Diagnostics in a process control system
First Claim
1. A diagnostic tool for use in a process control system having a multiplicity of function blocks adapted to control a process device during operation of a process, the diagnostic tool comprising:
- a data collection unit configured to communicate with each of the multiplicity of function blocks to receive, on a regular basis during operation of the process control system, data pertaining to a function block operating parameter for each of the multiplicity of function blocks;
a data analyzer that determines a value for the function block operating parameter for each of a number of times during operation of the process control system based on the received function block operating parameter data;
a detector that detects a problem within the process control system based on the determined values of the function block operating parameter; and
an output generator that creates a report indicating the detected problem, wherein the function block operating parameter is a variability parameter and wherein the data analyzer determines a variability value associated with one of the function blocks at each of the number of times based on collected function block operating parameter data.
1 Assignment
0 Petitions
Accused Products
Abstract
A diagnostic tool automatically collects and stores data indicative of a variability parameter, a mode parameter, a status parameter and a limit parameter associated with each of the different devices, loops or function blocks within a process control system, processes the collected data to determine which devices, loops or function blocks have problems that result in reduced performance of the process control system, displays a list of detected problems to an operator and then suggests the use of other, more specific diagnostic tools to further pinpoint or correct the problems. When the diagnostic tool recommends and executes a data intensive application as the further diagnostic tool, it automatically configures a controller of the process control network to collect the data needed for such a tool.
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Citations
69 Claims
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1. A diagnostic tool for use in a process control system having a multiplicity of function blocks adapted to control a process device during operation of a process, the diagnostic tool comprising:
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a data collection unit configured to communicate with each of the multiplicity of function blocks to receive, on a regular basis during operation of the process control system, data pertaining to a function block operating parameter for each of the multiplicity of function blocks;
a data analyzer that determines a value for the function block operating parameter for each of a number of times during operation of the process control system based on the received function block operating parameter data;
a detector that detects a problem within the process control system based on the determined values of the function block operating parameter; and
an output generator that creates a report indicating the detected problem,wherein the function block operating parameter is a variability parameter and wherein the data analyzer determines a variability value associated with one of the function blocks at each of the number of times based on collected function block operating parameter data. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A diagnostic tool for use in a process control system having a multiplicity of function blocks adapted to control a process device during operation of a process, the diagnostic tool comprising:
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a data collection unit configured to communicate with each of the multiplicity of function blocks to receive, on a regular basis during operation of the process control system, data pertaining to a function block operating parameter for each of the multiplicity of function blocks;
a data analyzer that determines a value for the function block operating parameter for each of a number of times during operation of the process control system based on the received function block operating parameter data;
a detector that detects a problem within the process control system based on the determined values of the function block operating parameter; and
an output generator that creates a report indicating the detected problem, wherein the function block operating parameter is a mode parameter and wherein the data collection unit receives a mode indication for each of the function blocks. - View Dependent Claims (9)
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10. A diagnostic tool for use in a process control system having a multiplicity of function blocks adapted to control a process device during operation of a process, the diagnostic tool comprising:
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a data collection unit configured to communicate with each of the multiplicity of function blocks to receive, on a regular basis during operation of the process control system, data pertaining to a function block operating parameter for each of the multiplicity of function blocks;
a data analyzer that determines a value for the function block operating parameter for each of a number of times during operation of the process control system based on the received function block operating parameter data;
a detector that detects a problem within the process control system based on the determined values of the function block operating parameter; and
an output generator that creates a report indicating the detected problem, wherein the function block operating parameter is a status parameter and wherein the data collection unit receives status indications for each of the multiplicity of function blocks. - View Dependent Claims (11, 12, 13)
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14. A diagnostic tool for use in a process control system having a multiplicity of function blocks adapted to control a process device during operation of a process, the diagnostic tool comprising:
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a data collection unit configured to communicate with each of the multiplicity of function blocks to receive, on a regular basis during operation of the process control system, data pertaining to a function block operating parameter for each of the multiplicity of function blocks;
a data analyzer that determines a value for the function block operating parameter for each of a number of times during operation of the process control system based on the received function block operating parameter data;
a detector that detects a problem within the process control system based on the determined values of the function block operating parameter; and
an output generator that creates a report indicating the detected problem, wherein the function block operating parameter is a limit parameter and the data collection unit collects limit indications associated with a function block variable. - View Dependent Claims (15, 16)
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17. A diagnostic tool for use in a process control system having a multiplicity of function blocks adapted to control a process device during operation of a process, the diagnostic tool comprising:
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a data collection unit configured to communicate with each of the multiplicity of function blocks to receive, on a regular basis during operation of the process control system, data pertaining to a function block operating parameter for each of the multiplicity of function blocks;
a data analyzer that determines a value for the function block operating parameter for each of a number of times during operation of the process control system based on the received function block operating parameter data;
a detector that detects a problem within the process control system based on the determined values of the function block operating parameter, wherein the detector detects the problem based on a plurality of past values for the function block operating parameter for one of the function blocks; and
an output generator that creates a report indicating the detected problem.
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18. A diagnostic tool for use in a process control system having a multiplicity of function blocks adapted to control a process device during operation of a process, the diagnostic tool comprising:
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a data collection unit configured to communicate with each of the multiplicity of function blocks to receive, on a regular basis during operation of the process control system, data pertaining to a function block operating parameter for each of the multiplicity of function blocks;
a data analyzer that determines a value for the function block operating parameter for each of a number of times during operation of the process control system based on the received function block operating parameter data;
a detector that detects a problem within the process control system based on the determined values of the function block operating parameter, wherein the detector detects the problem based on a plurality of values of the function block operating parameter over a particular time and further including a communicator that enables the particular time to be specified by the user; and
an output generator that creates a report indicating the detected problem.
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19. A diagnostic tool for use in a process control system that includes a processor and that uses a multiplicity of function blocks to control a process, the diagnostic tool comprising:
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a computer readable memory; and
a routine stored on the computer readable memory and adapted to be implemented on the processor, wherein the routine;
collects data pertaining to a function block operating parameter for each of a number of times during the operation of the process control system based on the collected function block operating parameter data;
detects a problem within the process control system based on the determined values of the function block operating parameter; and
produces a report that lists the detected problem, wherein the function block operating parameter is a variability parameter and wherein the routine collects variability indications for each of the multiplicity of function blocks. - View Dependent Claims (20)
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21. A diagnostic tool for use in a process control system that includes a processor and that uses a multiplicity of function blocks to control a process, the diagnostic tool comprising:
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a computer readable memory; and
a routine stored on the computer readable memory and adapted to be implemented on the processor, wherein the routine;
collects data pertaining to a function block operating parameter for each of a number of times during the operation of the process control system based on the collected function block operating parameter data;
detects a problem within the process control system based on the determined values of the function block operating parameter; and
produces a report that lists the detected problem, wherein the function block operating parameter is a mode parameter and wherein the routine collects mode indications for each of the multiplicity of function blocks. - View Dependent Claims (22)
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23. A diagnostic tool for use in a process control system that includes a processor and that uses a multiplicity of function blocks to control a process, the diagnostic tool comprising:
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a computer readable memory; and
a routine stored on the computer readable memory and adapted to be implemented on the processor, wherein the routine;
collects data pertaining to a function block operating parameter for each of a number of times during the operation of the process control system based on the collected function block operating parameter data;
detects a problem within the process control system based on the determined values of the function block operating parameter; and
produces a report that lists the detected problem, wherein the function block operating parameter is a status parameter and wherein the routine collects status indications for each of the multiplicity of function blocks. - View Dependent Claims (24)
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25. A diagnostic tool for use in a process control system that includes a processor and that uses a multiplicity of function blocks to control a process, the diagnostic tool comprising:
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a computer readable memory; and
a routine stored on the computer readable memory and adapted to be implemented on the processor, wherein the routine;
collects data pertaining to a function block operating parameter for each of a number of times during the operation of the process control system based on the collected function block operating parameter data;
detects a problem within the process control system based on the determined values of the function block operating parameter; and
produces a report that lists the detected problem, wherein the function block operating parameter is a limit parameter and the routine collects limit indications associated with a function block variable. - View Dependent Claims (26)
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27. A method of diagnosing problems in a process control system that uses a multiplicity of function blocks to control the operation of a process, the method comprising the steps of:
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collecting data pertaining to function block operation parameter from each of the multiplicity of function blocks during operation of the process control system;
determining a value for the function block operating parameter for each of a number of times during operation of the process control system based on the received function block operating parameter data; and
detecting a problem within the process control system based on the determined function block operating parameter values;
reporting the detected problem to a user, wherein the function block operating parameter is a variability parameter and the step of collecting data includes the step of collecting variability indications for each of the multiplicity of function blocks. - View Dependent Claims (28)
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29. A method of diagnosing problems in a process control system that uses a multiplicity of function blocks to control the operation of a process, the method comprising the steps of:
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collecting data pertaining to function block operation parameter from each of the multiplicity of function blocks during operation of the process control system;
determining a value for the function block operating parameter for each of a number of times during operation of the process control system based on the received function block operating parameter data;
detecting a problem within the process control system based on the determined function block operating parameter values; and
reporting the detected problem to a user, wherein the function block operating parameter is a mode parameter and the step of collecting data includes the step of collecting mode indications for each of the multiplicity of function blocks. - View Dependent Claims (30)
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31. A method of diagnosing problems in a process control system that uses a multiplicity of function blocks to control the operation of a process, the method comprising the steps of:
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collecting data pertaining to function block operation parameter from each of the multiplicity of function blocks during operation of the process control system;
determining a value for the function block operating parameter for each of a number of times during operation of the process control system based on the received function block operating parameter data;
detecting a problem within the process control system based on the determined function block operating parameter values; and
reporting the detected problem to a user, wherein the function block operating parameter is a status parameter and the step of collecting data includes the step of collecting status indications for each of multiplicity of function blocks. - View Dependent Claims (32)
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33. A method of diagnosing problems in a process control system that uses a multiplicity of function blocks to control the operation of a process, the method comprising the steps of:
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collecting data pertaining to function block operation parameter from each of the multiplicity of function blocks during operation of the process control system;
determining a value for the function block operating parameter for each of a number of times during operation of the process control system based on the received function block operating parameter data;
detecting a problem within the process control system based on the determined function block operating parameter values; and
reporting the detected problem to a user, wherein the function block operating parameter is a limit parameter related to whether a function block variable is at one or more limits and the step of collecting data includes the step of collecting limit indications for each of the multiplicity of function blocks. - View Dependent Claims (34)
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35. A function block adapted to control a process in a process control system and for execution by a processor in a process control environment, comprising:
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a computer readable memory;
a first routine stored on the computer readable memory and adapted to be executed on the processor to implement a process operation, wherein a first function block signal is associated with an operation of the first routine; and
a second routine stored on the computer readable memory and adapted to be executed on the processor to determine a variability indication based on the first function block signal, wherein the function block is an input function block, the first signal is indicative of a process parameter measurement and wherein the second routine compares a statistical measurement of the first signal to an instantaneous measurement of the first signal to determine the variability indication. - View Dependent Claims (36)
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37. A function block adapted to control a process in a process control system and for execution by a processor in a process control environment, comprising:
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a computer readable memory;
a first routine stored on the computer readable memory and adapted to be executed on the processor to implement a process operation, wherein a first function block signal is associated with an operation of the first routine; and
a second routine stored on the computer readable memory and adapted to be executed on the processor to determine a variability indication based on the first function block signal, wherein the function block is a control function block that uses a process parameter signal and a set point to produce a control signal and wherein the second routine compares the process parameter signal and the set point to determine the variability indication.
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38. A function block adapted to control a process in a process control system and for execution by a processor in a process control environment, comprising:
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a computer readable memory;
a first routine stored on the computer readable memory and adapted to be executed on the processor to implement a process operation, wherein a first function block signal is associated with an operation of the first routine; and
a second routine stored on the computer readable memory and adapted to be executed on the processor to determine a variability indication based on the first function block signal, wherein the variability indication is indicative of the integral squared error between the first signal and another value associated with the function block.
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39. A function block adapted to control a process in a process control system and for execution by a processor in a process control environment, comprising:
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a computer readable memory;
a first routine stored on the computer readable memory and adapted to be executed on the processor to implement a process operation, wherein a first function block signal is associated with an operation of the first routine; and
a second routine stored on the computer readable memory and adapted to be executed on the processor to determine a variability indication based on the first function block signal, wherein the second routine calculates a new value for the variability indication after each of a plurality of executions of the first routine.
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40. A function block adapted to control a process in a process control system and for execution by a processor in a process control environment, comprising:
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a computer readable memory;
a first routine stored on the computer readable memory and adapted to be executed on the processor to implement a process operation, wherein a first function block signal is associated with an operation of the first routine; and
a second routine stored on the computer readable memory and adapted to be executed on the processor to determine a variability indication based on the first function block signal, wherein the variability indication is based on a calculation of the mean absolute error of the first signal.
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41. A function block adapted to control a process in a process control system and for execution by a processor in a process control environment, comprising
a computer readable memory; -
a first routine stored on the computer readable memory and adapted to be executed on the processor to implement a process operation, wherein a first function block signal is associated with an operation of the first routine; and
a second routine stored on the computer readable memory and adapted to be executed on the processor to determine a variability indication based on the first function block signal, wherein the variability indication includes a variability indicative of an actual total standard deviation associated with the first signal and a second variability value indicative of a capability standard deviation associated with the first signal.
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42. A function block for execution on a processor as part of a process control application within a process control environment, comprising:
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a computer readable memory;
a first routine stored on the computer readable memory and adapted to be executed on the processor to implement a process operation as part of the process control application; and
a state variable that is set to a first state when the process control application is using the function block in an attempt to perform the process operation and is set to a second state when the process control application is not using the function block in an attempt to perform the process operation. - View Dependent Claims (43)
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44. A diagnostic tool for use in a process control system having a multiplicity of function blocks, the diagnostic tool comprising:
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a data collection unit configured to communicate with each of the multiplicity of function blocks to receive, on a regular basis during operation of the process control system, a first variability indication indicative of a mean absolute error of a function block operating parameter and a second variability indication indicative of a moving range average of a function block operating parameter for each of the multiplicity of function blocks;
a data analyzer that determines a variability value associated with one of the function blocks for each of a number of times during operation of the process control system based on the first variability indication and the second variability indication;
a detector that detects a problem within the process control system based on the determined variability value; and
an output generator that creates a report indicating the detected problem.
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45. A diagnostic tool for use in a process control system having a multiplicity of function blocks, the diagnostic tool comprising:
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a data collection unit configured to communicate with each of the multiplicity of function blocks to receive, on a regular basis during operation of the process control system, a first variability indication indicative of an actual total standard deviation of a function block operating parameter and a second variability indication indicative of a capability standard deviation associated with the function block operating parameter for each of the multiplicity of function blocks;
a data analyzer that determines a variability value associated with one of the function blocks for each of a number of times during operation of the process control system based on the first variability indication and the second variability indication;
a detector that detects a problem within the process control system based on the determined variability value; and
an output generator that creates a report indicating the detected problem. - View Dependent Claims (46, 47)
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48. A diagnostic tool for use in a process control system having a multiplicity of function blocks, the diagnostic tool comprising:
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a data collection unit configured to communicate with each of the multiplicity of function blocks to receive, on a regular basis during operation of the process control system, a mode indication for each of the multiplicity of function blocks;
a data analyzer that determines a mode value for one of the function blocks as a percentage of a specific period of time that the mode of the one of the function blocks was a non-normal mode based on received mode indication;
a detector that detects a problem within the process control system based on the determined mode value; and
an output generator that creates a report indicating the detected problem. - View Dependent Claims (49)
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50. A diagnostic tool for use in a process control system having a multiplicity of function blocks, the diagnostic tool comprising:
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a data collection unit configured to communicate with each of the multiplicity of function blocks to receive, on a regular basis during operation of the process control system, data pertaining to a function block operating parameter for each of the multiplicity of function blocks and an application state parameter for each of the multiplicity of function blocks;
a data analyzer that determines a value for the function block operating parameter for each of a number of times during operation of the process control system based on the received function block operating parameter data;
a detector that ignores the function block operating parameter based on function block operating parameter data associated with one of the multiplicity of function blocks when the function block parameter data is associated with a time in which the application state parameter was in a first state and that uses the function block operating parameter based on function block operating data associated with the one of the multiplicity of function blocks to detect a problem within the process control system when the function block parameter data is associated with a time in which the application state parameter was in a second state; and
an output generator that creates a report indicating the detected problem.
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51. A diagnostic tool for use in a process control system having a multiplicity of function blocks, the diagnostic tool comprising:
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a data collection unit configured to communicate with each of the multiplicity of function blocks to receive, on a regular basis during operation of the process control system, data pertaining to a function block operating parameter for each of the multiplicity of function blocks;
a data analyzer that determines a value for the function block operating parameter for each of a number of times during operation of the process control system based on received function block operating parameter data;
a detector that detects a problem within the process control system based on the determined values of the function block operating parameter;
a recommendation unit that recommends use of a further tool to correct the detected problem; and
an output generator that creates a report indicating the detected problem. - View Dependent Claims (52, 53, 54, 55, 56, 57)
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58. A diagnostic tool for use in a process control system that includes a processor and that uses a multiplicity of function blocks to control a process, the diagnostic tool comprising:
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a computer readable memory; and
a routine stored on the computer readable memory and adapted to be implemented on the processor, wherein the routine;
collects data pertaining to a function block operating parameter for each of a multiplicity of function blocks on a regular basis during operation of the process;
collects an application state parameter from one of the multiplicity of function blocks;
determines a value for a function block operating parameter for each of a number of times during the operation of the process control system based on the collected function block operating parameter data;
ignores the function block operating parameter based on function block operating parameter data associated with the one of the multiplicity of function blocks when the function block operating parameter data is associated with a time in which the application state parameter was in a first state;
uses the function block operating parameter to detect a problem within the process control system when the function block operating parameter is based on function block operating parameter data associated with the one of a multiplicity of function blocks when the function block operating parameter data is associated with a time in which the application state parameter was in a second state; and
produces a report which lists the detected problem.
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59. A diagnostic tool for use in a process control system that includes a processor and that uses a multiplicity of function blocks to control a process, the diagnostic tool comprising:
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a computer readable memory; and
a routine stored on the computer readable memory and adapted to be implemented on the processor, wherein the routine;
collects data pertaining to a function block operating parameter for each of a multiplicity of function blocks on a regular basis during operation of the process;
determines a value for the function block operating parameter for each of a number of times during the operation of the process control system based on the collected function block operating parameter data;
detects a problem within the process control system based on the determined values of the function block operating parameter;
recommends the use of a further tool to correct the detected problem; and
produces a report which lists the detected problem. - View Dependent Claims (60, 61, 62)
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63. A method of diagnosing problems in a process control system that uses a multiplicity of function blocks to control the operation of a process, the method comprising the steps of:
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collecting data pertaining to a function block operating parameter from each of a multiplicity of function blocks during operation of a process control system;
collecting an application state parameter from one of the multiplicity of function blocks;
determining a value for the function block operating parameter for each of a number of times during operation of the process control system based on the received function block operating parameter data;
ignoring the function operating parameter based on function block operating parameter data associated with one of the multiplicity of function blocks to detect a problem when the function block operating parameter data is associated with a time in which the application state parameter was in a first state;
using the function block operating parameter based on function block operating parameter data associated with one of the multiplicity of function blocks to detect the problem when the function block operating parameter data is associated with a time in which the application state parameter was in a second state. reporting the detected problem to a user.
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64. A method of diagnosing problems in a process control system that uses a multiplicity of function blocks to control the operation of a process, the method comprising the steps of:
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collecting data pertaining to a function block operating parameter from each of a multiplicity of function blocks during operation of a process control system;
determining a value for the function block operating parameter for each of a number of times during operation of the process control system based on the received function block operating parameter data;
detecting a problem within the process control system based on the determined function block operator parameter values;
automatically recommending the use of a further tool to correct the detected problem; and
reporting the detected problem to a user. - View Dependent Claims (65)
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66. A function block for execution by a processor in a process control environment, comprising:
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a computer readable memory;
a first routine stored on the computer readable memory and adapted to be executed on the processor to implement a process operation, wherein a first signal is associated with an operation of the first routine; and
a second routine stored on the computer readable memory and adapted to be executed on the processor to determine a variability indication based on a calculation of a moving range average associated with the first signal.
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67. A function block for execution by a processor in a process control environment, comprising:
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a computer readable memory;
a first routine stored on the computer readable memory and adapted to be executed on the processor to implement a process operation, wherein a first signal is associated with an operation of the first routine; and
a second routine stored on the computer readable memory and adapted to be executed on the processor to determine a variability indication including a first value representing a mean absolute error of the first signal and a second value representing a moving range average of the first signal.
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68. A function block for execution by a processor in a process control environment, comprising:
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a computer readable memory;
a first routine stored on the computer readable memory and adapted to be executed on the processor to implement a process operation, wherein a first signal is associated with an operation of the first routine; and
a second routine stored on the computer readable memory and adapted to be executed on the processor to determine a variability indication (V) computed as;
wherein Slq is a minimum standard deviation expected with feedback control, Stot is an actual measured standard deviation and s is a sensitivity factor.
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69. A Fieldbus function block for execution by a processor in a process control environment, comprising:
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a computer readable memory;
a first routine stored on the computer readable memory and adapted to be executed on the processor to implement a process operation, wherein a first signal is associated with an operation of the first routine;
a second routine stored on the computer readable memory and adapted to be executed on the processor to determine a variability indication based on the first signal; and
a communication unit that communicates the variability indication over a Fieldbus using Fieldbus protocol.
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Specification