Asset optimization reporting in a process plant

• US 7,634,384 B2
• Filed: 03/18/2003
• Issued: 12/15/2009
• Est. Priority Date: 03/18/2003
• Status: Active Grant

• Current Assignee: Computational Systems Incorporated (Emerson Electric Company)
• Original Assignee: CSI Technology Incorporated (Emerson Electric Company), Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Garvey, Raymond E. III, Eryurek, Evren, Hokeness, Scott N., Reeves, Todd W., Harris, Stuart
• Primary Examiner(s): West; Jeffrey R
• Assistant Examiner(s): Suglo; Janet L
• Application Number:
  US10/390,818
• Publication Number:
  US 20040186927A1
• Time in Patent Office: 2,464 Days
• Field of Search: 702/182, 705 8- 10, 700/95
• US Class Current: 702/182
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 19/02 electric
• CPC Class Codes: G05B 2219/31396 Business management, production, document, asset, regulatory management, high level
• CPC Class Codes: G05B 23/0278 Qualitative, e.g. if-then rules; Fuzzy logic; Lookup tables; Symptomatic search; FMEA
• 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
• CPC Class Codes: G06Q 10/063 Operations research, analysis or management
• CPC Class Codes: G06Q 10/103 Workflow collaboration or project management
• CPC Class Codes: G06Q 10/20 Administration of product repair or maintenance
• 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 90/82 Energy audits or management systems therefor
• CPC Class Codes: Y02P 90/845 Inventory and reporting systems for greenhouse gases [GHG]

Abstract

A process control system uses an asset optimization reporter to collect status information pertaining to the assets of a process plant from various data sources of the plant including, for example, data tools, data collectors, and data generators. This status information is used to generate reports that may be displayed to various users, including maintenance persons, process control persons and business persons. The status information may be used as the basis for further types of status information and/or be categorized in ways that are useful to the user. The reports are generally displayed via a user interface routine that enables users to view the status information and manipulate the display of the report to correspond to the user'"'"'s preferences, as contained in a user profile. The user interface routine further enables the user to view reports of various types of status information for various devices, loops, units, areas, etc., including status information for the process plant, and manipulate how the status information is displayed, such as with textual, numerical or graphical depictions or any combination thereof.

Claims

1. A method of reporting status information regarding an entity within a process plant comprising:

receiving status information of a first type, wherein the first type of status information reflects a condition having a first temporal consequence;

receiving status information of a second type, wherein the second type of status information reflects a condition having a second temporal consequence shorter than the first temporal consequence;

receiving status information of a third type, wherein the third type of status information reflects a condition having a third temporal consequence shorter than the first temporal consequence;

generating a report on a processor that includes the status information of the first, second and third types, wherein the report is indicative of the status of the entity; and

displaying the report to a user, wherein the display of the report includes a polygonal representation indicative of the status of the entity, wherein the polygonal representation comprises three or more axes each pertaining to a different entity status category having a spectrum of values between a good status quality and a bad status quality and normalized relative to the other spectrums of values, each axis having a finite number of increments measured from a common origin relative to one end of the spectrum of values to an endpoint relative to the other end of the spectrum of values, wherein each endpoint is normalized to be equidistant from the origin as other endpoints of the other axes, wherein entity status values pertaining to each status category are proportionally assigned to a point on the respective axis and the point is linearly connected to a point of an entity status value of at least one other axis to define the polygonal representation intersecting the axes for a combined display of each of the plurality of categories, and wherein each type of status information pertains to a different one of the plurality of categories.

2. The method of claim 1, wherein one or more of the status information of the first type, the status information of the second type and the status information of the third type pertains to the status of the entity.

3. The method of claim 1, wherein the entity is a first entity, and one or more of the status information of the first type, the status information of the second type and the status information of the third type pertains to the status of a second entity.

4. The method of claim 1, wherein generating a report comprises generating a report based in part on a user profile and displaying the report comprises displaying the report based at least in part on the user profile.

5. The method of claim 4, wherein the display of the report comprises dynamic and static information, and displaying the report comprises displaying the dynamic information based on one or more user preferences within the user profile and displaying the static information regardless of the user preferences.

6. The method of claim 4, wherein the user profile comprises default parameters, and generating a report comprises generating a report based at least in part on the default parameters.

7. The method of claim 4, wherein the user profile comprises information about the user'"'"'s responsibilities within the process plant, and generating a report comprises generating a report based at least in part on the user'"'"'s responsibilities within the process plant.

8. The method of claim 4, wherein the user profile comprises user preferences, and generating a report comprises generating a report based at least in part on the user preferences.

9. The method of claim 8, wherein the user preferences include preferences regarding the type of status information indicated in the report, and generating a report comprises generating a report based at least in part on the user preferences regarding the type of status information.

10. The method of claim 8, wherein the user preferences comprise preferences regarding the representation of the status information in the report, and displaying the report comprises displaying the report based at least in part on the user preferences regarding the representation of the status information.

11. The method of claim 10, wherein the user preferences regarding the representation of the status information comprise preferences regarding at least one of the type of representation of the status information and the placement of the representation of the status information.

12. The method of claim 8, wherein the user preferences comprise preferences predefined by the user, and generating a report comprises generating a report based at least in part on the predefined preferences.

13. The method of claim 8, wherein the user preferences comprise default preferences based at least in part on predictions about the user, and generating a report comprises generating a report based at least in part on the predictions about the user.

14. The method of claim 8 further comprising adjusting the user preferences while displaying the report to a user, wherein displaying the report comprises displaying the report based on the adjusted user preferences.

15. The method of claim 1, wherein the entity includes a plurality of lower level entities, the method further comprising:

receiving status information pertaining to the status of each of the plurality of lower level entities;

wherein generating a report comprises generating a report based at least in part on the status information pertaining to the status of one or more of the lower level entities, and displaying the report comprises displaying a lower level representation of the status information pertaining to the status of the one or more lower level entities.

16. The method of claim 15, wherein displaying a lower level representation comprises displaying a lower level representation in response to at least one of a user action and the user profile.

17. The method of claim 15, wherein the status information pertaining to the status of one or more of the lower level entities comprises at least one of the status information of the first type, status information of the second type and status information of the third type.

18. The method of claim 1, wherein the entity is a first entity and the report is a first report, the method further comprising:

receiving status information pertaining to the status of a second entity;

generating a second report based at least in part on the status information pertaining to the second entity; and

displaying the second report to the user, wherein the display of the second report includes a representation of the status information pertaining to the status of the second entity.

19. The method of claim 18, wherein the status information pertaining to the status of the second entity is of the same type as one of the status information of the first type, the second type or the third type.

20. The method of claim 18, wherein the status information pertaining to the status of the second entity has an impact on one or more of the status information of the first type, the second type and the third type.

21. The method of claim 18, wherein generating a second report comprises generating a second report based at least in part on a user profile, and wherein displaying the second report to the user comprises displaying the second report to the user based at least in part on the user profile.

22. The method of claim 21, wherein the status information comprises dynamic information and the status information pertaining to the status of the second entity comprises static information, wherein displaying the first and second reports comprises displaying the First report based on one or more user preferences contained within the user profile and displaying the second report regardless of the user preferences.

23. The method of claim 21, wherein the user profile comprises user preferences regarding the first and second entities, and generating a report comprises generating a report pertaining to the status of the preferred entity and displaying the report comprises displaying the report based at least in part on the status information of the preferred entity.

24. The method of claim 1, wherein the status information of the first type, the second type and the third type each pertain to one or more of business information, operational information and maintenance information.

25. The method of claim 1, wherein the status information of the first type, the second type and the third type each pertain to one or more of:

entity availability, entity health, entity downtime, entity utilization, entity reliability, entity performance, entity age, entity failure, entity prioritization, entity instructions, entity history, entity location, entity description, entity type, entity specifications, entity alignment, entity function, entity details, entity identification, entity manufacturer, entity alerts, entity optimization, entity alarms, entity configuration, entity calibration, entity position, entity speed, entity tolerances, entity chatter, key performance indicators, use indices, work orders, service orders, parts orders, predictions, models, waste, safety, environment, utilities, quality, throughput, an economic analysis, an impact analysis, a production analysis, a cost analysis, a vibration analysis, a thermography analysis, a lubricant analysis, a chemistry analysis, a balance analysis, an ultrasonic analysis, monitoring information, operating equipment effectiveness, efficiency, task planning, task assignment, a corrective measure, help information, recommendations, instructions, diagnostic information, event severity, and event urgency.

26. The method of claim 1, wherein at least one of the first, second and third types of status information comprise status information generated based on status information of a plurality of types.

27. The method of claim 1, further comprising:

receiving status information of a fourth type from a fourth data source wherein the fourth type of status information reflects a condition having a fourth temporal consequence shorter than the third term consequence,

wherein the polygonal representation comprises four or more axes each pertaining to a different entity status category having a spectrum of values between a good status quality and a bad status quality and normalized relative to the other spectrums of values.

28. The method of claim 27, wherein the status information of the first type comprises design and quality status information, the status information of the second type comprises an operating condition information, the status information of the third type comprises a measure of entity health, and the status information of the fourth type comprises production status information.

29. The method of claim 1, wherein the status information of the first type comprises design and quality status information, the status information of the second type comprises operating condition information, and the status information of the third type comprises a measure of entity health.

30. The method of claim 29, wherein the status information of the first type is associated with a fluid chemistry category, the status information of the second type is associated with a fluid contamination category and the status information of the third type is associated with an equipment wear category.

31. A method of reporting status information regarding an entity within a process plant, wherein the process plant includes a plurality of lower level entities and wherein the plurality of lower entities comprise a higher level entity, the method comprising:

receiving status information pertaining to the status of each of the plurality of lower level entities;

receiving status information of a plurality of types, the status information pertaining to the status of the higher level entity and each type of status information reflecting a condition having a different temporal consequence;

generating a higher level report on a processor based at least in part on the status information pertaining to the status of the higher level entity and based further in part on a user profile;

displaying the higher level report to a user based at least in part on the user profile, wherein the display of the report includes a polygonal representation of the status information pertaining to the status of the higher level entity, wherein the polygonal representation comprises three or more axes each pertaining to a different entity status category having a spectrum of values between a good status quality and a bad status quality and normalized relative to the other spectrums of values, each axis having a finite number of increments measured from a common origin relative to one end of the spectrum of values to an endpoint relative to the other end of the spectrum of values, wherein each endpoint is normalized to be equidistant from the origin as other endpoints of the other axes, wherein entity status values pertaining to each status category are proportionally assigned to a point on the respective axis and the point is linearly connected to a point of an entity status value of at least one other axis to define the polygonal representation intersecting the axes for a combined display of each of the plurality of categories, wherein each type of status information pertains to a different one of the plurality of categories;

wherein the status information comprises status information of a first, second, third and fourth type each reflecting a condition having a different temporal consequence, and

wherein the plurality of categories of the polygonal representation are arranged according to successively decreasing or increasing temporal consequences of the status information pertaining to the categories.

32. The method of claim 31 further comprising:

generating a lower level report pertaining to the status of at least one of the plurality of lower level entities; and

displaying the lower level report to the user, wherein the display of the lower level report includes a representation of the status information pertaining to the status of the lower level entity.

33. The method of claim 32, wherein displaying the lower level report comprises displaying the lower level report in response to a user action from the display of the higher level entity.

34. The method of claim 32, wherein displaying the higher level report comprises displaying the higher level report in response to a user action from the display of the lower level entity.

35. The method of claim 32, wherein displaying the lower level report comprises displaying the lower level report concurrently with displaying the higher level report.

36. The method of claim 31, wherein the report comprises status information pertaining to one or more of business information, operational information and maintenance information.

37. The method of claim 31, wherein the report further comprises status information pertaining to one or more of:

entity availability, entity health, entity downtime, entity utilization, entity reliability, entity performance, entity age, entity failure, entity prioritization, entity instructions, entity history, entity location, entity description, entity type, entity specifications, entity alignment, entity function, entity details, entity identification, entity manufacturer, entity alerts, entity optimization, entity alarms, entity configuration, entity calibration, entity position, entity speed, entity tolerances, entity chatter, key performance indicators, use indices, work orders, service orders, parts orders, predictions, models, waste, safety, environment, utilities, quality, throughput, an economic analysis, an impact analysis, a production analysis, a cost analysis, a vibration analysis, a thermography analysis, a lubricant analysis, a chemistry analysis, a balance analysis, an ultrasonic analysis, monitoring information, operating equipment effectiveness, efficiency, task planning, task assignment, a corrective measure, help information, recommendations, instructions, diagnostic information, event severity, and event urgency.

38. A system for reporting status information for a process plant having a plurality of entities, the system comprising:

a computer readable memory;

a display;

a routine stored on the computer readable memory and adapted to be executed by a processor which stores user profiles;

a routine stored on the computer readable memory and adapted to be executed by the processor which receives status information of a plurality of types, the status information pertaining to each of the plurality of entities and each type of status information reflecting a condition having a different temporal consequence;

a routine stored on the computer readable memory and adapted to be executed by the processor which generates a report based at least in part on the status information of one or more of the plurality of entities and based further in part on a user profile, wherein the report is indicative of the status of the one or more entities;

a routine stored on the computer readable memory and adapted to be executed by the processor which displays the report to the user in accordance with the user profile, wherein the display of the report includes a polygonal representation of the status information pertaining to the status of the one or more entities, wherein the polygonal representation comprises three or more axes each pertaining to a different entity status category having a spectrum of values between a good status quality and a bad status quality and normalized relative to the other spectrums of values, each axis having a finite number of increments measured from a common origin relative to one end of the spectrum of values to an endpoint relative to the other end of the spectrum of values, wherein each endpoint is normalized to be equidistant from the origin as other endpoints of the other axes, wherein entity status values pertaining to each status category are proportionally assigned to a point on the respective axis and the point is linearly connected to a point of an entity status value of at least one other axis to define the polygonal representation intersecting the axes for a combined display of each of the plurality of categories, wherein each type of status information pertains to a different one of the plurality of categories;

wherein the status information comprises status information of a first, second, third and fourth type each reflecting a condition having a different temporal consequence, and

wherein the plurality of categories of the polygonal representation are arranged according to successively decreasing or increasing temporal consequences of the status information pertaining to the categories.

39. The system of claim 38 further comprising a routine stored on the computer readable memory and adapted to be executed by the processor which stores a plurality of user-selectable representations, wherein the polygonal representation of the status information is selected from among a plurality of user-selectable representations in accordance with the user profile.

40. The system of claim 39, wherein the plurality of user-selectable representations comprise at least one of the polygonal representation, an alphanumeric representation and a graphical representation.

41. The system of claim 38, wherein the plurality of entities are lower level entities and the process plant further includes a higher level entity that includes two or more of the lower level entities, the system further comprising:

a routine stored on the computer readable memory and adapted to be executed by the processor which receives status information pertaining to the status of the higher level entity;

a routine stored on the computer readable memory and adapted to be executed by the processor which generates a higher level report pertaining to the status of the higher level entity; and

a routine stored on the computer readable memory and adapted to be executed by the processor which displays the higher level report to the user, wherein the display of the higher level report includes a representation of the status information pertaining to the status of the higher level entity.

42. The system of claim 41, wherein the higher level report is generated in response to a user request from the display of the status information of the one or more lower level entities.

43. The system of claim 41, wherein the higher level report is generated in response to a user preference contained in the user profile.

44. The system of claim 41, wherein the representation of the status information pertaining to the higher level entity is displayed concurrently with the polygonal representation of the status information pertaining to one or more of the lower level entities.

45. The system of claim 41, further comprising a routine stored on the computer readable memory and adapted to be executed by the processor which switches between displaying the representation of the status information pertaining to the higher level entity and displaying the polygonal representation of the status information of one or more of the plurality of entities in response to a user action.

46. The system of claim 41, wherein the higher level entity is the process plant.

47. The system of claim 38 further comprising:

a routine stored on the computer readable memory and adapted to be executed by the processor which alters the polygonal representation of the status information in response to a user request; and

a routine stored on the computer readable memory and adapted to be executed by the processor which displays the report to the user in accordance with a user profile, wherein the display of the report includes the altered representation of the status information.

48. The system of claim 47 further comprising a routine stored on the computer readable memory and adapted to be executed by the processor which updates the user profile in response to altering the polygonal representation of the status information.

49. The system of claim 38, wherein the report comprises status information pertaining to one or more of business information, operational information and maintenance information.

50. The system of claim 38, wherein the report further comprises status information pertaining to one or more of:

entity availability, entity health, entity downtime, entity utilization, entity reliability, entity performance, entity age, entity failure, entity prioritization, entity instructions, entity history, entity location, entity description, entity type, entity specifications, entity alignment, entity function, entity details, entity identification, entity manufacturer, entity alerts, entity optimization, entity alarms, entity configuration, entity calibration, entity position, entity speed, entity tolerances, entity chatter, key performance indicators, use indices, work orders, service orders, parts orders, predictions, models, waste, safety, environment, utilities, quality, throughput, an economic analysis, an impact analysis, a production analysis, a cost analysis, a vibration analysis, a thermography analysis, a lubricant analysis, a chemistry analysis, a balance analysis, an ultrasonic analysis, monitoring information, operating equipment effectiveness, efficiency, task planning, task assignment, a corrective measure, help information, recommendations, instructions, diagnostic information, event severity, and event urgency.

51. A system for displaying status information regarding an entity within a process plant having a plurality of entities, the system comprising:

a processor;

a display;

a routine adapted to be executed by the processor which receives status information pertaining to the status of the entity;

a routine adapted to be executed by the processor which generates a report based at least in part on the status information;

a routine adapted to be executed by the processor which displays a polygonal representation of categories comprising;

asset management information pertaining to the entity, monitoring information pertaining to the entity, maintenance information pertaining to the entity and performance information pertaining to the entity, each category corresponding to a condition having a different temporal consequence, wherein the polygonal representation comprises four or more axes each pertaining to a different entity status category having a spectrum of values between a good status quality and a bad status quality and normalized relative to the other spectrums of values, each axis having a finite number of increments measured from a common origin relative to one end of the spectrum of values to an endpoint relative to the other end of the spectrum of values, wherein each endpoint is normalized to be equidistant from the origin as other endpoints of the other axes, wherein entity status values pertaining to each status category are proportionally assigned to a point on the respective axis and the point is linearly connected to a point of an entity status value of at least one other axis to define the polygonal representation intersecting the axes for a combined display of each of the plurality of categories, wherein different types of status information pertain to a different one of the plurality of categories;

wherein the status information comprises status information of a first, second, third and fourth type each reflecting a condition having a different temporal consequence, and

wherein the plurality of categories of the polygonal representation are arranged according to successively decreasing or increasing temporal consequences of the status information pertaining to the categories.

52. The system of claim 51, further comprising a routine adapted to be executed by the processor which displays a representation of one or more of:

history information pertaining to the entity, alert information pertaining to the entity, failure information pertaining to the entity, calibration information pertaining to the entity, operating equipment effectiveness information pertaining to the entity, event information pertaining to the entity and key performance indicators pertaining to the entity.

53. The system of claim 51, wherein the entity comprises a two or more lower level entities and wherein the system further comprises a routine adapted to be executed by the processor which displays a representation of the two or more lower level entities.

54. The system of claim 51, further comprising a routine adapted to be executed by the processor which displays a representation of a use index pertaining to the entity.

55. The system of claim 51, further comprising a routine adapted to be executed by the processor which displays a representation of one or more data sources wherein the one or more data sources provide the status information pertaining to the status of the entity.

56. The method of claim 51, wherein the status information of the first type comprises design and quality status information, the status information of the second type comprises an operating condition information, the status information of the third type comprises a measure of entity health, and the status information of the fourth type comprises production status information.

57. A method of reporting status information regarding an entity within a process plant comprising:

receiving status information of a first type, wherein the first type of status information reflects a condition having a first temporal consequence;

receiving status information of a second type, wherein the second type of status information reflects a condition having a second temporal consequence shorter than the first temporal consequence;

categorizing the status information of the first type into a first status category;

categorizing the status information of the second type into a second status category;

generating a report on a processor based at least in part on the status information of the first and second type; and

displaying the report to a user, wherein the display of the report includes a polygonal representation of the first and second status categories, a representation of the status information of the first type displayed proximate the first status category and a representation of the status information of the second type displayed proximate the second status category, wherein the polygonal representation comprises three or more axes each pertaining to a different entity status category having a spectrum of values between a good status quality and a bad status quality and normalized relative to the other spectrums of values, each axis having a finite number of increments measured from a common origin relative to one end of the spectrum of values to an endpoint relative to the other end of the spectrum of values, wherein each endpoint is normalized to be equidistant from the origin as other endpoints of the other axes, wherein entity status values pertaining to each status category are proportionally assigned to a point on the respective axis and the point is linearly connected to a point of an entity status value of at least one other axis to define the polygonal representation intersecting the axes for a combined display of each of the plurality of categories, wherein each type of status information pertains to a different one of the plurality of categories.

58. The method of claim 57 further comprising:

determining a first severity level for the first status category based at least in part on the status information of the first type; and

determining a second severity level for the second status category based at least in part on the status information of the second type,

wherein the display of the report includes a representation of the first and second severity levels.

59. The method of claim 58, wherein the representation of the first and second severity levels each include multiple levels.

60. The method of claim 58, wherein the status information of the first type is associated with a third severity level and the status information of the second type is associated with a fourth severity level, and wherein the determining the first severity level comprises determining the first severity level based at least in part on the third severity level and determining the second severity level comprises determining the second severity level based at least in part on the fourth severity level.

61. The method of claim 58, wherein the status information of the first type is associated with a third severity level, the method further comprising:

receiving status information of a third type wherein the status information of the third type is associated with a fourth severity level; and

categorizing the status information of the third type into the first status category,

wherein determining the first severity level comprises determining the first severity level based on the greater severity from among the third severity level and the fourth severity level.

62. The method of claim 57, wherein receiving status information of the first type comprises receiving status information from the entity.

63. The method of claim 57, wherein one or more of the status information of the first type and the status information of the second type pertains to the status of the entity.

64. The method of claim 57, wherein the display of the report comprises a plurality of status categories including the first and second status categories, and wherein the plurality of status categories comprise a business category, an operational category and a maintenance category.

65. The method of claim 57, wherein the display of the report comprises a plurality of status categories including the first and second status categories, and wherein the plurality of status categories comprise a failure category, an operational category and a quality category.

66. The method of claim 57, wherein the display of the report comprises a plurality of status categories including the first and second status categories, and wherein the plurality of status categories comprise a quality category, an operation category and a performance category.

67. The method of claim 57, wherein the display of the report comprises a plurality of status categories including the first and second status categories, and wherein the plurality of status categories comprise at least one of a decision-making category and a process control category.

68. The method of claim 57, wherein the status information of the first type pertains to one or more of:

entity availability, entity health, entity downtime, entity utilization, entity reliability, entity performance, entity age, entity failure, entity prioritization, entity instructions, entity history, entity location, entity description, entity type, entity specifications, entity alignment, entity function, entity details, entity identification, entity manufacturer, entity alerts, entity optimization, entity alarms, entity configuration, entity calibration, entity position, entity speed, entity tolerances, entity chatter, key performance indicators, use indices, work orders, service orders, parts orders, predictions, models, waste, safety, environment, utilities, quality, throughput, an economic analysis, an impact analysis, a production analysis, a cost analysis, a vibration analysis, a thermography analysis, a lubricant analysis, a chemistry analysis, a balance analysis, an ultrasonic analysis, monitoring information, operating equipment effectiveness, efficiency, task planning, task assignment, a corrective measure, help information, recommendations, instructions, diagnostic information, event severity, and event urgency.