Abnormal situation prevention in a process plant

• US 7,079,984 B2
• Filed: 10/22/2004
• Issued: 07/18/2006
• Est. Priority Date: 03/03/2004
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Miller, John P., Eryurek, Evren, Kavaklioglu, Kadir
• Primary Examiner(s): Raymond, Edward
• Application Number:
  US10/971,361
• Publication Number:
  US 20050197803A1
• Time in Patent Office: 634 Days
• Field of Search: 702/185, 702182-184, 700/1, 709/236, 370/232, 370/469
• US Class Current: 702/185
• CPC Class Codes: G05B 23/0289 Reconfiguration to prevent failure, e.g. usually as a reaction to incipient failure detection

Abstract

A system detects abnormal conditions associated with a process plant. The system receives signal processing data generated by signal processing data collection blocks implemented by a plurality of devices. The signal processing data collection blocks may generate data such as statistical data, frequency analysis data, auto regression data, wavelets data, etc. The system includes an analysis engine configured to detect at least one abnormal condition associated with the process plant. The signal processing data is provided to the analysis engine, and the analysis engine determines if an action should be taken.

Claims

1. A method for detecting abnormal conditions associated with a process plant, the method comprising:

receiving signal processing data generated by signal processing data collection blocks implemented by a plurality of devices associated with the process plant;

providing configuration data to an analysis engine to configure the analysis engine to detect at least one abnormal condition associated with the process plant based at least on the collective signal processing data from each of the signal processing data collection blocks;

providing the signal processing data to the analysis engine; and

using the analysis engine to determine if an action should be taken.

2. A method according to claim 1, wherein receiving signal processing data comprises receiving signal processing data retrieved from a database.

3. A method according to claim 1, wherein receiving signal processing data comprises receiving signal processing data from at least one field device associated with the process plant.

4. A method according to claim 1, wherein receiving signal processing data comprises receiving a signal processing parameter associated with a process variable.

5. A method according to claim 1, wherein receiving signal processing data comprises receiving an indication of a condition of a signal processing parameter associated with a process variable.

6. A method according to claim 1, wherein receiving signal processing data comprises receiving at least one of statistical data, frequency analysis data, auto regression data, wavelets data, data generated using a neural network, and data generated using fuzzy logic.

7. A method according to claim 1, wherein receiving signal processing data comprises receiving signal processing data generated by at least one statistical data collection block.

8. A method according to claim 1, wherein receiving signal processing data comprises receiving signal processing data generated by at least one signal processing data collection block implemented by a field device.

9. A method according to claim 1, wherein receiving signal processing data comprises receiving signal processing data generated by at least one signal processing data collection block implemented by at least one of a process controller, a data historian, and a workstation.

10. A method according to claim 1, wherein receiving signal processing data comprises receiving data generated by a field device that conforms with at least one of the Foundation Fieldbus protocol, the HART protocol, the Profibus protocol, the WORLDFIP protocol, the Device-Net protocol, the AS-Interface protocol, and the CAN protocol.

11. A method according to claim 1, wherein receiving signal processing data comprises receiving signal processing data via at least one of a wired network and a wireless network.

12. A method according to claim 1, wherein receiving signal processing data comprises receiving signal processing data via at least one of a wired connection, a wireless connection, and an intermittent connection.

13. A method according to claim 1, wherein providing the signal processing data to the analysis engine comprises providing signal processing data to a rules engine.

14. A method according to claim 13, wherein providing signal processing data to the rules engine comprises providing signal processing data to a rules engine configured to apply at least one Boolean rule to at least some of the signal processing data.

15. A method according to claim 13, wherein providing signal processing data to the rules engine comprises providing signal processing data to a rules engine configured to apply at least one fuzzy logic rule to at least some of the signal processing data.

16. A method according to claim 1, wherein providing the signal processing data to the analysis engine comprises providing signal processing data to an analysis engine configured to determine a degree of correlation among at least some of the signal processing data.

17. A method according to claim 1, wherein providing the signal processing data to the analysis engine comprises providing the signal processing data to at least one of a neural network, mathematical computing engine, a fuzzy logic analysis engine, a pattern matching engine, and a regression analysis engine.

18. A method according to claim 1, wherein using the analysis engine comprises using the analysis engine to determine if an alert or alarm should be generated;

the method further comprising generating the alert or alarm.

19. A method according to claim 1, wherein using the analysis engine comprises using the analysis engine to determine if a control setting associated with the process plant should be changed;

the method further comprising causing the control setting to be changed.

20. A method according to claim 1, wherein using the analysis engine comprises using the analysis engine to determine if an operator should be prompted with one or more recommended actions to take regarding an abnormal condition;

the method further comprising causing the operator to be prompted with the one or more recommended actions.

21. A method according to claim 1 , wherein using the analysis engine comprises using the analysis engine to determine if at least one of a control condition and a setpoint associated with a controller should be changed;

the method further comprising causing the at least one of the control condition and the setpoint associated with the controller to be changed.

22. A method according to claim 1, further comprising providing, via a user interface, information indicative of a status of the analysis engine during an analysis of the signal processing data.

23. A method according to claim 1, further comprising providing, via a user interface, information indicative of a configuration of the analysis engine during an analysis of the signal processing data.

24. A method according to claim 1, wherein providing configuration data to the analysis engine comprises providing configuration data to the analysis engine to configure the analysis engine to detect at least one abnormal condition associated with the process plant further based on at least one of process configuration data, control strategy data, control output data, process variable data, historical data, simulation data, optimization data, an alert, an alarm, alert/alarm management data, document management data, help/guidance data, rotating equipment data, lab analysis data, and environmental regulation data.

25. A system for detecting abnormal conditions associated with a process plant, the system comprising:

at least one processor communicatively coupled to a network associated with the process plant;

at least one computer readable memory communicatively coupled to the at least one processor;

a first routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to receive signal processing data generated by signal processing data collection blocks implemented by a plurality of devices associated with the process plant;

a second routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to provide configuration data to an analysis engine to configure the analysis engine to detect at least one abnormal condition associated with the process plant; and

a third routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to implement the analysis engine to analyze the collective signal processing data from each of the signal processing data collection blocks to detennine if an action should be taken.

26. A system according to claim 25, wherein the third routine is to implement the analysis engine to additionally analyze at least one of process configuration data, control strategy data, control output data, process variable data, historical data, simulation data, optimization data, an alert, an alarm, alert/alarm management data, document management data, help/guidance data, rotating equipment data, lab analysis data, and environmental regulation data to determine if the action should be taken.

27. A method for configuring an analysis engine to detect an abnormal condition associated with a process plant, the method comprising:

providing a first user interface mechanism to specify a first signal processing parameter from a plurality of signal processing parameters generated by a plurality of signal processing data collection blocks implemented by a plurality of devices associated with the process plant;

providing a second user interface mechanism to specify a second signal processing parameter from the plurality of signal processing parameters generated by the plurality of signal processing data collection blocks implemented by the plurality of devices;

providing a third user interface mechanism to specify an analysis of at least the first signal processing parameter and the second signal processing parameter to be performed by the analysis engine;

receiving configuration data via the first user interface mechanism, the second user interface mechanism, and the third user interface mechanism; and

storing the configuration data.

28. A method according to claim 27, wherein the plurality of signal processing data collection blocks includes signal processing data collection blocks implemented by at least one of a field device, a process controller, a data historian, and a workstation.

29. A method according to claim 27, wherein providing the first user interface mechanism comprises:

providing a fourth user interface mechanism to specify one device from the plurality of devices; and

providing a fifth user interface mechanism to specify the first signal processing parameter from a first set of signal processing parameters generated by at least one signal processing data collection block implemented by the one device.

30. A method according to claim 29, wherein providing the fifth user interface mechanism comprises:

providing a sixth user interface device to specify one signal processing data collection block from a set of signal processing data collection blocks implemented by the one device; and

providing a seventh user interface device to specify the first signal processing parameter from a second set of signal processing parameters generated by the one signal processing data collection block.

31. A method according to claim 27, wherein providing the third user interface mechanism comprises providing a fourth user interface mechanism to specify a comparison analysis to be performed with respect to the first signal processing parameter.

32. A method according to claim 31, wherein providing the third user interface mechanism comprises providing a fifth user interface mechanism to specify a value to be compared with the first signal processing parameter.

33. A method according to claim 31, wherein providing the third user interface mechanism comprises providing a fifth user interface mechanism to specify a third signal processing parameter to be compared with the first signal processing parameter.

34. A method according to claim 27, wherein providing the third user interface mechanism comprises providing a fourth user interface mechanism to specify a Boolean logic operation to be performed with respect to the first signal processing parameter and the second signal processing parameter.

35. A method according to claim 27, further comprising:

providing a fourth user interface mechanism to specify an action to be taken if the

analysis indicates a condition has been met;

wherein receiving configuration data comprises receiving configuration data via the fourth user interface mechanism.

36. A method according to claim 35, wherein providing the fourth user interface mechanism comprises providing the fourth user interface mechanism to specify an alert to be generated if the analysis indicates the condition has been met.

37. A method according to claim 35, wherein providing the fourth user interface mechanism comprises providing the fourth user interface mechanism to specify a control setting change if the analysis indicates the condition has been met.

38. A method according to claim 35, wherein providing the fourth user interface mechanism comprises providing the fourth user interface mechanism to specify a prompt for prompting an operator with one or more recommended actions to take if the analysis indicates the condition has been met.

39. A method according to claim 35, wherein providing the fourth user interface mechanism comprises providing the fourth user interface mechanism to specify at least one of a control condition change and a setpoint change if the analysis indicates the condition has been met.

40. A system for configuring an analysis engine to detect an abnormal condition associated with a process plant, the system comprising:

at least one processor communicatively coupled to a network associated with the process plant;

at least one computer readable memory communicatively coupled to the at least one processor;

a first routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to provide a first user interface mechanism to specify a first signal processing parameter from a plurality of signal processing parameters generated by a plurality of signal processing data collection blocks implemented by a plurality of devices associated with the process plant;

a second routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to provide a second user interface mechanism to specify a second signal processing parameter from the plurality of signal processing parameters generated by the plurality of signal processing data collection blocks implemented by the plurality of devices;

a third routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to provide a third user interface mechanism to specify an analysis of at least the first signal processing parameter and the second signal processing parameter to be performed by the analysis engine;

a fourth routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to receive configuration data via the first user interface mechanism, the second user interface mechanism, and the third user interface mechanism; and

a fifth routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to store the configuration data.

41. A system according to claim 40, wherein the plurality of signal processing data collection blocks includes signal processing data collection blocks implemented by at least one of a field device, a process controller, a data historian, and a workstation.