Method and apparatus for monitoring and performing corrective measures in a process plant using monitoring data with corrective measures data

• US 8,005,647 B2
• Filed: 09/30/2005
• Issued: 08/23/2011
• Est. Priority Date: 04/08/2005
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Rosemount Incorporated (Emerson Electric Company)
• Inventors: Armstrong, Steve, Di Giovanni, Augustine, Hokeness, Scott N.
• Primary Examiner(s): Kundu; Sujoy K
• Application Number:
  US11/240,827
• Publication Number:
  US 20060229848A1
• Time in Patent Office: 2,153 Days
• Field of Search: 702/184, 702/182, 702/183, 702/185, 702/187, 702/188
• US Class Current: 702/188
• CPC Class Codes: G05B 23/0286 Modifications to the monitored process, e.g. stopping operation or adapting control

Abstract

A method and system of monitoring corrective measures within a process plant includes receiving equipment data pertaining to the status of equipment within the process plant, receiving corrective measure data pertaining to the status of a corrective measure associated with the equipment, and using the equipment data and the corrective measure data to perform a further function pertaining to the corrective measure associated with the equipment.

Claims

1. A non-transitory computer-readable storage medium having computer-executable instructions stored on the computer-readable storage medium for implementing a method of monitoring corrective measures within a process plant comprising:

receiving equipment data pertaining to the status of equipment within the process plant;

receiving corrective measure data pertaining to the status of a corrective measure associated with the equipment, wherein a corrective measure comprises a plurality of stages of execution and the status of the corrective measure pertains to the stage of execution of the corrective measure;

receiving criticality data pertaining to the importance of the equipment within the process plant, wherein the criticality data comprises a quantification of a failure defense planning evaluation of the importance of the entity as the entity affects other entities and/or operations within the process plant; and

using the criticality data with the equipment data and the corrective measure data to perform a further function pertaining to the corrective measure associated with the equipment.

2. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the equipment is one of a plurality of equipment comprising an entity within the process plant, and wherein the criticality data pertains to the importance of the equipment among the plurality of equipment within the entity.

3. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the further function is a corrective measure prioritization function and the instructions for using the criticality data with the equipment data and the corrective measure data to perform the further function comprises instructions for changing the priority of the corrective measure among a plurality of corrective measures.

4. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the instructions for receiving equipment data comprises instructions for receiving equipment data from one or more equipment monitoring devices.

5. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the instructions for receiving equipment data comprises instructions for receiving on-line monitoring data pertaining to the equipment.

6. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the instructions for receiving equipment data comprises instructions for receiving a use index representative of the status of the equipment.

7. The non-transitory computer-readable storage medium having computer-executable instructions of claim 6 wherein the use index pertains to one or more of the following:

health of the equipment, performance of the equipment, utilization of the equipment and variability of the equipment.

8. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the instructions for receiving corrective measure data comprises instructions for receiving data pertaining to an order for taking the corrective measure to solve a problem with the equipment.

9. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the instructions for receiving corrective measure data comprises instructions for receiving a request for an order for taking the corrective measure to solve a problem with the equipment.

10. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the instructions for receiving corrective measure data comprises instructions for receiving a maintenance request to service the equipment.

11. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the instructions for receiving corrective measure data comprises instructions for receiving a notification of a predicted future problem with the equipment.

12. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the instructions for receiving corrective measure data comprises instructions for receiving maintenance procedures pertaining to solving a problem with the equipment.

13. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the instructions for receiving corrective measure data comprises instructions for receiving data pertaining to a work order for performing maintenance related to solving a problem with the equipment.

14. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the instructions for receiving corrective measure data comprises instructions for receiving data pertaining to a part order related to solving a problem with the equipment.

15. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the further function comprises an order generation function and wherein the instructions for using the equipment data and the corrective measure data to perform a further function comprises instructions for generating an order in response to a detected problem with the equipment, wherein the detected problem is based on the data pertaining the status of the equipment and the order relates to taking one or more corrective measures to solve the problem.

16. The non-transitory computer-readable storage medium having computer-executable instructions of claim 15 wherein the order comprises a part order ordering one or more parts needed for the process plant, the computer-readable storage medium further comprising instructions for communicating the part order to a supplier of the part.

17. The non-transitory computer-readable storage medium having computer-executable instructions of claim 15 wherein the order comprises a work order ordering work to be performed within the process plant, the computer-readable storage medium further comprising instructions for communicating the work order to one or more maintenance personnel capable of performing the maintenance.

18. The non-transitory computer-readable storage medium having computer-executable instructions of claim 15 wherein generating an order comprises determining the corrective measure.

19. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the further function comprises an order generation function and wherein the instructions for using the equipment data and the corrective measure data to perform a further function comprises instructions for modifying an existing order for taking the corrective measure to solve a problem with the equipment.

20. The non-transitory computer-readable storage medium having computer-executable instructions of claim 1 wherein the further function comprises a viewing function and wherein the instructions for using the equipment data and the corrective measure data to perform a further function comprises instructions for creating a display screen using the equipment data and the corrective measure data to view a representation of the corrective measure.

21. A system to be used in a process control environment for monitoring corrective measures within a process plant comprising:

a computer readable memory;

a database operatively coupled to the computer system, the database adapted to store criticality data pertaining to the importance of the equipment within the process plant, wherein the criticality data comprises a quantification of a failure defense planning evaluation of the importance of the entity as the entity affects other entities and/or operations within the process plant;

a routine stored on the computer readable medium and adapted to be executed by a processor to receive equipment data pertaining to the status of equipment within the process plant;

a routine stored on the computer readable medium and adapted to be executed by a processor to receive corrective measure data pertaining to the status of one or more corrective measures associated with the equipment, wherein a corrective measure comprises a plurality of stages of execution and the status of the one or more corrective measures pertains to the stage of execution of the one or more corrective measures; and

a routine stored on the computer readable medium and adapted to be executed by a processor to use the criticality data with the equipment data and the corrective measure data to perform a further function within the process plant.

22. The system of claim 21 further comprising process equipment monitoring devices operatively coupled to the computer readable memory that collect the equipment data pertaining to the status of equipment within the process plant.

23. The system of claim 21 further comprising on-line monitoring devices operatively coupled to the computer readable memory that collect on-line monitoring data pertaining to the equipment within the process plant.

24. The system of claim 21 further comprising a maintenance monitoring system operatively coupled to the computer readable memory that collects the corrective measure data pertaining to the status of one or more corrective measures associated with the equipment.

25. The system of claim 21 wherein the equipment is one of a plurality of equipment comprising an entity within the process plant, and wherein the criticality data pertains to the importance of the equipment among the plurality of equipment within the entity.

26. The system of claim 21 wherein the further function is a corrective measure prioritization function, the system further comprising a routine stored on the computer readable medium and adapted to be executed by a processor to use the criticality data with the equipment data and the corrective measure data to change a priority of the corrective measure among a plurality of corrective measures.

27. The system of claim 21 wherein the further function comprises an order generation function, the system further comprising a routine stored on the computer readable medium and adapted to be executed by a processor to use the equipment data and the corrective measure data to generate an order in response to a detected problem with the equipment, wherein the detected problem is based on the data pertaining to the status of the equipment and the order relates to taking one or more corrective measures to solve the problem.

28. The system of claim 27 wherein the order comprises a part order ordering one or more parts needed for the process plant, the system further comprising a routine stored on the computer readable medium and adapted to be executed by a processor to communicate the part order to a supplier of the part.

29. The system of claim 27 wherein the order comprises a work order ordering work to be performed within the process plant, the system further comprising a routine stored on the computer readable medium and adapted to be executed by a processor to communicate the work order to one or more maintenance personnel capable of performing the maintenance.

30. The system of claim 27 further comprising a routine stored on the computer readable medium and adapted to be executed by a processor to determine the corrective measure.

31. The system of claim 21 wherein the further function comprises an order generation function, the system further comprising a routine stored on the computer readable medium and adapted to be executed by a processor to modify an existing order for taking the corrective measure to solve a problem with the equipment.

32. The system of claim 21 wherein the further function comprises a viewing function, the system further comprising a routine stored on the computer readable medium and adapted to be executed by a processor to create a display screen using the equipment data and the corrective measure data to view a representation of the corrective measure.

33. A non-transitory computer-readable storage medium having computer-executable instructions stored on the computer-readable storage medium for implementing a method of monitoring corrective measures within a process plant including an entity having a plurality of lower level entities comprising instructions for:

receiving status data pertaining to the status of the entity;

receiving corrective measure data pertaining to the status of a corrective measure associated with the entity, wherein a corrective measure comprises a plurality of stages of execution and the status of the corrective measure pertains to the stage of execution of the corrective measure;

receiving criticality data pertaining to the importance of one or more of the lower level entities among the plurality of lower level entities within the entity, wherein the criticality data comprises a quantification of a failure defense planning evaluation of the importance of the entity as the entity affects other entities and/or operations within the process plant; and

using the criticality data with the status data and the corrective measure data to perform a further function pertaining to the corrective measure associated with the entity.

34. The non-transitory computer-readable storage medium having computer-executable instructions of claim 33 wherein the instructions for receiving status data pertaining to the status of the entity comprises instructions for receiving status data pertaining to the status of at least one of the plurality of lower level entities.

35. The non-transitory computer-readable storage medium having computer-executable instructions of claim 33 wherein the instructions for receiving corrective measure data pertaining to the status of a corrective measure associated with the entity comprises instructions for receiving corrective measure data pertaining to the status of a corrective measure associated with at least one of the lower level entities.

36. The non-transitory computer-readable storage medium having computer-executable instructions of claim 33 wherein the further function is a corrective measure prioritization function and the instructions for using the criticality data with the status data and the corrective measure data to perform the further function comprises instructions for changing the priority of the corrective measure among a plurality of corrective measures.

37. The non-transitory computer-readable storage medium having computer-executable instructions of claim 33 wherein the instructions for receiving corrective measure data comprises instructions for receiving data pertaining to an order for taking the corrective measure to solve a problem with the entity.

38. The non-transitory computer-readable storage medium having computer-executable instructions of claim 33 wherein the instructions for receiving corrective measure data comprises instructions for receiving data pertaining to a work order for performing maintenance related to solving a problem with the entity.

39. The non-transitory computer-readable storage medium having computer-executable instructions of claim 33 wherein the instructions for receiving corrective measure data comprise instructions for receiving data pertaining to a part order related to solving a problem with the entity.

40. The non-transitory computer-readable storage medium having computer-executable instructions of claim 33 wherein the further function comprises an order generation function and wherein the instructions for using the status data and the corrective measure data to perform a further function comprises instructions for generating an order in response to a detected problem with the entity, wherein the detected problem is based on the status data and the order relates to taking one or more corrective measures to solve the problem.

41. The non-transitory computer-readable storage medium having computer-executable instructions of claim 40 wherein the order comprises a part order ordering one or more parts needed for the process plant, the computer-readable storage medium further comprising instructions for communicating the part order to a supplier of the part.

42. The non-transitory computer-readable storage medium having computer-executable instructions of claim 40 wherein the order comprises a work order ordering work to be performed within the process plant, the computer-readable storage medium further comprising instructions for communicating the work order to one or more maintenance personnel capable of performing the maintenance.

43. The non-transitory computer-readable storage medium having computer-executable instructions of claim 40 wherein the instructions for generating an order comprises instructions for determining the corrective measure.

44. The non-transitory computer-readable storage medium having computer-executable instructions of claim 33 wherein the further function comprises an order generation function and wherein the instructions for using the status data and the corrective measure data to perform a further function comprises instructions for modifying an existing order for taking the corrective measure to solve a problem with the equipment.

45. The non-transitory computer-readable storage medium having computer-executable instructions of claim 33 wherein the further function comprises a viewing function and wherein the instructions for using the status data and the corrective measure data to perform a further function comprises instructions for creating a display screen using the equipment data and the corrective measure data to view a representation of the corrective measure.

46. A system for displaying corrective measure status for an entity within a process plant having a plurality of entities, the system comprising:

a processor;

a display;

a database adapted to store status data for each of the plurality of entities, to store corrective measure status data for at least one of the plurality of entities, and to store criticality data pertaining to the importance of each of the plurality of entities among the plurality of entities, wherein a corrective measure comprises a plurality of stages of execution and the corrective measure status data pertains to the stage of execution of the corrective measure, and wherein the criticality data comprises a quantification of a failure defense planning evaluation of the importance of the entity as the entity affects other entities and/or operations within the process plant;

a routine adapted to be executed by the processor which stores a representation of each of the plurality of entities;

a routine adapted to be executed by the processor which displays a set of the representations, which displays the status data proximately to each corresponding representation in the set and which displays the corrective measure data of at least one corresponding representation in the set; and

a routine adapted to be executed by the processor which displays the criticality data proximately to each corresponding representation in the set.

47. The system of claim 46 further comprising a routine adapted to be executed by the processor which uses the status data and the corrective measure data to generate an order related to one or more corrective actions to generate an order in response to a detected problem with the at least one of the plurality of entities, wherein the detected problem is based on the status data and the order related to taking one or more corrective measures to solve the problem.

48. The system of claim 46 further comprising a routine adapted to be executed by the processor which uses the status data and the corrective measure data to modify an existing order for taking the corrective measure to solve a problem with the at least one of the plurality of entities.

49. The system of claim 46 further comprising a routine adapted to be executed by the processor which uses the criticality data, the status data and the corrective measure data to change the priority of the corrective measure among a plurality of corrective measures.

50. The system of claim 46 wherein the status data comprises use indices for each of the plurality of entities, the system further comprising a routine adapted to be executed by the processor which display use indices proximately to each corresponding representation in the set.