant, the method comprising:
- obtaining a process signal comprising time domain data generated as a result of one or more process control devices operating to control a process in the process plant;
determining, based on the obtained process signal, a leading indicator of a condition of the process plant;
defining a process variable corresponding to the leading indicator;
performing a rolling fast Fourier transform (FFT) on a subsequent process signal to determine time-series data corresponding to the defined process variable;
monitoring the time-series data corresponding to the defined process variable for a presence of the leading indicator; and
generating an indication corresponding to a prediction of the condition based on a detected presence of the leading indicator in the monitored time-series data.
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Abstract
A technique is provided for providing early fault detection using process control data generated by control devices in a process plant. The technique determines a leading indicator of a condition within the process plant, such as a fault, abnormality, or decrease in performance. The leading indicator may be determined using principal component analysis. A process signal indicating a process variable corresponding to the leading indicator is then obtained and analyzed. A rolling fast Fourier transform (FFT) may be performed on the process signal to generate time-series data with which to monitor the process plant. When the presence of the leading indicator is detected in the time-series data, an alert or other prediction of the condition may be generated. Thus, process faults may be identified using fluctuations and abnormalities as leading predictors.
72 Citations
32 Claims
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1. A method for providing early fault detection in a process plant, the method comprising:
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obtaining a process signal comprising time domain data generated as a result of one or more process control devices operating to control a process in the process plant; determining, based on the obtained process signal, a leading indicator of a condition of the process plant; defining a process variable corresponding to the leading indicator; performing a rolling fast Fourier transform (FFT) on a subsequent process signal to determine time-series data corresponding to the defined process variable; monitoring the time-series data corresponding to the defined process variable for a presence of the leading indicator; and generating an indication corresponding to a prediction of the condition based on a detected presence of the leading indicator in the monitored time-series data. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A system for providing early fault detection in a process plant, the system comprising:
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a plurality of process control devices operating in a process plant; a processor; a program memory, communicatively coupled to the processor, and comprising a tangible, non-transitory storage medium storing instructions that, when executed by the processor, cause the processor to; obtain a process signal comprising time domain data generated as a result of the plurality of process control devices operating in the process plant; determine a leading indicator of a condition of the process plant based on the obtained process signal; define a process variable corresponding to the leading indicator; perform a rolling fast Fourier transform (FFT) on a subsequent process signal to determine time-series data corresponding to the defined process variable; monitor the time-series data corresponding to the defined process variable for a presence of the leading indicator; and generate an indication corresponding to a prediction of the condition based on a detected presence of the leading indicator in the monitored time-series data. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27)
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28. A tangible, non-transitory computer-readable medium storing instructions for providing early fault detection in a process plant that, when executed by a processor of a computer system, cause the computer system to:
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obtain a process signal comprising time domain data generated as a result of one or more process control devices operating to control a process in the process plant; determine a leading indicator of a condition of the process plant based on the obtained process signal; define a process variable corresponding to the leading indicator; perform a rolling fast Fourier transform (FFT) on a subsequent process signal to determine time-series data corresponding to the defined process variable; monitor the time-series data corresponding to the defined process variable for a presence of the leading indicator; and generate an indication corresponding to a prediction of the condition based on a detected presence of the leading indicator in the monitored time-series data. - View Dependent Claims (29, 30, 31, 32)
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Specification