Asset optimization reporting in a process plant

• US 8,620,618 B2
• Filed: 11/25/2009
• Issued: 12/31/2013
• Est. Priority Date: 03/18/2003
• Status: Expired due to Term

• Current Assignee: Computational Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Eryurek, Evren, Harris, Stuart, Hokeness, Scott Nels, Reeves, Todd, Garvey, Raymond E. III
• Primary Examiner(s): SUGLO, JANET L
• Application Number:
  US12/625,861
• Publication Number:
  US 20100076809A1
• Time in Patent Office: 1,497 Days
• Field of Search: 702/182, 700/95, 705/8, 705/9, 705/10
• US Class Current: 702/182
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 19/02 electric
• CPC Class Codes: G05B 2219/31396 Business management, production, document, asset, regulatory management, high level
• CPC Class Codes: G05B 23/0278 Qualitative, e.g. if-then rules; Fuzzy logic; Lookup tables; Symptomatic search; FMEA
• CPC Class Codes: G05B 23/0283 Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06
• CPC Class Codes: G06Q 10/063 Operations research, analysis or management
• CPC Class Codes: G06Q 10/103 Workflow collaboration or project management
• CPC Class Codes: G06Q 10/20 Administration of product repair or maintenance
• 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 90/82 Energy audits or management systems therefor
• CPC Class Codes: Y02P 90/845 Inventory and reporting systems for greenhouse gases [GHG]

Abstract

A process control system uses an asset optimization reporter to collect status information of dissimilar types pertaining to the assets of a process plant from various data sources of the plant including, for example, data tools, data collectors, and data generators. This status information is used to generate reports that may be displayed to various users, including maintenance persons, process control persons and business persons. The status information may be used as the basis for further types of status information and/or be categorized in based on an assessment of relative consequence, where each category has a spectrum of status quality values between a good status quality and a relatively worse status quality. The reports are generally displayed via a user interface routine that enables users to view the status information as a graphical representation having a leg of a normalized spectrum of values for each category arranged in order of the relative consequence, the relative status quality value being identified at a point on the respective leg.

Claims

1. A method of reporting status information regarding an entity within a process plant, the method comprising:

categorizing one or more of a plurality of types of status information based on an assessment of at least one of a temporal consequence, a criticality consequence, a prioritization consequence, or an availability consequence as a result of the status information such that each type of status information is associated with at least one of a first entity status category, a second entity status category, and a third entity status category, the status information pertaining to the entity and reflecting a condition of the entity,

wherein the types of status information associated with the first entity status category have a relatively greater consequence than the types of status information associated with the second entity status category, and the types of status information associated with the second entity status category have a relatively greater consequence than the types of status information associated with the third entity status category, and

wherein each entity status category has a spectrum of status quality values between a good status quality and a relatively worse status quality;

generating a report on a processor that includes relative status quality values, wherein the report is indicative of the status of the entity and the values of relative status quality are determined for the entity status categories from the status information; and

displaying the report to a user indicative of the status of the entity,

wherein the display of the report includes a graphical representation indicative of the status of the entity,

wherein the graphical representation comprises a leg for each entity status category,

wherein each leg has a normalized spectrum of values, and

wherein the relative status quality value is identified at a point on the respective leg.

2. The method of claim 1, wherein each leg comprises a number of increments measured from a common origin relative to one end of the spectrum of values to an endpoint relative to the other end of the spectrum of values, wherein each endpoint is normalized to be equidistant from the origin as other endpoints of the other legs.

3. The method of claim 1, wherein entity status values pertaining to each status category are proportionally assigned to a point on the respective leg and the point is linearly connected to a point of an entity status value of at least one other leg to define the graphical representation intersecting the legs for a combined display of each of the plurality of categories.

4. The method of claim 1, wherein the consequence comprises a temporal consequence.

5. The method of claim 1, wherein the consequence comprises a priority index.

6. The method of claim 1, wherein the consequence comprises an availability consequence.

7. The method of claim 1, wherein the consequence comprises entity criticality.

8. The method of claim 1, wherein the entity is a first entity, and one or more of the status information of the first type, the status information of the second type and the status information of the third type pertains to the status of a second entity.

9. The method of claim 1, wherein the status information of the first type, the second type and the third type each pertain to one or more of:

entity availability, entity health, entity downtime, entity utilization, entity reliability, entity performance, entity age, entity failure, entity prioritization, entity instructions, entity history, entity location, entity description, entity type, entity specifications, entity alignment, entity function, entity details, entity identification, entity manufacturer, entity alerts, entity optimization, entity alarms, entity configuration, entity calibration, entity position, entity speed, entity tolerances, entity chatter, key performance indicators, use indices, work orders, service orders, parts orders, predictions, models, waste, safety, environment, utilities, quality, throughput, an economic analysis, an impact analysis, a production analysis, a cost analysis, a vibration analysis, a thermography analysis, a lubricant analysis, a chemistry analysis, a balance analysis, an ultrasonic analysis, monitoring information, operating equipment effectiveness, efficiency, task planning, task assignment, a corrective measure, help information, recommendations, instructions, diagnostic information, event severity, and event urgency.

10. The method of claim 1, wherein the legs comprise axes having polygonal representation of status categories having a spectrum of values between a good status quality and a bad status quality and normalized relative to the other spectrums of values.

11. The method of claim 1, wherein the status information of one entity status category comprises design status information, another entity status category comprises an operating condition information, and a further entity status category comprises a measure of entity health.

12. The method of claim 1, wherein the process plant includes a plurality of lower level entities,

wherein the plurality of lower entities comprise a higher level entity,

wherein receiving status information comprises receiving status information pertaining to the status of each of the plurality of lower level entities;

wherein generating a report comprises generating a higher level report on a processor that includes relative status quality values, wherein the report is indicative of the status of the higher level entity and the values of relative status quality are determined for the entity status categories from the status information; and

wherein displaying the report comprises displaying the higher level report to a user, wherein the display of the higher level report includes a graphical representation indicative of the status of the higher level entity, wherein the graphical representation comprises a leg for each entity status category, wherein each leg has a normalized spectrum of values, wherein the relative status quality value is identified at a point on the respective leg.

13. A system for reporting status information for a process plant having a plurality of entities, the system comprising:

a computer readable memory;

a display;

a routine stored on the computer readable memory and adapted to be executed on a processor to categorize one or more of a plurality of types of status information based on an assessment of at least one of a temporal consequence, a criticality consequence, a prioritization consequence, or an availability consequence as a result of the status information such that each type of status information is associated with at least one of a first entity status category, a second entity status category, and a third entity status category, the status information pertaining to the entity and reflecting a condition of the entity and the relative consequences including at least one of a temporal consequence, a criticality consequence, a prioritization consequence, or an availability consequence,

wherein the types of status information associated with the first entity status category have a relatively greater consequence than the types of status information associated with the second entity status category, and the types of status information associated with the second entity status category have a relatively greater consequence than the types of status information associated with the third entity status category, and

wherein each entity status category has a spectrum of status quality values between a good status quality and a relatively worse status quality;

a routine stored on the computer readable memory and adapted to be executed on a processor to generate a report on a processor that includes relative status quality values, wherein the report is indicative of the status of the entity and the values of relative status quality are determined for the entity status categories from the status information; and

a routine stored on the computer readable memory and adapted to be executed on a processor to display the report to a user indicative of the status of the entity,

wherein the display of the report includes a graphical representation indicative of the status of the entity,

wherein the graphical representation comprises a leg for each entity status category,

wherein each leg has a normalized spectrum of values, and

wherein the relative status quality value is identified at a point on the respective leg.

14. The system of claim 13, wherein each leg comprises a number of increments measured from a common origin relative to one end of the spectrum of values to an endpoint relative to the other end of the spectrum of values, wherein each endpoint is normalized to be equidistant from the origin as other endpoints of the other legs.

15. The system of claim 13, wherein entity status values pertaining to each status category are proportionally assigned to a point on the respective leg and the point is linearly connected to a point of an entity status value of at least one other leg to define the graphical representation intersecting the legs for a combined display of each of the plurality of categories.

16. The system of claim 13, wherein the consequence comprises a temporal consequence.

17. The system of claim 13, wherein the consequence comprises a priority index.

18. The system of claim 13, wherein the consequence comprises an availability consequence.

19. The system of claim 13, wherein the consequence comprises entity criticality.

20. The system of claim 13, wherein the entity is a first entity, and one or more of the status information of the first type, the status information of the second type and the status information of the third type pertains to the status of a second entity.

21. The system of claim 13, wherein the plurality of entities are lower level entities and the process plant further includes a higher level entity that includes two or more of the lower level entities, the system further comprising:

a routine stored on the computer readable memory and adapted to be executed on a processor to receive status information pertaining to the status of the higher level entity;

a routine stored on the computer readable memory and adapted to be executed on a processor to generate a higher level report pertaining to the status of the higher level entity; and

a routine stored on the computer readable memory and adapted to be executed on a processor to display the higher level report to the user, wherein the display of the higher level report includes a representation of the status information pertaining to the status of the higher level entity.

22. The system of claim 13, wherein the report further comprises status information pertaining to one or more of:

entity availability, entity health, entity downtime, entity utilization, entity reliability, entity performance, entity age, entity failure, entity prioritization, entity instructions, entity history, entity location, entity description, entity type, entity specifications, entity alignment, entity function, entity details, entity identification, entity manufacturer, entity alerts, entity optimization, entity alarms, entity configuration, entity calibration, entity position, entity speed, entity tolerances, entity chatter, key performance indicators, use indices, work orders, service orders, parts orders, predictions, models, waste, safety, environment, utilities, quality, throughput, an economic analysis, an impact analysis, a production analysis, a cost analysis, a vibration analysis, a thermography analysis, a lubricant analysis, a chemistry analysis, a balance analysis, an ultrasonic analysis, monitoring information, operating equipment effectiveness, efficiency, task planning, task assignment, a corrective measure, help information, recommendations, instructions, diagnostic information, event severity, and event urgency.

23. A method of reporting status information regarding an entity within a process plant, the comprising:

categorizing one or more of a plurality of types of status information based on an assessment of at least one of a temporal consequence, a criticality consequence, a prioritization consequence, or an availability consequence as a result of the status information such that each type of status information is associated with at least one of a first entity status category, a second entity status category, and a third entity status category, the status information pertaining to the entity and reflecting a condition of the entity and the relative consequences including at least one of a temporal consequence, a criticality consequence, a prioritization consequence, or an availability consequence;

wherein the types of status information associated with the first entity status category have a relatively greater consequence than the types of status information associated with the second entity status category, and the types of status information associated with the second entity status category have a relatively greater consequence than the types of status information associated with the third entity status category, and

wherein each entity status category has a spectrum of status quality values between a good status quality and a relatively worse status quality;

receiving status information for at least a portion of the status types, the status information pertaining to the entity and each type of status information reflecting a condition;

determining a value of relative status quality for the entity status categories from the status information;

generating a report on a processor that includes the relative status quality values for the entity status categories, wherein the report is indicative of the status of the entity; and

displaying the report to a user,

wherein the display of the report includes a graphical representation indicative of a the status of the entity,

wherein the graphical representation comprises a leg for each entity status category,

wherein each leg has a normalized spectrum of values,

wherein the relative status quality value is identified at a point on the respective leg.

24. The method of claim 23, wherein each leg comprises a number of increments measured from a common origin relative to one end of the spectrum of values to an endpoint relative to the other end of the spectrum of values, wherein each endpoint is normalized to be equidistant from the origin as other endpoints of the other legs.

25. The method of claim 23, wherein entity status values pertaining to each status category are proportionally assigned to a point on the respective leg and the point is linearly connected to a point of an entity status value of at least one other leg to define the graphical representation intersecting the legs for a combined display of each of the plurality of categories.

26. The method of claim 23, wherein the consequence comprises a temporal consequence.

27. The method of claim 23, wherein the consequence comprises a priority index.

28. The method of claim 23, wherein the consequence comprises an availability consequence.

29. The method of claim 23, wherein the consequence comprises entity criticality.

30. The method of claim 23, wherein the entity is a first entity, and one or more of the status information of the first type, the status information of the second type and the status information of the third type pertains to the status of a second entity.

31. The method of claim 23, wherein the status information of the first type, the second type and the third type each pertain to one or more of:

entity availability, entity health, entity downtime, entity utilization, entity reliability, entity performance, entity age, entity failure, entity prioritization, entity instructions, entity history, entity location, entity description, entity type, entity specifications, entity alignment, entity function, entity details, entity identification, entity manufacturer, entity alerts, entity optimization, entity alarms, entity configuration, entity calibration, entity position, entity speed, entity tolerances, entity chatter, key performance indicators, use indices, work orders, service orders, parts orders, predictions, models, waste, safety, environment, utilities, quality, throughput, an economic analysis, an impact analysis, a production analysis, a cost analysis, a vibration analysis, a thermography analysis, a lubricant analysis, a chemistry analysis, a balance analysis, an ultrasonic analysis, monitoring information, operating equipment effectiveness, efficiency, task planning, task assignment, a corrective measure, help information, recommendations, instructions, diagnostic information, event severity, and event urgency.

32. The method of claim 23, wherein the legs comprise axes having polygonal representation of status categories having a spectrum of values between a good status quality and a bad status quality and normalized relative to the other spectrums of values.

33. The method of claim 23, wherein the status information of one entity status category comprises design status information, another entity status category comprises an operating condition information, and a further entity status category comprises a measure of entity health.

34. A method of reporting status information regarding an entity within a process plant, the method comprising:

receiving a plurality of types of status information, the status information pertaining to the entity and reflecting a condition of the entity;

categorizing one or more of the plurality of types of status information based on a logical sequential order such that the types of status information associated with a first entity status category are relatively greater in a logical sequence compared to the types of status information associated with a second entity status category, and the types of status information associated with the second entity status category are relatively greater in a logical sequence compared to the types of status information associated with a third entity status category, and

wherein each entity status category has a spectrum of status quality values between a good status quality and a relatively worse status quality;

generating a report on a processor that includes relative status quality values, wherein the report is indicative of the status of the entity and the values of relative status quality are determined for the entity status categories from the status information; and

displaying the report to a user indicative of the status of the entity,

wherein the display of the report includes a graphical representation indicative of the status of the entity,

wherein the graphical representation comprises a leg for each entity status category,

wherein each leg has a normalized spectrum of values, and

wherein the relative status quality value is identified at a point on the respective leg.