Remote analysis of process control plant data

• US 6,795,798 B2
• Filed: 05/10/2001
• Issued: 09/21/2004
• Est. Priority Date: 03/01/2001
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Raynor, Stuart Brian, Smith, Ross Stephen, Minto, Jeffrey Alan, Eryurek, Evren, Dewar, Ian Bryce
• Primary Examiner(s): Hoff, Marc S.
• Assistant Examiner(s): O MALLEY, MARY CATHERINE
• Application Number:
  US09/852,945
• Publication Number:
  US 20020123864A1
• Time in Patent Office: 1,230 Days
• Field of Search: 702/113-115, 702/122, 702/182-185, 702/187-188, 376/215-216, 700/28-31, 700/95-96, 700/108-109, 700/117, 700/266, 700/275, 700/286-291, 703/7, 703/12, 703/18
• US Class Current: 702/188
• CPC Class Codes: G05B 2223/06 Remote monitoring
• CPC Class Codes: G05B 23/0254 based on a quantitative model, e.g. mathematical relationships between inputs and outputs; functions: observer, Kalman filter, residual calculation, Neural Networks

Abstract

A system and method for analyzing a process collects process data within a process control plant and transmits the collected process data to a remote data processing facility. The remote data processing facility analyzes the process data using a process analysis tool such as a process monitoring tool, an equipment monitoring tool, a device monitoring tool, an index generation tool, a work order generation tool and/or an accounting tool to generate analysis data. The analysis data is then transmitted to the process control plant via a communication link such as the Internet.

Claims

1. A method of analyzing a process, comprising the steps of:

collecting process data within a process plant;

transmitting the collected process data to a remote data processing facility;

providing process plant configuration data relating to the setup of the process plant to the remote data processing facility;

storing the process plant configuration data within a database at the remote data processing facility;

analyzing the process data within the remote data processing facility to generate analysis data using the process plant configuration data and one of a plurality of asset or process analysis tools stored within a database of the remote data processing facility; and

transmitting the analysis data to the process plant.

2. The method of claim 1, wherein the step of analyzing the process data within the remote data processing facility to generate analysis data using the process plant configuration data and one of the plurality of asset or process analysis tools includes the step of using one of a process control tool, a process monitoring tool, an equipment monitoring tool, a device monitoring tool, an index generation tool, a work order generation tool and a business tool.

3. The method of claim 1, wherein the step of transmitting the collected process data to the remote data processing facility includes the step of transmitting the collected process data via an open network.

4. The method of claim 3, wherein the step of transmitting the collected process data via the open network includes the step of transmitting the collected process data using the Internet.

5. The method of claim 1, wherein the step of analyzing the process data within the remote data processing facility to generate analysis data using the process plant configuration data and one of the plurality of asset or process analysis tools includes the step of using a model of a portion of the process plant.

6. The method of claim 5, wherein the step of using the model of the portion of the process plant includes the step of using one of a device model, a loop model and a unit model.

7. The method of claim 1, wherein the step of analyzing the process data within the remote data processing facility to generate analysis data using the process plant configuration data and one of the plurality of asset or process analysis tools includes the step of using an optimization tool.

8. The method of claim 1, wherein the step of transmitting the analysis data to the process plant includes the step of transmitting one of problem data, condition data, plant data, process data, device data and optimization data.

9. The method of claim 1, wherein the step of transmitting the analysis data to the process plant includes the step of transmitting one of a health index value, a performance index value, a utilization index value and a variability index value that is associated with a portion of the process plant.

10. The method of claim 1, wherein the step of collecting the process data within the process plant includes the step of collecting a predetermined set of process data for use by the plurality of asset or process analysis tools.

11. The method of claim 1, wherein the step of collecting the process data within the process plant includes the step of repeatedly collecting the process data at a predetermined rate.

12. The method of claim 1, further comprising the step of transmitting update information from the process plant to the remote data processing facility to update the one of the plurality of asset or process analysis tools.

13. The method of claim 12, wherein the step of transmitting the update information from the process plant to the remote data processing facility to update the one of the plurality of asset or process analysis tools includes the step of transmitting updated model information.

14. The method of claim 12, wherein the step of transmitting the update information from the process plant to the remote data processing facility to update the one of the plurality of asset or process analysis tools includes the step of using a communication format based on a markup language.

15. A system for analyzing process data, comprising:

a server that has a processor and that is communicatively coupled to a remote process plant;

a database that is communicatively coupled to the server;

process plant configuration data relating to the setup of the remote process plant stored within the database; and

a plurality of asset or process analysis tools stored within the database, wherein the processor is programmed to use the process plant configuration data and one of the plurality of asset or process analysis tools to analyze the process data received from the remote process plant to generate analysis data and to send the analysis data to the remote process plant.

16. The system of claim 15, wherein the server is communicatively coupled to the remote process plant via an open network.

17. The system of claim 16, wherein the open network is the Internet.

18. The system of claim 15, wherein the plurality of asset or process analysis tools includes one of a process control tool, a process monitoring tool, an equipment monitoring tool, a device monitoring tool, an index generation tool, a work order generation tool and an accounting tool.

19. The system of claim 15, wherein the one of the plurality of asset or process analysis tools includes a model of a portion of the remote process plant.

20. The system of claim 19, wherein the model of the portion of the remote process plant includes one of a device model, a loop model and a unit model.

21. The system of claim 15, wherein the one of the plurality of asset or process analysis tools includes an optimization tool.

22. The system of claim 15, wherein the analysis data includes one of problem data, condition data, plant data, process data, device data and optimization data.

23. The system of claim 15, wherein the analysis data includes one of a health index value, a performance index value, a utilization index value, and a variability index value that is associated with a portion of the remote process plant.

24. The system of claim 15, wherein the processor is further programmed to receive update information from the remote process plant for updating the one of the plurality of asset or process analysis tools.

25. The system of claim 24, wherein the update information includes updated model information.

26. The system of claim 25, wherein the processor is further programmed to send the analysis data to the process plant using a communication format based on a markup language.

27. A system that analyzes process data, comprising:

a computer readable medium; and

a first routine stored on the computer readable medium and adapted to be executed by a processor that receives process data from a remote process plant;

a second routine stored on the computer readable medium and adapted to be executed by the processor that analyzes the process data received from the remote process plant using process plant configuration data relating to the setup of the remote process plant to generate analysis data; and

a third routine stored on the computer readable medium and adapted to be executed by the processor that sends the analysis data to the remote process plant.

28. The system of claim 27, wherein the third routine is further adapted to send the analysis data to the remote process plant via the Internet.

29. The system of claim 27, wherein the plurality of asset or process analysis tools includes one of a process control tool, a process monitoring tool, an equipment monitoring tool, a device monitoring tool, an index generation tool, a work order generation tool and a business tool.

30. The system of claim 27, wherein the plurality of asset or process analysis tools includes an optimization tool.

31. The system of claim 27, wherein the analysis data includes one of a health index value, a performance index value, a utilization index value and a variability index value that is associated with a portion of the remote process plant.

32. A method of analyzing asset utilization, comprising the steps of:

receiving process data from a remote process plant via the Internet;

storing process plant configuration data relating to the setup of the remote process plant;

analyzing the process data to generate analysis data using the process plant configuration data and one of a plurality of asset or process analysis tools stored within a database; and

transmitting the analysis data to the remote process plant via the Internet.

33. The method of claim 32, wherein the step of analyzing the process data using the process plant configuration data and one of the plurality of asset or process analysis tools includes the step of using one of a process control tool, a process monitoring tool, an equipment monitoring tool, a device monitoring tool, an index generation tool, a work order generation tool and an accounting tool.

34. The method of claim 32, wherein the step of analyzing the process data using the process plant configuration data and one of the plurality of asset or process analysis tools includes the step of using a model of a portion of the remote process plant.

35. The method of claim 32, wherein the step of analyzing the process data using the process plant configuration data and one of the plurality of asset or process analysis tools includes the step of using an optimization tool.

36. The method of claim 32, wherein the step of transmitting the analysis data to the remote process plant includes the step of transmitting one of problem data, condition data, plant data, process data, device data and optimization data.

37. The method of claim 32, wherein the step of transmitting the analysis data to the remote process plant includes the step of transmitting one of a health index value, a performance index value, a utilization index value and a variability index value that is associated with a portion of the remote process plant.

38. A method of analyzing process control data, comprising the steps of:

sending a first data template to a customer associated with a process plant;

receiving a second data template that is formed using the first data template and process control information generated within the process plant;

analyzing the process control information within the second data template to produce analysis results; and

notifying the customer of the availability of the analysis results via an internet.

39. The method of claim 38, wherein the step of sending the first data template to the customer includes the step using the internet to send the first data template in response to a request from the customer received via a web site associated with an application service provider.

40. The method of claim 38, wherein the step of receiving the second data template that is formed using the first data template and process control information generated by the process plant associated with the customer includes the step of receiving process control information associated with a particular piece of equipment within the process plant.

41. The method of claim 38, wherein the step of analyzing the process control information within the second data template to produce the analysis results includes the step of using one of a data analysis tool, a model and an optimizer to analyze the process control information.

42. The method of claim 38, wherein the step of notifying the customer of the availability of the analysis results via the internet includes the step of using one of an electronic mail and a web page to notify the customer.

43. The method of claim 38, further comprising the step of storing the second data template and the analysis results in a customer database.

44. The method of claim 38, further comprising the steps of pre-processing the process control information using a data reconciliation routine and validating the analysis results prior to notifying the customer of the availability of the analysis results.

45. The method of claim 38, further comprising the step of displaying a web page to the customer containing a report based on the analysis results, wherein the report includes one of performance information, cost information and historical information associated with a particular piece of equipment within the process plant.

46. A system for use in analyzing process control data, the system comprising:

a computer readable medium;

a first routine stored on the computer readable medium and adapted to be executed by a processor that enables a customer to contract with an application service provider to analyze process control data for the purpose of providing data analysis services and results for at least a portion of a process plant;

a second routine stored on the computer readable medium and adapted to be executed by the processor that designs a data model based on design data received from the customer and a model stored by the application service provider; and

a third routine stored on the computer readable medium and adapted to be executed by the processor that processes the data model using process control data received from the customer and that provides analysis results to the customer via an internet communication link.

47. The system of claim 46, wherein the first routine is further adapted to download contract terms and conditions to the customer via the internet communication link.

48. The system of claim 46, wherein the first routine is further adapted to configure a customer account in response to receiving an executed contract from the customer.

49. The system of claim 46, wherein the second routine is further adapted to download design data requirements to the customer via the internet communication link.

50. The system of claim 46, wherein the second routine is further adapted to use the design data received from the customer to form a design data spreadsheet and to fit the design data into the model stored by the application service provider.

51. The system of claim 46, wherein the third routine is further adapted to download a process data template to the customer via the internet communication link.

52. The system of claim 46, wherein the third routine is further adapted to pre-process the process control data using a data reconciliation routine.

53. The system of claim 46, wherein the third routine is further adapted to use one of a data analysis tool and an optimizer to process the data model.

54. The system of claim 46, wherein the third routine is further adapted to store the analysis results in a customer database and to notify the customer via the internet communication link of the availability of the analysis results.

55. The system of claim 46, wherein the third routine is further adapted to display a web page to the customer containing a report based on the analysis results, wherein the report includes one of performance information, cost information and historical information associated with a particular piece of equipment within a process plant associated with the customer.

56. A system for use analyzing process control data, the system comprising:

a server that is communicatively coupled to an internet communication link; and

a processor communicatively coupled to the server and to a plurality of databases, wherein the processor is programmed to download a process control data template to a customer via the internet communication link and wherein the processor is further programmed to use one of an optimizer and a data analysis tool to analyze a populated design data template that is formed using the process control data template and process data generated within a process plant associated with the customer.

57. The system of claim 56, wherein the plurality of databases includes one of a data analysis tools database, a models database, an optimizers database, a web pages database and a customer database.

58. A method of maintaining a process control system, comprising the steps of:

sending a first data template to a customer associated with a process plant;

receiving a second data template that is formed using the first data template and process control information generated within the process plant;

analyzing the process control information within the second data template to produce analysis results; and

scheduling maintenance activities for the process plant based on the analysis results via an internet communication link.

59. The method of claim 58, wherein the step of scheduling maintenance activities for the process plant based on the analysis results via an internet communication link includes the step of scheduling a maintenance outage within the process plant based on the analysis results.

60. The method of claim 58, wherein the step of scheduling maintenance activities for the process plant based on the analysis results via an internet communication link includes the step of ordering a part from a supplier via the internet communication link based on the analysis results.