On line interactive monitoring of the execution of process operating procedures

• US 4,803,039 A
• Filed: 02/03/1986
• Issued: 02/07/1989
• Est. Priority Date: 02/03/1986
• Status: Expired due to Term

• Current Assignee: Westinghouse Electric Company LLC (Brookfield Asset Management Incorporated)
• Original Assignee: Westinghouse Electric Company LLC (Brookfield Asset Management Incorporated)
• Inventors: Lipner, Melvin H., Mundy, Roger A., Impink, Albert J. Jr.
• Primary Examiner(s): Tarcza, Thomas H.
• Assistant Examiner(s): CAIN, DAVID C
• Application Number:
  US06/825,427
• Time in Patent Office: 1,100 Days
• Field of Search: 364/188, 364/189, 364/431.01, 364/431.12, 376/245, 376/215, 376/216, 376/217, 371/29
• US Class Current: 376/216
• CPC Class Codes: G05B 19/409 characterised by using manual data input [MDI] or by using control panel, e.g. controlling functions with the panel; characterised by control panel details or by setting parameters G05B19/408, G05B19/4093 take precedence
• CPC Class Codes: G05B 2219/32001 Computer assisted machining, signals guide operator to manual machine object
• CPC Class Codes: G05B 2219/32004 Graphical, textual instructions, sheet for operator to resume process

Abstract

The operator of a complex process facility is aided in executing step by step procedures by a computer based system which incorporates monitored plant data and interactive plant operator responses to prompts to progress step by step through selected procedures. At each procedure step the plant status is evaluated and a recommended course of action is identified. The results are displayed on a visual display device to provide operator guidance for executing the procedure in effect. Parallel process monitoring visually alerts the user to conditions not considered by the current step of the active procedure, and where the seriousness of the other condition warrants, provides procedure-based recommendations for priority action. The system can be accessed by multiple users at separate locations for coordinated execution of a single procedure or simultaneous execution of two different procedures. A permanent chronological record of the step by step execution of the selected procedures including the pertinent plant conditions and operator responses, and the parallel monitored status tree conditions is also generated by the system for subsequent review and analysis.

Claims

1. A method of on-line monitoring of the execution by a human operator of procedures for a complex process facility comprising the steps of:

storing electric signals representative of step by step procedures for the complex process facility, at least some steps of which require verification of a selected process condition;

generating parameter signals representaitve of the real time value of predetermined process parameters;

sequentially electrically selecting a step of one of said stored step by step procedures as a current step;

electrically processing selected parameter signals to determine the state of the process condition to be varied by a current step which requires verification;

generating a visual representation of said current step including a visible textual statemenet of the condition to be verified, a visual indication of the state of the selected process condition to be verified by the current step, and, where the state of the selected condition indicates that it is not verified, a visible textual statement of recommended operator action;

providing means for the operator to electrically generate an operator response signal in response to a textural statement of recommended operator action by said visal display of said current step, including providing means for the operator to select between electrically generating an action complete response signal and an override response signal, and

electrically sequentially selecting the next step in said stored procedure as the current step in response to said operator response siganl.

2. The method of claim 1 including the step of updating the visual indication of the state of the selected process condition to be verified by the current step and the visible statement of recommended operator action in response to changes in the selected process condition as a result of operator response to the recommended action.

3. The method of claim 1 wherein said step of generating said visual representations includes generating the same at two separate locations and wherein the step of providing means for the operator to electrically generate an operator response signal includes providing such means at said two separate locations.

4. The method of claim 3 wherein said step of generating a visible textual statement of recommended operator action includes generating a visual indication of which of said two locations at which the action is required.

5. The method of claim 1 including the steps of electrically monitoring, while successive current steps of said stored step by step procedures are being executed, certain parameter signals representative of another process condition not being addressed by said current steps and simultaneously, with the generation of the visual display of said current step, generating a visual indication of said another process condition when the monitoring step generates an indication that said another process condition is in a specified state which warrants attention.

6. The method of claim 5 wherein said step of generating a visual indication of said another process condition includes generating a visible textual statement of action recommended in response to said another process condition when the moitoring step generates an indication that the state of the another process condition requires immediate attention and providing a visual indication that said statement of action recommended in response to said another process condition has priority over the action recommended in response to the current step.

7. The method of claim 1 including electrically logging the response signals generated by the operator.

8. The method of claim 6 including electrically removing the visible textual statement of the action recommended in response to the another process condition upon generation by the operator of either a complete or override signal.

9. The method of claim 8 wherein the steps of generating the visual representation of said current step and of generating a visual indication of said another process condition include generating said representation and indication at two spaced apart locations and wherein the step of providing means for the operator to select between electrically generating a complete signal and an override signal includes providing such means at both of said spaced apart locations.

10. The method of claim 6 including generating a prominent visual indication when the values of said specified parameters indicate that the overall status of the process facility is in a state requiring immediate operator action and a visible textual statement of a specified step by step procedure which should be implemented in response thereto, providing means by which the operator can selectively generate a transfer signal in response to the prominent visual indication, and electrically selecting a step of said specified step by step procedure in response to a transfer signal in place of the step which is the current step at the time of the generation of said prominent visual indication.

11. The method of claim 10 including in response to an override signal generated by the operator, maintaining as the current step, the step which was current at the time that the prominent visual indication was generated.

12. The method of claim 1 including the steps of continuously electrically monitoring the overall status of the process facility as represented by the values of specified parameters and generating simultaneously with the display of said current step a visual display of said overall status of the process facility.

13. A method of on-line monitoring of the execution by a human operator of procedures for a complex process facility comprising the steps of:

storing electrical signals representative of step by step procedures for the complex process facility;

generating sequentially from said stored electrical signals a visual representation of the current step to be executed of said step by step procedures, in the form of a textual statement of the current step and a textual statement of operator action recommended in response to said current step;

generating visual prompts informing the operator of how to generate an input signal in response to the visible textual statement of recommended action;

providing means for the operator to electrically generate such an input signal;

indexing the current step to the next step in the stored step by step procedures in response to an input signal generated by the operator;

measuring selected process parameters and generating parameter signals representative of the measured values of said selected parameters; and

simultaneously with said visual representation of the current procedure step, and in response to predetermined values of said parameter signals indicative of an abnormal process condition, generating a visual indication of the existence of the abnormal condition.

14. The method of claim 13 wherein the step of generating a visual indication of the abnormal condition includes generating a visible textual statement of the abnormal condition, generating a visible textual statement of operator action recommended in response to the abnormal condition, and selectively generating visual prompts for the operator to indicate a response thereto, and said method including the step of electrically assigning priorities to the action required by said current step and the recommended action in response to the abnormal condition, and wherein said step of generating the visual prompts includes only generating a display of the prompts associated with the visible textual statement of recommended action for the action having the higher priority.

15. The method of claim 14 including generating indicia to visually indicate the association of the prompts displayed with the appropriate one of the recommended action in response to the current step and the recommended action in response to the abnormal condition.

16. The method of claim 15 wherein the visible textual statement of recommended action in response to the current step is presented in one color, the visible textual statement of recommended action in response to the abnormal condition is presented in a second color, and the prompts are generated in the same color as the visible textual statement of recommended action which is in priority.

17. The method of claim 15 including automatically electrically logging the occurrence of each current step, abnormal condition and input signal generated by the operator.

18. The method of claim 17 including providing means by which an operator can generate an override signal in response to the generation of prompts associated with a priority visible textual statement of recommended action for an abnormal condition, and regenerating the prompts associated with the visible textual statement of recommended action by the current step in response to said override signal.

19. The method of claim 13 including the step of generating simultaneously with the visual representation of the current step, a visible representation of the textual statements of a selected number of most recent current steps.

20. The method of claim 13 including the step of generating simultaneously with the visual representation of the current step a visible representation of the textual statements of a selected number of subsequent steps in the step by step procedures.

21. The method of claim 20 including the step of generating also a visual representation of the textual statement of a selected number of the most recent current steps.

22. A method of on-line monitoring of the execution of procedures for a complex process facility comprising the steps of:

storong sets of electrical signals representative of a plurality of step-by-step procedures for the complex process facility;

generating on an on-line basis, parameter signals representative of the current values of selected process parameters;

selecting the set of electrical signals representative of one of said step-by-step procedures based upon the values of said parameters signals;

generating sequentially from said selected electrical signals a visual representation of each step of the selected procedure, one step at a time, at least some of said steps including generating a visual recommendation to the operator that a transfer be made to another set of stored electrical signals representative of another one of said step-by-step procedures based upon the current values of certain of said process parameters selected by the visually presented step;

providing means for an operator to generate an electrical response signal to each visually presented step;

indexing said visual display to the next step in the selected procedures in response to each response signal; and

providing mens for the operator to select between generating an electrical transfer signal and an electrical override signal in response to said visual recommendation, selecting in response to a transfer signal said another set of stored electrical signals representative of another one of said procedures for sequential generation of a visual representation of each step, and continuing in response to an override signal to generate a visual respresentation of each step in the first selected procedure.

23. The method of claim 22 including the steps of electrically monitoring the current values of designated ones of said parameter signals in parallel with the sequential generation of a visual representation of each step of the selected procedure, generating a visual representation of a recommendation to transfer to a designated set of stored electrical signals representative of a different procedure than the selected procedure in response to selected values of said designated parameters, selecting said different set of stored signals for generating sequentially visual representation of each step of said different procedure in response to the generation of a transfer signal by the operator, and continuing to generate a visual representation of each step of the first selected procedure in response to an override signal.

24. The method of claim 22 wherein said step of generating a visual representation of each step of the selected procedure includes generating such visual representations at two separate locations, and wherein said step of providing means for an operator to generate an electrical response signal to each visually presented step includes providing such means at said two separate locations.

25. A method of on-line monitoring of the execution of procedures for a nuclear power plant comprising the steps of:

storing sets of electrical signals representative of a plurality of step-by-step plant procedures;

generating on an on-line basis, parameter signals representative of the current values of selected plant parameters;

selecting a set of electrical signals representative of one of said step-by-step procedures;

generating sequentially from said selected electrical signals a visual representation of each step of the selected procedure;

electrically monitoring the current values of designated ones of said parameter signals in parallel with the sequential generation of a visual representation of each step of the selected procedure;

generating a visual representation of a recommendation to transfer to a designated set of stored electrical signals representative of a different procedure than the selected procedure in response to selected values of said designated parameters;

providing means for an operator to select between generating an electric transfer signal and an electric override signal; and

electrically selecting said different set of stored signals for generating sequentially the visual representation of each step of said different procedures in response to the generation of a transfer signal by the operator, and continuing to generate a visual representation of each step of the first selected procedure in response to an override signal.

26. The method of claim 25 wherein the selected parameters include parameters indicative of a reactor trip and wherein said step of selecting a set of electrical signals representative of one of said step-by-step procedures is performed electrically in response to an indication of a reactor trip.

27. The method of claim 26 wherein at least some of said steps of the selected procedure electrically monitor certain plant parameters to verify the status of certain plant conditions and to generate a visual representation of a textual statement of recommended action selected from a library of textual statements when said certain condition is not verified.

28. The method of claim 27 wherein the step of electrically monitoring the current values of designated ones of said parameter signals in parallel with the sequential generation of a visual representation of each step of the selected procedure includes, monitoring parameters representative of plant critical safety functions and generating a visual display representative of said status of each of the critical safety functions.

29. Apparatus for on-line interactive monitoring of the execution of procedures in a complex process plant comprising:

a plurality of sensors for generating sensor signals representative of the current values of a plurality of plant parameters;

a storage medium for storing electrical signals representative of the steps of a plurality of step-by-step procedures as a current step, to process selected

a digital computer programmed to sequentially select stored signals representative of a selected one of the steps of one of said plurality of step-by-step procedures as a current step, to process selected sensor signals to determine the status of a process condition selected by the current step and recommended action as a result thereof, and to select from said library textual statement signals representative of the current step, the status of the designated process condition and the recommended action;

a display device for generating a visible display of said textual statements; and

an input device including means by which an operator generates a response signal to the visible display, said digital computer being further programmed to generate in the display device selected prompts including a completion prompt to indicate completion of the action recommended by the current step and an override prompt to indicate an override of the recommended action, said input device including means for the operator to generate completion and override response signals responsive to the respective prompts.

30. The apparatus of claim 29 wherein said digital computer is further programmed to continuously monitor certain of the sensor signals to generate additional status signals representative of the current status of designated process conditions other than the conditions selected by the current steps, and to select from said library additional textual statements in response to the additional status signals, and wherein said display device includes means to generate a visible display of said additional textual statements simultaneously with the display of the textual statements associated with the current step.

31. The apparatus of claim 30 wherein said digital computer is further programmed to indicate action recommended in response to a specified status of said designated other process conditions, to determine priority between the action recommended in response to the current step and the other process conditions, to select textual statements of action recommended, and to generate prompts associated with the priority action, and wherein said display device includes means to generate a visible display of the priority action textual statement and prompts, and to visually associate the prompts with the priority action recommended.

32. The apparatus of claim 31 wherein said means for visually associating the prompts with the textual statements of priority action recommended include means for generating different portions of the display in different colors and for generating the textual statement of the priority action recommended and the prompts in the same color.

33. The apparatus of claim 32 wherein the priority action recommended is to transfer to another of said plurality of step-by-step procedures, wherein said prompts include a prompt for implementing such transfer, wherein said input device includes means to generate a transfer signal in addition to said complete and override signals and wherein said digital computer is programmed in response to said transfer signal to select said another step-by-step procedure and sequentially select the steps thereof as the current step.

34. The apparatus of claim 33 including means for generating a chronological log of the current steps, the status conditions and the operator generated response signals.

35. The apparatus of claim 34 wherein said digital computer is further programmed to continuously monitor previously determined sensor signals and to generate therefrom safety status signals representative of overall plant safety conditions, and wherein said display device includes means to generate a visible indication of overall plant safety status in response to the safety status signals simultaneously with the display of said textual statements and additional textual statements.

36. A method of on line monitoring of the simultaneous execution of two different procedures for a complex process facility comprising the steps of:

storing electrical signals representative of at least two, step-by-step procedures for the complex process facility;

generating parameter status signals representative of the real-time status of predetermined process parameters and storing said parameter status signals in a common memory;

electrically selecting electrical signals representative of one of said procedures as a first active procedure, presenting sequentially on a first display a visual textual statement of action recommended by each step of said first active procedure to be executed, said actions affecting the status of some of said stored parameter status signals, and simultaneously electrically monitoring selected parameter status signals stored in the common memory and generating a visual indication on said first display of any conditions represented by the real-time status of said selected parameter status signals which conflict with the first active procedure; and

simultaneously electrically selecting electrical signals representative of another one of said procedures as a second active procedure, presenting sequentially on a second display a visual textual statement of action recommended by each step of said second active procedure to be executed, said actions affecting the status of certain of said stored parameter status signals, and simultaneously electrically monitoring predetermined ones of said parameter status signals stored in the common memory and generating a visual indication on said second display of any conditions represented by the real-time status of said predetermined ones of said parameter status signals which conflict with the second active procedure.

37. The method of claim 36 wherein the steps of sequentially presenting a visible textual statement of action recommended by each step of said first and second active procedures each include electrically determining the status of designated ones of the parameter status signals stored in said common memory and selecting from a library of textual statements a statement for visual presentation dependent upon the status of said designated parameter status signals, generating on the respective displays visual prompts indicating steps to take to generate an input signal in response to the selected textual statement, and presenting the next step in the procedure in response to said input signal.

38. The method of claim 37 wherein said steps of generating a visual indication of conditions which create a conflict include choosing from said library a textual statement of action recommended by the respective operator PG,66 in response to the conflict condition and generating prompts indicating to the respective operator steps to take to generate an input signal in response to the chosen statement in place of the prompts generated for the action recommended by the visibly presented step of the appropriate one of the first and second procedures.

39. Apparatus for on-line monitoring of the simultaneous execution of two different procedures for a complex process facility comprising:

a plurality of sensors for generating parameter signals representative of the current values of a plurality of facility parameters;

digital processing means having memory in which at least two, step-by-step procedures and libraries of textual statements are stored and including common memory, said digital processing means being programmed, to process said parameter signals to generate parameter status signals representative of the real-time conditions in the facility, to store said parameter status signals in said common memory, to independently sequentially select a step from two different step-by-step procedures stored in memory as the current step of a first and second active procedure respectively, to independently determine as to the current step of each active procedure the condition of associated stored parameter status signals and action recommended as a result hereof, to independently select from said library, textual statements for the current step and the actions recommended thereby for each active procedure, to independently as to each active procedure simultaneously monitor certain parameter status signals stored in said common memory and when the values thereof indicate a conflict with the associated active procedure, to select a textual statement from the library indicative of the same; and

display means for generating for each active procedure a visible display of the textual statement of the current step and the action recommended thereby, and when conditions so indicate, the textual statement of a conflict between the monitored parameter status signals and that active procedure.

40. The apparatus of claim 39 wherein said display means comprises a first display device upon which the visible display for the first active procedure is generated and a second display device upon which the visible display for the second active procedure is generated.

41. The apparatus of claim 39 wherein said digital processing means is further programmed to generate prompts to indicate steps to be taken in response to a visual statement of action recommended by the first and second procedures, and wherein said first and second display devices generate visual displays of the prompts associated with the first and second active procedures respectively, said apparatus also including first input signal generating means by which an operator generates first electrical input signals to the digital processing means as indicated by the prompts displayed by the first display device, and second input signal generating means by which an operator generates second electrical input signals to the digital processing means as indicated by the prompts displayed by the second display device, said digital processing means being programmed to select the next step as the current step in the first active procedure in response to said first input signal and to select the next step as the current step in the second active procedure in response to said second input signal.

42. The apparatus of claim 41 wherein said digital processing means comprises:

first digital computing means having said common memory and programmed to generate said parameter status signals and store them in said common memory, and to perform all the program functions associated with the first active procedure;

second digital computing means programmed to perform all of the program functions associated with the second active procedure; and

data link means connecting the second digital computing means with the common memory in the first digital computing means, said first display device and first input signal generating means being connected to the first digital computing means and the second display device and second input signal generating means being connected to the second digital computing means.

43. A method of on-line monitoring of the simultaneous execution of two different procedures for a nuclear power plant comprising the steps of:

storing electrical signals representative of at least two, step-by-step procedures for the plant;

generating parameter status signals representantive of the real-time status of predetermined process parameters and storing said parameter status signals in a common memory;

electronically selecting electrical signals representative of one of said procedures as a first active procedure, electrically determining for each step of said first active procedure the status of designated ones of the parameter status signals stored in said common memory, presenting sequentially on a first display a visual textual statement of action recommended by each step of said first active procedure to be executed based upon the status of said designated parameter status signals, said actions affecting the status of some of said stored parameter status signals, and simultaneously electrically monitoring selected parameter status signals stored in the common memory and generating a visual indication on said first display of any conditions represented by the real-time status of said selected parameter status signals which conflict with the first active procedure; and

simultaneously electrically selecting electrical signals representative of another one of said procedures as a second active procedure, electrically determining for each step of said second active procedure the status of designated ones of the parameter status signals stored in said common memory, presenting sequentially on a second display a visual textual statement of action recommended by each step of said second active procedure to be executed based upon the status of said designated parameter status signals, said actions affecting the status of certain of said stored parameter status signals, and simultaneously electrically monitoring predetermined ones of said parameter status signals stored in the common memory and generating a visual indication on said second display of any conditions represented by the real-time status of said predetermined ones of said parameter status signals which conflict with the second active procedure.