Methods and systems for detecting deviation of a process variable from expected values

• US 7,657,399 B2
• Filed: 07/25/2006
• Issued: 02/02/2010
• Est. Priority Date: 07/25/2006
• 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., Kant, Ravi
• Primary Examiner(s): Nghiem; Michael P.
• Assistant Examiner(s): KHUU, HIEN DIEU THI
• Application Number:
  US11/492,347
• Publication Number:
  US 20080027677A1
• Time in Patent Office: 1,288 Days
• Field of Search: 702179-185, 700108-111, 700/174, 700/175, 703/4, 703/13
• US Class Current: 702/183
• CPC Class Codes: G05B 19/4184 characterised by fault tolerance, reliability of production system
• CPC Class Codes: G05B 2219/32058 Execute program as function of deviation from predicted state, result
• CPC Class Codes: G05B 2219/33314 Failure reason analysis, simple strategy or multiple outcome analysis
• CPC Class Codes: G05B 2219/34465 Safety, control of correct operation, abnormal states
• CPC Class Codes: G05B 2219/34477 Fault prediction, analyzing signal trends
• 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 90/80 Management or planning

Abstract

In methods and systems that may facilitate detecting abnormal operation in a process plant, values of a process variable are analyzed to determine whether they significantly deviate from expected values. If there is a significant deviation, an indicator may be generated. Analyzing the process variable may include, for example, determining whether a number of values of the process variable are increasingly deviating from expected values, or determining whether the process variable is cycling. Analyzing the process variable may also include, for example, processing and analyzing the process variable to determine whether the process is in a normal state, one or more abnormal states, or an indeterminate state.

Claims

1. A method for facilitating detection of abnormal operation of a process in a process plant, comprising:

receiving process variable data associated with the process plant;

generating predicted process variable data using a model;

generating a difference signal based on the received process variable data and the predicted process variable data;

detecting whether the difference signal is increasingly deviating from zero over a plurality of values of the difference signal using a processor hardware device; and

generating an indicator of significant deviation based on whether the difference signal is increasingly deviating from zero using the processor hardware device;

wherein detecting whether the difference signal is increasingly deviating from zero comprises at least one of;

determining whether Z_k1>

Z_k2>

. . . >

Z_kB>

X, wherein Z_k1, Z_k2, . . . , Z_kB are at least a subset of B values within a set of A consecutive values of the difference signal at time indexes k1, k2, . . . kB, wherein A is a positive integer greater than 2, B is a positive integer less than or equal to A and greater than 2, wherein X is a first threshold, and wherein k1>

k2 . . . >

kB; and

determining whether Z_k1<

Z_k2 <

. . . <

Z_kB<

Y, wherein Y is a second threshold.

2. A method according to claim 1, wherein detecting whether the difference signal is increasingly deviating from zero comprises at least one of:

detecting whether a rate of change of the difference signal is greater than a first threshold;

detecting whether the rate of change of the difference signal is less than a second threshold; and

detecting whether a first derivative of the difference signal is greater than a third threshold;

detecting whether the first derivative of the difference signal is less than a fourth threshold;

detecting whether a second derivative of the difference signal is greater than a fifth threshold; and

detecting whether the second derivative of the difference signal is less than a sixth threshold.

3. A method according to claim 1, wherein B<

A.

4. A method according to claim 3, wherein detecting whether the difference signal is increasingly deviating from zero further comprises at least one of:

detecting whether a rate of change of the difference signal is greater than a first threshold;

detecting whether the rate of change of the difference signal is less than a second threshold; and

detecting whether a first derivative of the difference signal is greater than a third threshold;

detecting whether the first derivative of the difference signal is less than a fourth threshold;

detecting whether a second derivative of the difference signal is greater than a fifth threshold; and

detecting whether the second derivative of the difference signal is less than a sixth threshold.

5. A method according to claim 1, wherein detecting whether at least the subset of values in the set of values of the difference signal are increasingly deviating from zero comprises at least one of:

detecting whether the difference signal includes a first number of consecutively increasing values; and

detecting whether the difference signal includes a second number of consecutively decreasing values.

6. A method according to claim 1, wherein detecting whether at least the subset of values in the set of values of the difference signal are increasingly deviating from zero comprises:

detecting whether at least the subset of values in the set of values of the difference signal are increasingly deviating from zero in a positive direction, and detecting whether at least the subset of values in the set of values of the difference signal are increasingly deviating from zero in a negative direction;

the method further comprising;

generating an indicator of an upward trend based on whether the at least the subset of values in the set of values of the difference signal are increasingly deviating from zero in the positive direction;

generating an indicator of a downward trend based on whether the at least the subset of values in the set of values of the difference signal are increasingly deviating from zero in the negative direction.

7. A method according to claim 1, wherein A equals B, X=0 and Y=0.

8. A method according to claim 1, wherein the difference signal is an absolute value of a difference between the received process variable data and the predicted process variable data.

9. A computer readable medium storing machine readable instructions, the machine readable instructions capable of causing one or more machines to:

receive process variable data associated with a process plant;

generate predicted process variable data using a model;

generate a difference signal based on the received process variable data and the predicted process variable data;

detect whether the difference signal is increasingly deviating from zero over a plurality of values of the difference signal; and

generate an indicator of significant deviation based on whether the difference signal is increasingly deviating from zero;

wherein the machine readable instructions capable of causing one or more machines to detect whether the difference signal is increasingly deviating from zero comprises machine readable instructions capable of causing one or more machines to, at least one of;

determine whether Z_k1>

Z_k2>

. . . >

Z_kB>

X, wherein Z_k1, Z_k2, . . . , Z_kB are at least a subset of B values within a set of A consecutive values of the difference signal at time indexes k1, k2, . . . kB, wherein A is a positive integer greater than 2, B is a positive integer less than or equal to A, wherein X is a first threshold, and wherein k1>

k2 . . . >

kB; and

determine whether Z_k1<

Z_k2<

. . . <

Z_kB<

Y, wherein Y is a second threshold.

10. A system for facilitating detection of abnormal operation of a process in a process plant, comprising:

at least one computer readable medium;

at least one processor coupled to the at least one computer readable medium, the processor configured according to executable instructions stored on the at least one computer readable medium to;

receive process variable data associated with the process plant,

receive predicted process variable data generated using a model,

generate a difference signal based on the received process variable data and the predicted process variable data,

detect whether the difference signal is increasingly deviating from zero over a plurality of values of the difference signal, and

generate an indicator of significant deviation based on whether the difference signal is increasingly deviating from zero;

wherein the processor is configured to, at least one of;

determine whether Z_k1>

Z_k2>

. . . >

Z_kB>

X, wherein Z_k1, Z_k2, . . . , Z_kB are at least a subset of B values within a set of A consecutive values of the difference signal at time indexes k1, k2, . . . kB, wherein A is a positive integer greater than 2, B is a positive integer less than or equal to A, wherein X is a first threshold, and wherein k1>

k2 . . . >

kB; and

determine whether Z_k1<

Z_k2<

. . . <

Z_kB<

Y, wherein Y is a second threshold.

11. A method for facilitating detection of abnormal operation of a process in a process plant, comprising:

receiving process variable data associated with the process plant;

generating predicted process variable data using a model;

generating a difference signal based on the received process variable data and the predicted process variable data;

detecting whether the difference signal is increasingly deviating from zero over a plurality of values of the difference signal using a processor hardware device; and

generating an indicator of significant deviation based on whether the difference signal is increasingly deviating from zero using the processor hardware device;

wherein detecting whether the difference signal is increasingly deviating from zero comprises at least one of;

detecting whether a rate of change of the difference signal is greater than a first threshold;

detecting whether the rate of change of the difference signal is less than a second threshold; and

detecting whether a first derivative of the difference signal is greater than a third threshold;

detecting whether the first derivative of the difference signal is less than a fourth threshold;

detecting whether a second derivative of the difference signal is greater than a fifth threshold; and

detecting whether the second derivative of the difference signal is less than a sixth threshold.

12. A method according to claim 11, wherein detecting whether at least the subset of values in the set of values of the difference signal are increasingly deviating from zero comprises:

detecting whether at least the subset of values in the set of values of the difference signal are increasingly deviating from zero in a positive direction, and

detecting whether at least the subset of values in the set of values of the difference signal are increasingly deviating from zero in a negative direction;

the method further comprising;

generating an indicator of an upward trend based on whether the at least the subset of values in the set of values of the difference signal are increasingly deviating from zero in the positive direction;

generating an indicator of a downward trend based on whether the at least the subset of values in the set of values of the difference signal are increasingly deviating from zero in the negative direction.

13. A method according to claim 11, wherein the difference signal is an absolute value of a difference between the received process variable data and the predicted process variable data.

14. A computer readable medium storing machine readable instructions, the machine readable instructions capable of causing one or more machines to:

receive process variable data associated with a process plant;

generate predicted process variable data using a model;

generate a difference signal based on the received process variable data and the predicted process variable data;

detect whether the difference signal is increasingly deviating from zero over a plurality of values of the difference signal; and

generate an indicator of significant deviation based on whether the difference signal is increasingly deviating from zero;

wherein the machine readable instructions capable of causing one or more machines to detect whether the difference signal is increasingly deviating from zero comprises machine readable instructions capable of causing one or more machines to, at least one of;

detect whether a rate of change of the difference signal is greater than a first threshold;

detect whether the rate of change of the difference signal is less than a second threshold; and

detect whether a first derivative of the difference signal is greater than a third threshold;

detect whether the first derivative of the difference signal is less than a fourth threshold;

detect whether a second derivative of the difference signal is greater than a fifth threshold; and

detect whether the second derivative of the difference signal is less than a sixth threshold.

15. A system for facilitating detection of abnormal operation of a process in a process plant, comprising:

at least one computer readable medium;

at least one processor coupled to the at least one computer readable medium, the processor configured according to executable instructions stored on the at least one computer readable medium to;

receive process variable data associated with the process plant,

receive predicted process variable data generated using a model,

generate a difference signal based on the received process variable data and the predicted process variable data,

detect whether the difference signal is increasingly deviating from zero over a plurality of values of the difference signal, and

generate an indicator of significant deviation based on whether the difference signal is increasingly deviating from zero;

wherein the processor configured to, at least one of;

detect whether a rate of change of the difference signal is greater than a first threshold;

detect whether the rate of change of the difference signal is less than a second threshold; and

detect whether a first derivative of the difference signal is greater than a third threshold;

detect whether the first derivative of the difference signal is less than a fourth threshold;

detect whether a second derivative of the difference signal is greater than a fifth threshold; and

detect whether the second derivative of the difference signal is less than a sixth threshold.