Big Data in Process Control Systems

• US 20170115648A1
• Filed: 01/05/2017
• Published: 04/27/2017
• 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 D., Muston, Paul R., Beoughter, Ken
• Granted Patent: US 11,385,608 B2
• Time in Patent Office: Days
• 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 via a process control big data network and to cause the received data to be stored in the unitary, logical data storage area, wherein at least one of the one or more other devices communicates with one or more field devices in the process plant via another communication network different from the process control big data network,

each of the one or more other devices being a respective node of the process control big data network that (i) collects data that is generated by the respective node, (ii) transmits the collected data via the process control big data network to the one or more data receiver computing devices, and (iii) excludes a respective configuration or definition indicating a rate at which the collected data is to be transmitted by the respective node.

2. The system of claim 1, wherein the data stored in the unitary, logical data storage area includes time series data, and wherein a data entry of the time series data stored in the unitary, logical data storage area includes content of a respective data point of the time series data and a timestamp, the timestamp being indicative of a time of generation of the content of the data point corresponding to the data entry.

3. The system of claim 1, wherein the unitary, logical data storage area is further configured to store metadata corresponding to the received data, the received data is stored using a common structured format, and the metadata is stored using an unstructured format.

4. The system of claim 1, wherein the data stored in the unitary, logical data storage area 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,

data corresponding to a parameter related to safety of the process plant, or

data corresponding to at least one of a performance, a resource, or a configuration of the another communication network.

5. The system of claim 1, wherein the received data includes data received from another process plant.

6. The system of claim 1, wherein the one or more data storage devices are included in a cloud data storage system.

7. The system of claim 1, wherein at least the portion of the received data is streamed over the process control big data network 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.

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

a controller that communicates with at least one of the one or more field devices via the another communication network to control the process.

9. The system of claim 8, wherein the one or more other devices further includes at least one of a user interface device or a network management device.

10. 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.

11. The system of claim 10, 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 and at least one of:

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

12. The system of claim 10, 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, 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, and wherein the set of definitions are able to be transformed and loaded into the runtime environment of the process plant.

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

receiving, via a process control big data network at one or more data receiver computing devices from each of one or more nodes of the process control big data network, data corresponding to at least one of the process plant or a process controlled by the process plant, wherein at least one of the one or more nodes communicates with one or more field devices in the process plant via another communication network different from the process control big data network,

the data received from the each node including data that is generated by the each node while the process is being controlled, and

the each node excluding a respective configuration or definition indicating a rate at which data is to be transmitted by the each node via the process control big data network; 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.

14. The method of claim 13, wherein the one or more nodes of the process control big data network includes one or more other devices included in the process plant, and the one or more other devices includes a controller in communicative connection, via the another communication network, with at least one of the one or more field devices to control the process.

15. The method of claim 13, further comprising causing a computational analysis to be automatically performed using at least a portion of the data stored in the unitary, logical data storage area.

16. The method of claim 15,

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, and

storing the second set of data in the unitary, logical data storage area.

17. The method of claim 16, wherein the second set of data includes 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.

18. The method claim 16,

wherein the computational analysis is a first service;

and

the method further comprises causing a second service to be automatically performed using the second set of data.

19. 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 via a communication network of the process plant, 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, via the communication network, 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 (i) receive, via a process control system big data network different than the communication network, the real-time data and the configuration data corresponding to the controller, and (ii) 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,

the process control system big data apparatus is a second node of the process control system big data network, and

at least one of the field device or the controller excludes a respective configuration or definition indicating a rate at which the real-time data corresponding to the physical function is to be transmitted by the at least one of the field device or the controller via the process control system big data network.

20. The process control system of claim 19, 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.

21. The process control system of claim 19, 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 at least the portion of the data stored in the unitary, logical data storage area;

view a result of a performance of the service;

or

configure an additional service.

22. The process control system of claim 21, 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

one or more user actions included in the set of user actions is made available to the user for selection based on the authentication.