Field device management system

• US 6,317,701 B1
• Filed: 09/04/1998
• Issued: 11/13/2001
• Est. Priority Date: 06/17/1998
• Status: Expired due to Fees

• Current Assignee: Metso Field Systems Oy (Neles Oyj)
• Original Assignee: Metso Field Systems Oy (Neles Oyj)
• Inventors: Cederlöf, Harri, Pyötsiä, Jouni
• Primary Examiner(s): SHAH, KAMINI S
• Application Number:
  US09/148,068
• Time in Patent Office: 1,166 Days
• Field of Search: 702/183, 702/182, 702/186, 700/11, 709/223, 709/225, 710/109, 706/45, 706/46, 706/50, 340/825.49, 379/106.1
• US Class Current: 702/188
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/31121 Fielddevice, field controller, interface connected to fieldbus
• CPC Class Codes: G05B 2219/31211 Communicate diagnostic data from intelligent field device controller to central
• CPC Class Codes: G05B 2219/31324 Distributed real time knowledge, database
• CPC Class Codes: G05B 2219/32226 Computer assisted repair, maintenance of system components
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

The invention relates to field management in industrial process systems and similar systems. In the invention, maintenance management systems of industrial processes of separate plants located geographically apart from each other are networked in such a way that they may communicate with each other or with a centralized maintenance management server and transmit information on maintenance parameters of field devices of different types. As a result, experience obtained in one industrial process can be transferred to other respective industrial processes and applications. By utilizing this globally collected cumulative information, it is possible to improve and specify the diagnostics of the separate local maintenance systems (6) essentially faster than in case if the local maintenance management system were independent and the diagnostics were changed on the basis of local experience only.

Claims

1. A maintenance management system for maintenance management of field devices in industrial processes located in different plants at different geographical locations that are remote from each other, said maintenance management system comprising:

a local maintenance management system in association with each of said industrial processes,

wherein the local maintenance management systems of said industrial processes are arranged to form a network and to communicate with at least one of each other and a centralized maintenance management unit and to exchange information relating to maintenance management of the field devices to learn and utilize the information on a network level,

wherein each of said local maintenance management systems is arranged to control local maintenance management parameters independently based on data collected locally and data received from local maintenance management systems of other plants.

2. A system according to claim 1, wherein said local maintenance management parameters include data representing at least one of performance and need of maintenance of a field device.

3. A system according to claim 2, wherein each of the field devices is a valve and a management parameter representing the performance comprises or is affected by one or more of a static error, a rate of change in static error, a dynamic error, a rate of change in dynamic error, an opening accumulation, a load, or a rate of change in load.

4. A system according to claim 2, wherein each of the field devices is a valve and a management parameter representing the need of maintenance comprises or is affected by one or more of a control performance, an odometer of valve, an odometer of actuator, a number of valve reversals, a number of actuator reversals, a valve seal leakage, a valve emission, a valve wall thickness, a cavitation level, a load, or a rate of change in load.

5. A system according to claim 1, wherein each of the local maintenance management systems is arranged to independently adapt the maintenance management to changes the maintenance management system has detected in properties of the field devices.

6. A maintenance management system for managing field devices in an industrial process, said maintenance management system comprising:

a communicating mechanism arranged to communicate with other maintenance management systems of industrial processes of other plants located geographically apart from each other in order to transmit and receive data which relates to a maintenance of field devices; and

a maintenance management parameters adjusting mechanism arranged to adjust maintenance management parameters of field device types in a self-learning manner based on data collected locally and data received from said other maintenance management systems.

7. A system according to claim 6, wherein said maintenance management parameters comprise parameters representing performance and/or need of maintenance of the field devices.

8. A system according to claim 6 or 7, wherein the maintenance management system is arranged to independently adapt maintenance management to changes the maintenance management system has detected in the properties of the field devices.

9. A maintenance management system for maintenance management of field devices in industrial processes located at different geographical locations remote from each other, said maintenance management system comprising:

a local maintenance management system in association with each of the industrial processes,

wherein the local maintenance management systems of said industrial processes are arranged to form a network and to communicate with each other and to exchange information relating to maintenance management of the field devices to learn and utilize the information on a network level,

wherein each of said local maintenance management systems is arranged to control local maintenance management parameters independently based on data collected locally and data received from other local maintenance management systems, each of said local maintenance management systems comprises;

a knowledge database arranged to store knowledge types of at least one of application-specific knowledge data, field device-specific knowledge data, and field device-type specific knowledge data;

an analyzer arranged to analyze conditions of the field devices based on measurement data obtained from a respective local process and knowledge data obtained from said knowledge database, said analyzer is further able to change value of at least one maintenance parameter in the respective local process, when required according to results of an analysis; and

a knowledge database controller arranged to modify content of said knowledge database based on maintenance management history data collected locally and maintenance management history data received from the other local maintenance management systems.

10. A system according to claim 9, wherein said local maintenance management parameters comprise at least one of data representing a performance of a field device, data representing a need of maintenance of a field device, a maintenance alarm threshold for a field device, a performance alarm threshold for a field device, or a maintenance priority level for a field device.

11. A system according to claim 9 or 10, wherein knowledge data comprises data representing control performance history data or maintenance-need history data of a field device, a field device type, or a process control application.

12. A maintenance management system for managing field devices in an industrial process, said maintenance management system comprising:

a maintenance management system communication mechanism arranged to communicate with respective maintenance management systems of industrial processes of other plants located geographically apart from each other in order to transmit and receive data which relates to a maintenance of field devices; and

a maintenance management parameter adjusting mechanism arranged to adjust maintenance management parameters of field device types in a self-learning manner based on data collected locally and data received from said other maintenance management systems,

said maintenance management system further comprising;

a knowledge database arranged to store knowledge types of at least one of application-specific knowledge data, field device-specific knowledge data, or field device-type specific knowledge data;

an analyzer arranged to analyze a condition of the field devices based on measurement data obtained from a respective local process and knowledge data obtained from said knowledge database, said analyzer is further able to change value of at least one maintenance parameter in the respective local process, when required according to results of an analysis; and

a knowledge database controller to modify content of said knowledge database based on maintenance management history data collected locally and maintenance management history data received from the other maintenance management systems.

13. A maintenance management system according to claim 12, wherein said maintenance management parameters comprise at least one of data representing a performance of a field device, data representing a need of maintenance of the field device, a maintenance alarm threshold for the field device, a performance alarm threshold for the field device, and a maintenance priority level of the field device.

14. A maintenance management system according to claim 12 or 13, wherein said knowledge data includes data representing control performance history data or maintenance-need history data of a field device, field device type, or a process control application.

15. A maintenance management system according to claim 12, wherein a local maintenance management system is arranged to independently adapt to maintenance management changes that the maintenance management system has detected in properties of the field devices.