System and method for continuous online safety and reliability monitoring

• US 7,133,727 B2
• Filed: 10/10/2003
• Issued: 11/07/2006
• Est. Priority Date: 08/01/2003
• Status: Active Grant

• Current Assignee: Schneider Electric Systems USA, Inc. (Schneider Electric SE)
• Original Assignee: Invensys Systems Incorporated (Invensys PLC)
• Inventors: Powers, Les, Adamski, Robert S., McCrea-Steele, Robin, Van Dyk, Paul J.
• Primary Examiner(s): PATEL, RAMESH B
• Application Number:
  US10/684,329
• Publication Number:
  US 20050027374A1
• Time in Patent Office: 1,124 Days
• Field of Search: 700/21, 700/78, 700/79, 700/80, 700/81, 700/82, 702/181, 702/182, 702/183, 702/184, 702/185, 719/4, 719/6, 719/36
• US Class Current: 700/21
• CPC Class Codes: G05B 23/0283 Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06

Abstract

A system and method for continuous online safety and reliability monitoring is disclosed. The method includes the steps of obtaining operating information about at least one of a plurality of instrumented function components, which are part of an instrumented function, and determining a probability of failure on demand for the instrumented function based on the operating information. In variations, instantaneous probability of failure on demand, online mean time to failure (MTTF), and online safety integrity level (SIL) are also calculated for an instrumented function. In other variations of the invention, alarms are reported to an operator based on the variance indicating the probability of failure on demand for the instrumented function is too high. In yet further variations, the system allows a user to predict probability of failure on demand values into the future based on hypothetical and/or future planned test times.

Claims

1. A method for managing a safety instrumented function including a plurality of instrumented function components, the method comprising:

obtaining a test completion time for at least one of the plurality of instrumented function components;

determining a probability of failure on demand for the safety instrumented function based on the test completion time;

comparing the probability of failure on demand with a designed probability of failure on demand for the safety instrumented function to establish a variance; and

managing the plurality of instrumented function components based on the variance.

2. The method of claim 1 wherein the probability of failure on demand is an instantaneous probability of failure on demand.

3. The method of claim 1 wherein the probability of failure on demand is an average probability of failure on demand.

4. The method of claim 1, wherein the test completion time is a future test completion time, and wherein the determining the probability of failure on demand is performed before the future test completion time.

5. The method of claim 1 wherein the obtaining includes obtaining an indication that the at least one of the plurality of instrumented function components has failed.

6. The method of claim 5 including:

setting a probability of failure on demand for the at least one of the plurality of instrumented function components to a predefined value;

wherein the determining includes calculating the probability of failure on demand for the safety instrumented function as a function of the probability of failure on demand for the at least one of the plurality of instrumented function components.

7. The method of claim 6 wherein the obtaining comprises obtaining environmental operating information.

8. The method of claim 7 wherein the environmental operating information includes information selected from the group consisting of:

temperature information, pressure information and humidity information.

9. The method of claim 1 wherein the obtaining further includes:

obtaining operating information about each of the plurality of instrumented function components;

wherein the determining includes calculating probability of failure on demand for each of the plurality of instrumented function components as a function of corresponding operating information received for each of the plurality of instrumented function components, thereby generating a plurality of probability of failure on demand values; and

wherein the probability of failure on demand for the safety instrumented function is determined as a function of the plurality of probability of failure on demand values.

10. The method of claim 1 wherein the managing comprises reducing a test interval between tests of the at least one of a plurality of instrumented function components in response to the variance exceeding a maximum variance.

11. The method of claim 1 wherein the managing comprises reducing a test interval between tests of another of the plurality of instrumented function components in response to the variance exceeding a maximum variance.

12. A system for managing a safety instrumented function including a plurality of instrumented function components, the system comprising:

means for obtaining a test completion time for at least one of the plurality of instrumented function components;

means for determining a probability of failure on demand for the safety instrumented function based on the test completion time;

means for comparing the probability of failure on demand with a designed probability of failure on demand for the safety instrumented function to establish a variance; and

means for providing, based on the variance, information useable for managing the plurality of instrumented function components.

13. The system of claim 12, wherein the probability of failure on demand is an instantaneous probability of failure on demand.

14. The system of claim 12, wherein the probability of failure on demand is an average probability of failure on demand.

15. The system of claim 12, wherein the test completion time is a future test completion time, wherein the means for determining the probability of failure on demand includes means for determining the probability of failure on demand before the future test completion time.

16. The system of claim 12 wherein the means for obtaining comprises means for obtaining environmental operating information.

17. The system of claim 16, wherein the environmental operating information includes information selected from the group consisting of:

temperature information, pressure information and humidity information.