Diagnostics in process control and monitoring systems
First Claim
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1. A method of diagnosing a condition of a component of an industrial process control system used to process a process fluid;
- coupling a process variable transmitter field device to process piping of the industrial process;
the process piping carrying a process fluid;
measuring a process variable of the process fluid with the process variable transmitter field device, the process variable comprises flow velocity;
communicating the process variable to a control room over a process control loop;
calculating histogram information in the process variable transmitter field device based upon the measured process variable and time information related to a duration of time the measured process variable has a value, the histogram information comprising cumulative time durations during which the measured process variable has had a value within a plurality of ranges of values;
determining a total effective wear time of the component based upon the histogram information and a wear scaling factor applied to the histogram,wherein the total effective wear time is based upon an increasing and decreasing wear scaling factor which is non-monotonic with respect to increasing values of the measured process variable; and
diagnosing, in the transmitter field device, a condition of the component of the industrial process based upon a comparison of the determined total effective wear time to a threshold wherein the diagnostic condition is indicative of wear.
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Abstract
A condition of an industrial process is diagnosed based upon process variable information related to a value of a measured process variable. Histogram information is calculated based upon the determined process variable information and time information related to a duration of time the measured process variable has the value. Condition of the industrial process is diagnosed based upon the calculated histogram information.
67 Citations
31 Claims
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1. A method of diagnosing a condition of a component of an industrial process control system used to process a process fluid;
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coupling a process variable transmitter field device to process piping of the industrial process; the process piping carrying a process fluid; measuring a process variable of the process fluid with the process variable transmitter field device, the process variable comprises flow velocity; communicating the process variable to a control room over a process control loop; calculating histogram information in the process variable transmitter field device based upon the measured process variable and time information related to a duration of time the measured process variable has a value, the histogram information comprising cumulative time durations during which the measured process variable has had a value within a plurality of ranges of values; determining a total effective wear time of the component based upon the histogram information and a wear scaling factor applied to the histogram, wherein the total effective wear time is based upon an increasing and decreasing wear scaling factor which is non-monotonic with respect to increasing values of the measured process variable; and diagnosing, in the transmitter field device, a condition of the component of the industrial process based upon a comparison of the determined total effective wear time to a threshold wherein the diagnostic condition is indicative of wear. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A process variable transmitter for use in measuring a process variable in an industrial process, comprising:
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a process variable sensor which couples to a process fluid of the industrial process and provides a sensor output related to a process variable of the process fluid; measurement circuitry coupled to the process variable sensor which provides a process variable output as a function of the sensor output; output circuitry coupled to the measurement circuitry which provides a transmitter output on a process control loop related to the process variable output; diagnostic circuitry that monitors magnitude of the sensor output and time, and increments a first stored value stored in a memory in response to a duration of time during which the sensor output magnitude is within a first magnitude range and increment a second value stored in the memory in response to a duration of time during which the sensor output magnitude is within a second magnitude range and responsively calculate a total effective wear time of the component and thereby determine a diagnostic condition of a component of the industrial process based upon a comparison of the total effective wear time and a threshold wherein the total effective wear time is based upon an increasing and decreasing wear scaling factor which is non-monotonic with respect to increasing values of the sensor output. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27)
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28. A method of diagnosing a condition of a component in an industrial process control system used to process a process fluid comprising:
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coupling a process variable transmitter to process piping of the industrial process, the process piping carrying the process fluid; placing a process variable sensor in the process fluid which responsively provides a sensor output related to a process variable in the process fluid; measuring the process variable of the process fluid in response to the sensor output; communicating the measured process variable to a control room over a process control loop; incrementing a first counter stored in a memory based upon a duration of time during which a magnitude of the sensor output is within a first magnitude range; incrementing a second counter stored in the memory based upon a duration of time during which the sensor output has a magnitude within a second magnitude range; determining a total effective wear time of the component based upon the first and second magnitudes; and diagnosing condition of the component of the industrial process based upon a comparison of the total effective wear time and a threshold wherein the total effective wear time is based upon a an increasing and decreasing wear scaling factor which is non-monotonic with respect to increasing values of the process variable. - View Dependent Claims (29, 30, 31)
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Specification