Configuration system and method for abnormal situation prevention in a process plant

• US 7,676,287 B2
• Filed: 10/22/2004
• Issued: 03/09/2010
• Est. Priority Date: 03/03/2004
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Miller, John P., Eryurek, Evren, Kavaklioglu, Kadir
• Primary Examiner(s): Hartman, Jr.; Ronald D
• Application Number:
  US10/972,224
• Publication Number:
  US 20050197806A1
• Time in Patent Office: 1,964 Days
• Field of Search: 702/1, 702/57, 702/189, 702182-185, 702/188, 700/1, 700 17- 20, 700/83, 700/86
• US Class Current: 700/83
• CPC Class Codes: G05B 23/0221 Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods

Abstract

A system for gathering data associated with a process plant, in which parameters are generated by a plurality of signal processing data collection blocks, automatically determines parameters to be monitored. The signal processing data collection blocks may generate data such as statistical data, frequency analysis data, auto regression data, wavelets data, etc. Then, the system monitors the determined parameters.

Claims

1. A signal processing data gathering system associated with a process plant, the signal processing data gathering system comprising:

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

at least one computer readable medium communicatively coupled to the at least one processor, the at least one computer readable medium storing instructions that, when executed by the at least one processor, cause the at least one processor to;

analyze process plant hierarchy data to determine a plurality of statistical parameters to be generated by a plurality of statistical data collection blocks implemented by a plurality of field devices communicatively coupled to the network, each field device being a device that performs a physical step in the process plant;

generate data indicative of the plurality of statistical parameters to be generated based on the analysis of the process plant hierarchy data;

store the data indicative of the plurality of statistical parameters to be generated; and

use the stored data to enable the plurality of field devices to provide the plurality of statistical parameters to the signal processing data gathering system via the network.

3. A system according to claim 1, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to:

analyze the process plant hierarchy data to identify the plurality of statistical data collection blocks; and

wherein the plurality of statistical parameters to be generated is determined based on the identification of the plurality of statistical data collection blocks.

4. A system according to claim 3, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to:

analyze the process plant hierarchy data to identify a plurality of field devices having statistical data collection blocks; and

wherein the statistical data collection blocks are identified based on the identification of the plurality of field devices having statistical data collection blocks.

5. A system according to claim 1, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to analyze names of nodes of a process plant hierarchy to determine the plurality of statistical parameters to be generated.

6. A system according to claim 5, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to analyze names of all the nodes of the process plant hierarchy.

7. A system according to claim 5, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to analyze names of a subset of the nodes of the process plant hierarchy.

8. A system according to claim 5, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to determine whether a name of a node is indicative of a field device associated with the node having a capability to implement at least one statistical data collection block.

9. A system according to claim 8, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to determine whether a name of a sub-node is indicative of the field device having the capability to implement at least one statistical data collection block if the name of the node is indicative of the field device having the capability.

10. A system according to claim 8, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to analyzing data transmitted by the field device via the network to determine whether the field device has the capability to implement at least one statistical data collection block if the name of the node is indicative of the field device associated with the node having the capability.

11. A system according to claim 1, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to determine a set of statistical data collection blocks configured to generate statistical data.

12. A system according to claim 11, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to automatically configure at least some statistical data collection blocks not configured to generate statistical data.

13. A system according to claim 11, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to determine a set of one or more statistical parameters to be generated by each statistical data collection block in the set of statistical data collection blocks configured to generate statistical data.

14. A system according to claim 13, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to receive data indicative of the set of one or more statistical parameters via a user interface.

15. A system according to claim 11, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to determine a set of one or more statistical parameters to be generated by each statistical data collection block in a subset of the set of statistical data collection blocks configured to generate statistical data.

16. A system according to claim 15, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to receive data indicative of the set of one or more statistical parameters via a user interface.

17. A system according to claim 11, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to determine one or more statistical parameters to be generated by an individual statistical data collection block.

18. A system according to claim 17, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to receive data indicative of the set of one or more statistical parameters via a user interface.

19. A system according to claim 11, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to store data indicative of the set of signal processing data collection blocks configured to generate signal processing data.

20. A system according to claim 19, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to generate a set of Object Linking &

Embedding for Process Control (OPC) items based on the data indicative of the set of statistical data collection blocks and data indicative of one or more statistical parameters generated by each statistical data collection block of the set of statistical data collection blocks.

21. A system according to claim 1, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to store data indicative of a plurality of field devices that implement statistical data collection blocks.

22. A system according to claim 1, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to analyze hierarchy data generated by at least one of an Object Linking &

Embedding for Process Control (OPC) server, a process controller, a data historian, and a workstation associated with asset management in a process plant.

23. A system according to claim 1, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to receive statistical parameters data generated by a field device that conforms with at least one of the Foundation Fieldbus protocol, the HART protocol, the Profibus protocol, the WORLDFIP protocol, the Device-Net protocol, the AS-Interface protocol, and the CAN protocol.

24. A system according to claim 1, wherein the network includes at least one of a wired network and a wireless network.

25. A system according to claim 1, wherein the plurality of statistical parameters is received via at least one of a wired connection, a wireless connection, and an intermittent connection.

26. A system according to claim 1, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to:

receive an indication that data corresponding to at least one statistical parameter of the plurality of statistical parameters has changed; and

in response to receiving the indication, retrieve at least the data corresponding to the at least one statistical parameter.

27. A system according to claim 1, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to:

poll to determine whether data corresponding to at least one statistical parameter of the plurality of statistical parameters has changed; and

retrieve at least the data corresponding to the at least one statistical parameter if the polling indicates that data corresponding to at least one statistical parameter of the plurality of statistical parameters has changed.

28. A system according to claim 1, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to periodically retrieve data corresponding to at least one statistical parameter of the plurality of statistical parameters.

29. A system according to claim 1, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to retrieve data corresponding to at least one statistical parameter of the plurality of statistical parameters at particular times.

30. A system according to claim 1, wherein the computer readable medium stores instructions that, when executed by the at least one processor, cause the at least one processor to receive data corresponding to at least one statistical parameter of the plurality of statistical parameters sent by field device in the process plant upon the field device detecting a change in the at least one statistical parameter.

2. A signal processing data gathering system for gathering signal processing data associated with a process plant, the signal processing data gathering system comprising:

a computer readable medium storing instructions that, when executed by the at least one processor, cause the at least one processor to;

analyze process plant hierarchy data to determine a plurality of statistical parameters to be generated by a plurality of statistical data collection blocks implemented by a plurality of field devices communicatively coupled to the network, each field device being a device that performs a physical step in the process plant;

generate data indicative of the plurality of statistical parameters to be generated based on the analysis of the process plant hierarchy data;

store the data indicative of the plurality of statistical parameters to be generated; and

use the stored data to enable the plurality of field devices to provide the plurality of statistical parameters to the signal processing data gathering system via the network.