Method and system for detecting abnormal operation in a process plant
First Claim
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1. A method for facilitating detection of abnormal operation of a process in a process plant, the method comprising:
- collecting first data sets for the process is producing a product by processing physical materials using one or more field devices communicatively coupled to one or more process controllers and while the device is in a first normal operating region, the first data sets generated from process variables of the process in the first normal operating region;
generating a first regression model of the process in the first normal operating region using the first data sets, the first regression model a function of an independent process variable;
determining a first range for the independent process variable in which the first regression model is valid;
generating a process model to include the first regression model, the process model a function of the independent process variable;
collecting second data sets for the process while the process is in a second normal operating region, the second data sets generated from process variables of the process in the second normal operating region;
generating a second regression model of the process in the second operating region using the second data sets, the second regression model a function of the independent process variable;
determining a second range for the independent process variable in which the second regression model is valid;
revising the process model to include simultaneously the first regression model for the first range of the independent process variable and the second regression model for the second range of the independent process variable; and
using the process model to detect and provide an indication of abnormal operation of the process,wherein abnormal operation is indicated based on one or more difference values, each difference value the difference between a measured value of a dependent process variable at a corresponding value of the independent process variable and a modeled value of the dependent process variable at the corresponding value of the independent process variable.
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Abstract
A system for detecting abnormal operation of at least a portion of a process plant includes a model to model at least the portion of the process plant. The model may be configurable to include multiple regression models corresponding to multiple different operating regions of the portion of the process plant. The system may also include a deviation detector configured to determine if the actual operation of the portion of the process plant deviates significantly from the operation predicted by the model. If there is a significant deviation, this may indicate an abnormal operation.
201 Citations
34 Claims
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1. A method for facilitating detection of abnormal operation of a process in a process plant, the method comprising:
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collecting first data sets for the process is producing a product by processing physical materials using one or more field devices communicatively coupled to one or more process controllers and while the device is in a first normal operating region, the first data sets generated from process variables of the process in the first normal operating region; generating a first regression model of the process in the first normal operating region using the first data sets, the first regression model a function of an independent process variable; determining a first range for the independent process variable in which the first regression model is valid; generating a process model to include the first regression model, the process model a function of the independent process variable; collecting second data sets for the process while the process is in a second normal operating region, the second data sets generated from process variables of the process in the second normal operating region; generating a second regression model of the process in the second operating region using the second data sets, the second regression model a function of the independent process variable; determining a second range for the independent process variable in which the second regression model is valid; revising the process model to include simultaneously the first regression model for the first range of the independent process variable and the second regression model for the second range of the independent process variable; and using the process model to detect and provide an indication of abnormal operation of the process, wherein abnormal operation is indicated based on one or more difference values, each difference value the difference between a measured value of a dependent process variable at a corresponding value of the independent process variable and a modeled value of the dependent process variable at the corresponding value of the independent process variable. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. A tangible, non-transitory medium storing machine readable instructions, the machine readable instructions capable of causing one or more processors to:
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collect first data sets for a process operating in a process plant while the process is in a first normal operating region, the first data sets generated from process variables of the process in the first normal operating region, the process producing a product by processing physical materials using one or more field devices communicatively coupled to one or more process controllers; generate a first regression model of the process in the first operating region using the first data sets, the first regression model a function of an independent process variable; determine a first range for the independent process variable in which the first regression model is valid; generate a process model to include the first regression model, the process model a function of the independent variable; collect second data sets for the process while the process is in a second normal operating region, the second data sets generated from process variables of the process in the second normal operating region; generate a second regression model of the process in the second operating region using the second data sets, the second regression model a function of the independent variable; determine a second range for the independent variable in which the second regression model is valid, the second range different than the first range; and revise the process model to include simultaneously the first regression model for the first range of the independent process variable and the second regression model for the second range of the independent process variable.
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26. A system for detecting an abnormal operation in a process plant, comprising:
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a configurable process model of the process in the process plant, the configurable process model a function of an independent process variable and including a first regression model in a first range of the independent variable corresponding to a first normal operating region of the process, the first regression model a function of the independent process variable, the configurable process model capable of being subsequently configured to include simultaneously with the first regression model a second regression model in a second range of the independent variable corresponding to a second normal operating region different than the first normal operating region, the second regression model a function of the independent process variable; wherein, after the configurable process model is configured to include the second regression model simultaneously with the first regression model, the configurable process model is capable of modeling the process in the first normal operating region using the first regression model, and modeling the process in the second normal operating region using the second regression model; and the system further comprising a deviation detector coupled to the configurable process model, the deviation detector configured to determine if the process significantly deviates from an output of the process model by comparing one or more measured values of a dependent process variable at a corresponding value of the independent process variable to one or more modeled values of the dependent process variable at the corresponding value of the independent process variable. - View Dependent Claims (27, 28, 29, 30, 31, 32, 33, 34)
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Specification