Quality control system and method for construction, commissioning, and other initiation of a process plant

• US 8,645,092 B2
• Filed: 10/22/2004
• Issued: 02/04/2014
• Est. Priority Date: 10/22/2004
• Status: Expired due to Fees

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Manning, Anthony J., Martyna, Chuck
• Primary Examiner(s): BHAT, ADITYA S
• Application Number:
  US10/971,670
• Publication Number:
  US 20060087402A1
• Time in Patent Office: 3,392 Days
• Field of Search: 702/84
• US Class Current: 702/84
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/24012 Use camera of handheld device, head mounted display
• CPC Class Codes: G05B 2219/32196 Store audit, history of inspection, control and workpiece data into database
• CPC Class Codes: G05B 2219/36159 Detachable or portable programming unit, display, pc, pda
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

Disclosed herein are a system and method useful for providing quality control services in connection with a project for initiation of a process plant having field devices disposed at respective field sites in the process plant. Quality control data is generated at the field sites with a portable computer in response to quality control task information provided via a user interface of the portable computer. The quality control data is transmitted to a host computer having a database with project history information, and stored in the database through integration of the quality control data with the project history information. The quality control data may be generated via check lists downloaded from the host computer to the portable computer, where the check lists specify tasks customized for the respective field site. Recordation of the quality control data via the check lists may include entering deficiency information. The initiation project may include commissioning of the process plant, and the project history information in the database may be made available for subsequent preventative maintenance or other work during operation of the process plant.

Claims

1. A method for providing quality control services in connection with a project for initiation of a process plant wherein field devices are disposed at respective field sites in the process plant, the method comprising:

generating quality control data at the field sites with a portable computer in response to quality control task information provided via a user interface of the portable computer;

transmitting, from the portable computer, the quality control data to a host computer having a database with initiation project history information wherein the initiation of a process plant includes phases leading up to normal, live operation of the process plant; and

storing the quality control data in the database of the host computer by integrating the quality control data with the initiation project history information in the database.

2. The method of claim 1, further comprising storing the quality control task information in a memory of the portable computer to enable quality control work at the field sites.

3. The method of claim 2, wherein the quality control task information comprises a check list for each respective field device, and wherein the check list is stored in the memory of the portable computer in association with equipment specification data for each respective field device.

4. The method of claim 3, wherein generating quality control data comprises entering comment data via the user interface for storage in the memory of the portable computer in connection with a task specified in the respective check list.

5. The method of claim 3, wherein generating quality control data comprises modifying the equipment specification data stored in the memory of the portable computer upon visual inspection of the field device.

6. The method of claim 3, further comprising using the portable computer to select a respective field device by searching the memory of the portable computer based on one or more initiation project criteria selected from the group consisting of plant, system, subsystem, equipment type, and equipment tag name.

7. The method of claim 3, wherein generating quality control data comprises selecting a task from the check list for a respective field device and entering deficiency information associated with the task via the user interface for storage in the memory of the portable computer.

8. The method of claim 3, wherein generating quality control data comprises entering, via the user interface for storage in the memory of the portable computer, an indication that each task shown in the check list for a respective field device has been completed such that the quality control data comprises a signoff indication for the respective field device.

9. The method of claim 1, wherein the quality control data comprises a digital image of the respective field device such that generating quality control data comprises storing the digital image recorded by a digital camera of the portable computer in a memory of the portable computer.

10. The method of claim 9, wherein storing the digital image is performed in connection with a quality control problem such that the quality control data further comprises textual description of the quality control problem.

11. The method of claim 1, wherein the storing the quality control data comprises synchronizing the quality control data with the initiation project history information such that the quality control data overwrites portions of the initiation project history information for a respective field device.

12. The method of claim 11, wherein synchronizing the quality control data comprises exporting deficiency information stored in the database in association with respective field devices to a memory of the portable computer such that the deficiency information becomes a portion of the quality control task information available for display via the user interface of the portable computer.

13. The method of claim 11, wherein synchronizing the quality control data is implemented in accordance with rules specifying conditions under which the quality control data may overwrite portions of the initiation project history information for a respective field device.

14. The method of claim 1, wherein the initiation project comprises a commissioning project wherein the method further comprises utilizing the commissioning history information in a preventative maintenance system used during subsequent operation of the process plant.

15. The method of claim 1, wherein transmitting the quality control data comprises establishing communication between the portable computer and the host computer via an Internet connection.

16. A method of using a portable computer to facilitate quality control in connection with a project for initiation of a process plant wherein the initiation of a process plant may include phases leading up to normal, live operation of the process plant and wherein having a field device disposed at a field site in the process plant, the method comprising:

displaying a quality control check list on a user interface of the portable computer at the field site;

recording quality control data at the field site via the user interface by storing the quality control data in a memory of the portable computer;

transmitting the quality control data from the portable computer to a host computer for quality control in connection with the initiation project which includes phases leading up to normal, live operation of the process plant; and

,

storing the quality control data in a database of the host computer by integrating the quality control data with initiation project history information in the database.

17. The method of claim 16, further comprising storing the quality control check list in the memory of the portable computer in association with equipment specification data for the field device.

18. The method of claim 17, wherein recording quality control data comprises modifying the equipment specification data stored in the memory of the portable computer upon inspection of the field device.

19. The method of claim 16, further comprising entering search criteria via the user interface to search the memory of the portable computer to select the field device wherein the search criteria are selected from the group consisting of plant, system, subsystem, equipment type, and equipment tag name.

20. The method of claim 16, wherein recording quality control data comprises entering deficiency information associated with the field device via the user interface for storage in the memory of the portable computer.

21. The method of claim 16, wherein recording quality control data comprises entering, via the user interface for storage in the memory of the portable computer, an indication that each task shown in the quality control check list has been completed such that the quality control data comprises a signoff indication for the field device.

22. The method of claim 16, wherein the quality control data comprises a digital image of the field device such that recording quality control data comprises actuating a digital camera of the portable computer.

23. The method of claim 16, wherein storing the quality control data comprises synchronizing the quality control data with the initiation project history information such that the quality control data overwrites a portion of the database associated with the field device.

24. The method of claim 23, wherein synchronizing the quality control data is implemented in accordance with rules specifying conditions under which the quality control data may overwrite portions of the database associated with the field device.

25. The method of claim 23, wherein synchronizing the quality control data comprises exporting deficiency information stored in the database in association with the field device to the memory of the portable computer such that the deficiency information is available for display via the user interface of the portable computer in connection with the quality control check list.

26. The method of claim 16, wherein the initiation project comprises a commissioning project such that the initiation project history information comprises commissioning history information, and wherein the method further comprises utilizing the commissioning history information in a preventative maintenance system used during subsequent operation of the process plant.

27. The method of claim 16, wherein transmitting the quality control data comprises establishing communication between the portable computer and the host computer via an Internet connection.

28. A portable computer for quality control in connection with a project for initiation of a process plant wherein having field equipment at a field site, the portable computer comprising:

a user interface suitable for operation at the field site;

a processor communicatively coupled to the user interface;

a memory with initiation project history information which includes information from phases leading up to normal, live operation of the process plant communicatively coupled to the processor;

a data collection routine stored in the memory and adapted for execution by the processor to display via the user interface a quality control check list for the field equipment and to store in the memory quality control data entered via the user interface and in accordance with the quality control check list; and

,

a data transmission routine stored in the memory for execution by the processor to deliver the quality control data from the memory to a host computer for recordation in the host computer'"'"'s database by integrating the quality control data with initiation project history information in the database.

29. The portable computer of claim 28, wherein the data transmission routine is executable to retrieve equipment specification data associated with the field equipment in connection with the quality control check list.

30. The portable computer of claim 28, further comprising a communications port for wireless transmission of the quality control check list to another portable computer at the field site.

31. The portable computer of claim 28, wherein the user interface comprises a digital camera such that the quality control data comprises a digital image.

32. The portable computer of claim 28, further comprising a wireless communication transceiver such that the quality control data is delivered via an Internet connection.

33. The portable computer of claim 28, wherein the data collection routine provides via the user interface a prompt for check list signoff such that the quality control data comprises a signoff indication that the quality control check list has been fully completed.

34. The portable computer of claim 28, wherein the data collection routine provides via the user interface a form for entering deficiency information indicative of a problem encountered during action taken in accordance with the quality control check list.

35. The portable computer of claim 34, further comprising an audio recorder communicatively coupled to the processor such that the data collection routine provides via the user interface an option to record audio clips as the deficiency information.

36. A system for quality control in connection with a project for initiation of a process plant wherein having field equipment at field sites in the process plant, the quality control system comprising:

a host computer having a database with initiation project history information which includes information from phases leading up to normal, live operation of the process plant;

a portable computer configured for communication with the host computer and having a user interface, a processor coupled to the user interface, and a memory coupled to the processor for execution of a quality control routine stored in the memory;

wherein the quality control routine comprises a data synchronization routine to download, from the database to the memory, respective quality control check lists and equipment specification data for the field equipment and a data collection routine to record in the memory quality control data entered via the user interface in accordance with the quality control check lists, wherein the data synchronization routine uploads the quality control data from the memory for storage in the database by integrating the quality control data with the intiation project history information.

37. The system of claim 36, wherein the data collection routine comprises a deficiency recordation routine to enter, via the user interface, deficiency information associated with a task specified in the quality control check list.

38. The system of claim 37, wherein the deficiency recordation routine provides an opportunity to enter, via the user interface, an indication that the task has been completed.

39. The system of claim 38, wherein the host computer comprises a database management routine to generate reports from information set forth in the database, and wherein the reports include a deficiency management report derived from the deficiency information and indication entered via the deficiency recordation routine.

40. The system of claim 36, wherein the portable computer comprises a transceiver such that the host computer and portable computer communicate via an Internet connection.