Distributed diagnostic operations system

• US 7,627,455 B2
• Filed: 08/31/2005
• Issued: 12/01/2009
• Est. Priority Date: 08/31/2004
• Status: Active Grant

• Current Assignee: Watlow Electric Manufacturing Company
• Original Assignee: Watlow Electric Manufacturing Company
• Inventors: Steinhauser, Louis P., Culbertson, David P., McNutt, Leon J., Schuh, William C., Lenz, Gary A., Fennewald, Kenneth F.
• Primary Examiner(s): Dunn; Drew A
• Assistant Examiner(s): Cherry; Stephen J
• Application Number:
  US11/216,379
• Publication Number:
  US 20060058847A1
• Time in Patent Office: 1,553 Days
• Field of Search: 702/130, 702/188, 702/183
• US Class Current: 702/183
• CPC Class Codes: G01K 1/024 for remote indication
• CPC Class Codes: G01K 1/026 arrangements for monitoring a plurality of temperatures, e.g. by multiplexing
• CPC Class Codes: G01K 1/028 arrangements for numerical indication
• CPC Class Codes: G01K 15/00 Testing or calibrating of thermometers
• CPC Class Codes: G01K 3/14 in respect of space
• CPC Class Codes: G05B 2219/31211 Communicate diagnostic data from intelligent field device controller to central
• 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 distributed operations system having integrated diagnostics, a bitbus and a fieldbus and includes a field device for generating a field operating characteristic and a field processing module for receiving the field operating characteristic from the field device. The field processing module includes a field diagnostic component and a field communication component configured for communication over the bitbus. The field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic. An auxiliary processing module is configured for communicating with the bitbus and receiving the field operating data. The auxiliary processing module includes an auxiliary diagnostic component and an auxiliary communication component having a fieldbus interface and a gateway component. The auxiliary processing module is also configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the fieldbus.

Claims

1. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the field operating characteristic is indicative of a sensed temperature and the field device is a temperature sensor selected from the group consisting of a thermocouple, a resistance temperature detector, a thermopile, a diode, a semiconductor sensor, a resonance temperature sensor, an infrared sensor, and a thermistor; and

wherein the field processing module is configured for determining a sensed temperature as a function of the field operating characteristic and the field diagnostic parameter.

2. The system of claim 1 wherein the system is selected from the group consisting of a fabrication system, a packaging system, an engineering management system, a semiconductor tool, a manufacturing system, an assembly system, a processing system, an operational control system, an asset management system, a maintenance system including a predictive maintenance system, and a supervisory control and data acquisition system.

3. The system of claim 1 wherein the field operating characteristic is selected from the group consisting of a resistance, a current, a voltage, a Hall effect voltage, an energy, a mass, a power including an electrical power, a capacitance, an inductance, a reluctance, a phase, a timing, a frequency, a time, a mode, a status, a failure, a position, an alert, an alarm, a comparison, a state, a magnetic intensity, data, and a parameter.

4. The system of claim 1 wherein the field device is selected from the group consisting of a temperature sensor, a pressure sensor, a flow sensor, a level sensor, a force sensor, a leak detection sensor, a stress sensor, a motion sensor, a position sensor, a voltage sensor, a current sensor, a chemical property sensor, an actuator, a leak sensor, an accelerometer, a velocimeter, a valve positioner, a valve position sensor, an RFID tag, a smart card, a gauge including a pressure gauge, a solenoid, a power supply, a heater, a valve including a solenoid valve, a meter, a motor, a pump, a switch including a thermal switch, a Hall effect sensor, a magnetic intensity sensor, a gas sensor, a fusible link, an RFID tag, a smart card, and a memory device.

5. The system of claim 1 wherein the field processing module is configured for determining a thermal characteristic of the field device as a function of the field operating characteristic.

6. The system of claim 1 wherein the field device is configured to generate the field operating characteristic in at least one of encoded in a bar code format, a radio frequency identification format, a data matrix, and a smart card format.

7. The system of claim 1 wherein the field processing module generates the field operating data responsive to a field operating event.

8. The system of claim 7 wherein the field operating event is selected from the group consisting of a change of a state, a change of a mode, a change of a status, a failure, a change of a field parameter, a change of the field operating characteristic, a time rate of change of a temperature characteristic, a value of a field parameter exceeding a threshold, an alarm, a comparison, an alert, and a value of the field operating characteristic exceeding a threshold.

9. The system of claim 1 wherein the field operating data includes the field operating characteristic.

10. The system of claim 1 wherein the field processing module includes a field memory for storing one or more field administrative parameters.

11. The system of claim 10 wherein memory includes two related field administrative parameters.

12. The system of claim 11 wherein at least one of the field administrative parameters is the field diagnostic parameter.

13. The system of claim 11 wherein the memory is configured to store the received field operating characteristic.

14. The system of claim 1 wherein the field processing module includes a microprocessor.

15. The system of claim 1 wherein the field diagnostic component includes at least one of an algorithm, a program, an artificial intelligence module, a modeling module, a mapping, a graphical analysis, a rule, a comparator, and a look-up table.

16. The system of claim 1 wherein the field diagnostic component includes an algorithm selected from the group consisting of a neural network, an empirical data, a numerical data, a look-up table, a fuzzy logic circuit, a neural fuzzy circuit, a polynomial algorithm, a residual life algorithm, an artificial intelligence module, a wavelet, a modeling module, and a statistical function.

17. The system of claim 1 wherein the field diagnostic parameter is selected from the group consisting of an operational diagnostic, a device calibration, a system administration, and a system operation.

18. The system of claim 1 wherein field processing module is configured to determine the field diagnostic parameter as a function of the received field operating characteristic.

19. The system of claim 1 wherein the field processing module is configured to perform an operational function associated with at least one of the field devices, the field processing module, the first bus, and the system, said operational function being selected from the group consisting of a diagnostics, a trouble shooting method, a statistical process control computed parameter, a fault detection, a fault isolation, a root cause, a setting, a limit, a threshold, a calibration, a failure prediction, a maintenance procedure, a validation, a verification, a traceability, an auto-configuration, an architecture alignment, a fingerprint, an identification, a biometric identification, a theoretical modeling, a self-administration, a self-tuning rule, an operational device control.

20. The system of claim 1 wherein the field diagnostic parameter is selected from the group consisting of the field operating characteristic, an event, a status, a failure, a mode, and a state.

21. The system of claim 1 wherein the field processing module includes an analog-to-digital conversion component, and wherein the field device is configured to generate the field operating characteristic in an analog format and the field processing module generates the field operating data in a digital format.

22. The system of claim 1 wherein the field processing module includes a data compression component, said field processing module being configured for compressing at least a portion of the field operating data for communication over the first bus.

23. The system of claim 22 wherein the data compression component includes at least one of a table mapping, an algorithm, and a coding.

24. The system of claim 22 wherein the data compression component is configured for mapping the field diagnostic parameter to a prime number for communication over the first bus.

25. The system of claim 1 wherein the field processing module includes a data encryption component, said field processing module being configured for encrypting at least a portion of the field operating data for communication over the first bus.

26. The system of claim 1 wherein the field communication component includes a bus communication interface such that the field operating data is communicated to the first bus in a bus protocol.

27. The system of claim 1 wherein the field device and the field processing module are configured as a mechanically integrated unit.

28. The system of claim 1 wherein the field device is a first field device and the field processing module is a first field processing module, further comprising:

a second field device for generating a second field operating characteristic; and

a second field processing module for communicating with the first bus, said second field processing module for receiving the second field operating characteristic from the second field device, the second field processing module having a second field diagnostic component and a second field communication component,

wherein the second field processing module is adapted for communicating to the first field processing module at least one of a second administrative parameter, a second field operating data, a second field diagnostic parameter, and the second field operating characteristic.

29. The system of claim 1 wherein the field device is a first field device, further comprising a second field device for generating a second operating characteristic, wherein the field processing module is configured to receive the second operating characteristic, the field processing module configured for communicating the received second operating characteristic to the first field device.

30. The system of claim 1 wherein the first bus, field communication component and auxiliary communication component are each selected from the group consisting of hard-wired electrical communication interface, optical interface, a wireless interface, and a satellite interface.

31. The system of claim 1 wherein the field communication component and the auxiliary communication component are configured to communicate with a bus protocol over the first bus.

32. The system of claim 1 wherein the field communication component and the auxiliary communication component are each a bus modem.

33. The system of claim 1 wherein the first bus is configured to communicate in a format that is less than or equal to 8 bits and the second bus is configured to communicate in a format greater than 8 bits.

34. The system of claim 1 wherein a single bit is representative of the field diagnostic parameter.

35. The system of claim 1 wherein the second bus is selected from the group consisting of a wireless network, an enterprise communication bus including an Ethernet TCP/IP, an Internet, a token ring LAN, an Ethernet LAN, an EDDI network, a private data network, an ISDN, and a VPN.

36. The system of claim 1 wherein the auxiliary processing module includes an auxiliary memory for storing at least one auxiliary parameter, said at least one auxiliary parameter including at least one auxiliary diagnostic parameter.

37. The system of claim 1 wherein the auxiliary processing module includes a microprocessor.

38. The system of claim 1 wherein the auxiliary diagnostic component includes at least one of an algorithm, an artificial intelligence module, a modeling module, a mapping, a graphical analysis, a rule, a comparator, and a look-up table.

39. The system of claim 1 wherein the auxiliary processing module includes an auxiliary diagnostic parameter, the auxiliary processing module configured for generating the auxiliary field data as a function of the auxiliary diagnostic parameter.

40. The system of claim 1 wherein the auxiliary processing module includes an auxiliary diagnostic parameter and wherein the auxiliary field data includes the auxiliary diagnostic parameter.

41. The system of claim 1 wherein the auxiliary processing module includes an auxiliary diagnostic parameter selected from the group consisting of an operational diagnostic, a device calibration, a system administration, and a system operation.

42. The system of claim 1 wherein the auxiliary processing module is configured for performing an operational function associated with at least one of the field device, the field processing module, the first bus, the auxiliary processing module, the second bus, and the system, the operational function being selected from the group consisting of a diagnostics, a trouble shooting method, a statistical process control computed parameter, a fault detection, a fault isolation, a root cause, a setting, a limit, a threshold, a calibration, a failure prediction, a maintenance procedure, a validation, a verification, a traceability, an auto-configuration, an architecture alignment, a fingerprint, an identification, a biometric identification, a theoretical modeling, a self-administration, a self-tuning rule, an operational device control.

43. The system of claim 1 wherein the auxiliary processing module includes an algorithm selected from the group consisting of a neural network, an empirical data, a numerical data, a table look-up, a fuzzy logic circuit, a neural fuzzy circuit, a polynomial algorithm, a residual life algorithm, a wavelet, an artificial intelligence module, a modeling module, and a statistical function.

44. The system of claim 1 wherein the auxiliary processing module is configured for communicating the auxiliary field data over the second bus to a field operations management system coupled to the second bus.

45. The system of claim 1 wherein the auxiliary processing module is configured for communicating an auxiliary administrative parameter to the field processing module over the first bus.

46. The system of claim 45 wherein the auxiliary processing module is configured for generating the auxiliary administrative parameter in response to an auxiliary administrative event.

47. The system of claim 1 wherein the auxiliary processing module includes at least one of a protocol converter component, a data concentrator component, an encryption component, an administrative component, and an inter-field processing module communication component.

48. The system of claim 1 wherein the field processing module and the auxiliary processing module are each configured to interoperate to perform an operational function for at least one of the field device, the field processing module, the auxiliary processing module, the first bus, and the system, said operational function being selected from the group consisting of a diagnostics, a trouble shooting method, a statistical process control computed parameter, a fault detection, a fault isolation, a root cause, a setting, a limit, a threshold, a calibration, a failure prediction, a maintenance procedure, a validation, a verification, a traceability, an auto-configuration, an architecture alignment, a fingerprint, an identification, a biometric identification, a theoretical modeling, a self-administration, a self-tuning rule, an operational device control.

49. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the field operating characteristic is indicative of a sensed temperature and the field device is a temperature sensor selected from the group consisting of a thermocouple, a resistance temperature detector, a thermopile, a diode, a semiconductor sensor, a resonance temperature sensor, an infrared sensor, and a thermistor; and

wherein the sensed temperature is determined as a function of an EMF-to-temperature relationship defined by the field diagnostic parameter.

50. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the field operating data includes a product of a plurality of prime numbers, wherein at least one of the plurality of prime numbers is representative of a field diagnostic parameter.

51. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the field processing module is configured for generating a field administrative parameter and communicates the field administrative parameter to the field device, and wherein the field device generates the field operating characteristic as a function of the received field administrative parameter.

52. The system of claim 51 wherein the field processing module generates the field administrative parameter responsive to at least one of an operating event, an administrative event, and a maintenance event.

53. The system of claim 51 wherein the field administrative parameter is at least one of an instruction and a query.

54. The system of claim 51 wherein the field processing module generates the field administrative parameter in response to receiving an auxiliary administrative parameter over the first bus.

55. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the field device includes a field device memory storing a second field diagnostic parameter and wherein the field device provides the second field diagnostic parameter to the field processing module.

56. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the field processing module is a first field processing module, further comprising a second field processing module configured for generating second field operating data and in communication with the first bus, said second field processing module communicating second field operating data to the first field processing module over the first bus.

57. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the field device is a first field device and the field processing module is a first field processing module, further comprising;

a second field device for generating a second field operating characteristic; and

a second field processing module for communicating with the first bus, said second field processing module for receiving the second field operating characteristic from the second field device, the second field processing module having a second field diagnostic component and a second field communication component, said second field processing module configured for generating second field operating data including a second field diagnostic parameter as a function of the second field operating characteristic,

wherein the auxiliary field processing module is adapted to receive the second field operating data and wherein said auxiliary field processing module includes a supervisory module generating supervisory data as a function of the first field operating data and the second field operating data, said auxiliary field processing module configured to communicate the supervisory data over the second bus.

58. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the field device is a first field device, and the field processing module is a first field processing module, further comprising;

a second field device for generating a second field operating characteristic;

a second field processing module for receiving the second field operating characteristic from the second field device, the second field processing module having a second field diagnostic component and a second field communication component, the second field processing module configured for generating second field operating data including a second field diagnostic parameter as a function of the second field operating characteristic; and

a third bus for communicating with the second field processing module,

wherein the auxiliary processing module is adapted for communicating with the third bus and the first bus, the auxiliary processing module being configured for communicating to the first field processing module at least one of a second administrative parameter, the second field operating data, the second field diagnostic parameter, the second field operating characteristic, and a field administrative parameter.

59. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the first bus is configured as a single wire communication medium.

60. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the auxiliary processing module is configured for communicating the auxiliary field data over the second bus to a field operations management system coupled to the second bus;

wherein the field operations management system is configured for receiving the auxiliary field data and for generating a field device control instruction as a function of the received auxiliary field data.

61. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the auxiliary processing module is configured for communicating the auxiliary field data over the second bus to a field operations management system coupled to the second bus;

wherein the field operations management system is configured for performing an operational function associated with at least one of the field device and the system, said operational function being selected from the group consisting of a diagnostics, a trouble shooting method, a statistical process control computed parameter, a fault detection, a fault isolation, a root cause, a setting, a limit, a threshold, a calibration, a failure prediction, a maintenance procedure, a validation, a verification, a traceability, an auto-configuration, an architecture alignment, a fingerprint, an identification, a biometric identification, a theoretical modeling, a self-administration, a self-tuning rule, an operational device control.

62. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the auxiliary processing module is configured for communicating an auxiliary administrative parameter to the field processing module over the first bus;

wherein the auxiliary processing module is configured for generating the auxiliary administrative parameter in response to an administrative instruction received over the second bus.

63. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the auxiliary processing module is configured for communicating an auxiliary administrative parameter to the field processing module over the first bus;

wherein the auxiliary processing module is configured for generating the auxiliary administrative parameter in response to an auxiliary administrative event;

wherein a field operations management system coupled to the second bus is configured for generating the administrative instruction.

64. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the auxiliary processing module is configured for communicating an auxiliary administrative parameter to the field processing module over the first bus;

wherein the auxiliary processing module is configured for generating the auxiliary administrative parameter in response to an auxiliary administrative event;

wherein the auxiliary processing module is a first auxiliary processing module, further comprising;

a second auxiliary processing module coupled to the second bus, said second auxiliary processing module configured for generating the administrative instruction and for communicating the administrative instruction over the second bus to the first auxiliary processing module.

65. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

wherein the field device is a first field device, the field processing module is a first field processing module, and the auxiliary processing module is a first auxiliary processing module, further comprising;

a second field device for generating a second field operating characteristic;

a second field processing module coupled to the second field device, the second field processing module including a second field diagnostic component and a second field communication component, the second field processing module configured for receiving the second field operating characteristic from the second field device and for generating second field operating data including a second field diagnostic parameter as a function of the second field operating characteristic;

a third bus adapted for communication with the second field processing module; and

a second auxiliary processing module for communicating with the third bus and having a second bus interface for communicating over the second bus,

wherein said second field processing module is configured to communicate with the first field processing module via the third bus, the second auxiliary processing module, the second bus, the first auxiliary processing module, and the first bus.

66. The system of claim 65 wherein said the second field processing module is configured for communicating to the first field processing module at least one of a second administrative parameter, the second field operating data, the second field diagnostic parameter, and the second field operating characteristic.

67. A distributed operations system with integrated diagnostics having a first bus and a second bus, the system comprising:

a field device for generating a field operating characteristic;

a field processing module for receiving the field operating characteristic from the field device, the field processing module includes a field diagnostic component and a field communication component configured for communication over the first bus, said field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over the second bus;

a heater coupled to a heater power circuit for receiving heating power from a power supply, the heater power circuit having a first interface, a second interface, and an intermediate portion between the first interface and the second interface; and

a power controller coupled about the intermediate portion of the heater power circuit, the power controller having at least two states, a first state for providing at least a portion of the power to the heater and a second state for terminating power to the heater, said power controller including the field device and the field processing module.

68. A distributed operations system with integrated diagnostics having a first bus,

a first field device for generating a first field operating characteristic, and a second field device for generating a second field operating characteristic, the system comprising:

a first field processing module for receiving the first field operating characteristic from the first field device, the first field processing module includes a first field diagnostic component and a first field communication component configured for communication over the first bus, said first field processing module is configured for generating first field operating data including a first field diagnostic parameter as a function of the first field operating characteristic;

a second field processing module for receiving the second field operating characteristic from the second field device, the second field processing module having a second field diagnostic component and a second field communication component configured for communication over the first bus, said second field processing module being configured for generating second field operating data including a second field diagnostic parameter as a function of the second operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the first field operating data from the first field processing module and the second field operating data from the second field processing module, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a second bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of at least one of the first field operating data and the second field operating data and for communicating the auxiliary field data over a second bus.

69. The system of claim 68 wherein the auxiliary field processing module includes a supervisory module generating supervisory data as a function of the first field operating data and the second field operating data, said auxiliary field processing module configured to communicate the supervisory data over the second bus.

70. The system of claim 68 further comprising a third bus, wherein the first field communication component is configured for communication with the first bus and the second field communication component is configured for communication with the third bus, the auxiliary processing module being configured for communicating with the first bus for receiving the first field operating data and configured for communicating with the third bus for receiving the second field operating data.

71. The system of claim 70, further comprising a second auxiliary processing module for communicating with the third bus and having a second bus interface for communicating over the second bus, wherein said second field processing module is configured to communicate with the first field processing module via the third bus, the second auxiliary processing module, the second bus, the first auxiliary processing module, and the first bus.

72. The system of claim 68 wherein the first field processing module is configured to receive the second field operating data and to transmit the second field operating data over the first bus as a function, at least in part, of the received second field operating data.

73. A distributed operations system with integrated diagnostics having a first bus, the system comprising:

a first field device for generating a first field operating characteristic;

a second field device for generating a second field operating characteristic;

a field processing module for receiving the first field operating characteristic from the first field device and the second field operating characteristic from the second field device, the field processing module including a field diagnostic component and a field communication component for communicating with the first bus, the field processing module being configured for generating field operating data including at least one of a first field diagnostic parameter as a function of the first field operating characteristic and a second field diagnostic parameter as a function of the second field operating characteristic; and

an auxiliary processing module configured for communicating with the first bus and receiving the generated field operating data, said auxiliary processing module including an auxiliary diagnostic component and an auxiliary communication component having a bus interface and a gateway component, said auxiliary processing module configured for generating auxiliary field data as a function of the received field operating data and for communicating the auxiliary field data over a second bus.

74. The system of claim 73 wherein the field processing module is configured to transmit the received second operating characteristic to the first field device.