Large-scale comprehensive real-time monitoring framework for industrial facilities

• US 9,310,790 B2
• Filed: 05/23/2011
• Issued: 04/12/2016
• Est. Priority Date: 05/23/2011
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Krishnaswamy, Meenakshi Sundaram, Boggarapu, Venkata Naresh Kumar, Pothakamuri, Srikanth
• Primary Examiner(s): Ali, Mohammad
• Assistant Examiner(s): Karim, Ziaul
• Application Number:
  US13/113,593
• Publication Number:
  US 20120303150A1
• Time in Patent Office: 1,786 Days
• Field of Search: 700/85, 700/90, 700/108, 700/110
• US Class Current: 1/1
• CPC Class Codes: G05B 17/02 electric
• CPC Class Codes: G05B 23/0251 Abstraction hierarchy, e.g. "complex systems", i.e. system is divided in subsystems, subsystems are monitored and results are combined to decide on status of whole system

Abstract

A method includes associating multiple real-time applications with a framework. The real-time applications include applications for monitoring or controlling equipment in at least one industrial facility. Each application has at least one input variable and at least one output variable. The method also includes identifying relationships between the input and output variables of the applications to identify data dependencies. The method further includes receiving data updates at the framework and notifying at least one of the applications of the data updates based on the data dependencies to support data-driven operation of the framework. The data-driven operation of the framework provides data to the applications to support performance monitoring of the equipment, analysis of the equipment'"'"'s operation, and/or identification of abnormal equipment conditions.

Claims

1. A method comprising:

associating, by at least one processing device, multiple real-time applications with a framework, the multiple real-time applications comprising applications for monitoring or controlling equipment in at least one industrial facility, each application having at least one input variable and at least one output variable that are stored in at least one memory, the framework comprising an execution environment, an input/output (IO) environment, and a data cache;

using, by the at least one processing device, one or more graphical function blocks in a graphical application to identify relationships between the at least one input variable and the at least one output variable of each application, generate a variable dependency matrix for each application, and combine the variable dependency matrices for the applications to generate a final variable dependency matrix defining a hierarchy of variables, the variable dependency matrices used to identify data dependencies;

storing in the data cache, by the at least one processing device, data being transported between the execution environment and the IO environment in real-time, wherein the data is stored in an address format defined by a data model configured by a user for the framework; and

receiving, in the data cache, a change to at least one of the input or output variables, identifying by the at least one processing device at least one of the applications associated with the at least one changed variable based on the data dependencies, and publishing by the at least one processing device the at least one changed variable to the at least one identified application to support data driven operation of the framework;

wherein the data-driven operation of the framework provides data to the applications to support at least one of;

performance monitoring of the equipment, analysis of the equipment'"'"'s operation, and identification of abnormal equipment conditions,

wherein the framework further comprises multiple layers, the layers comprising;

a data collector layer configured to receive the at least one changed variable from data sources;

a data validation layer configured to validate the received at least one changed variable;

an extraction layer configured to identify key process indicators associated with the equipment using the at least one changed variable;

a fault diagnosis layer configured to identify faults associated with sub-components of the equipment; and

a health index integration layer configured to identify health index values for the equipment using the identified faults.

2. The method of claim 1, wherein the data-driven operation of the framework maintains multiple sequences of operations in the applications, the sequences of operations performed using the provided data.

3. The method of claim 1, wherein the applications comprise both native applications embedded within the execution environment and custom applications added to the execution environment.

4. The method of claim 1, further comprising:

executing an asset manager that uses the layers of the framework to monitor operation of the equipment, the asset manager configured to monitor the operation of the equipment by receiving real-time field data from one or more sensors associated with the equipment and processing the real-time field data to identify one or more fault conditions of the equipment.

5. The method of claim 4, further comprising:

providing a graphical user interface (GUI) for the asset manager, the GUI identifying the equipment and statuses of the equipment.

6. The method of claim 5, wherein the GUI comprises:

a tree map comprising multiple blocks, each block associated with a piece of equipment; and

an indicator of each block identifying the status of the associated piece of equipment and the equipment'"'"'s sub-components.

7. The method of claim 1, wherein:

the equipment comprises a piece of equipment having a rotating component;

the at least one changed variable comprises vibration data; and

the key process indicators comprise a frequency spectrum associated with the vibration data.

8. The method of claim 1, further comprising:

propagating a data quality of a plurality of input variables through the hierarchy of variables, at least one of the input variables associated with a suction pressure or vapor pressure of a pump in the at least one industrial facility.

9. The method of claim 1, wherein the IO environment comprises multiple separate data streams managed by a thread pool, the data streams comprising a first data stream for real-time field data and a second data stream for historical data.

10. The method of claim 9, wherein:

receiving the change to the at least one of the input or output variables comprises receiving the at least one changed variable in one or more of the data streams; and

notifying the at least one identified application comprises using a real-time data service.

11. A non-transitory computer readable medium encoded with a computer program, the computer program comprising:

computer readable program code for causing at least one processing device to use one or more graphical function blocks in a graphical application to identify relationships between input variables and output variables of multiple real-time applications associated with a framework, generate a variable dependency matrix for each application, and combine the variable dependency matrices for the applications to generate a final variable dependency matrix defining a hierarchy of variables, the variable dependency matrices used to identify data dependencies, the applications comprising applications for monitoring or controlling equipment in at least one industrial facility, each application having at least one input variable and at least one output variable that are stored in at least one memory, the framework comprising an execution environment, an input/output (IO) environment, and a data cache;

computer readable program code for storing, in the data cache, data being transported between the execution environment and the IO environment in real-time, wherein the data is stored in an address format defined by a data model configured by a user for the framework; and

computer readable program code for causing the at least one processing device, after the data cache has received a change to at least one of the input or output variables, to identify at least one of the applications associated with the at least one changed variable based on the data dependencies and publish the at least one changed variable to the at least one identified application to support data driven operation of the framework;

wherein the data-driven operation of the framework is configured to provide data to the applications to support at least one of;

performance monitoring of the equipment, analysis of the equipment'"'"'s operation, and identification of abnormal equipment conditions,

wherein the framework further comprises multiple layers, the layers comprising;

a data collector layer configured to receive the at least one changed variable from data sources;

a data validation layer configured to validate the received at least one changed variable;

an extraction layer configured to identify key process indicators associated with the equipment using the at least one changed variable;

a fault diagnosis layer configured to identify faults associated with sub-components of the equipment; and

a health index integration layer configured to identify health index values for the equipment using the identified faults.

12. The non-transitory computer readable medium of claim 11, wherein the framework is configured to maintain multiple sequences of operations in the applications, the sequences of operations performed using the provided data.

13. The non-transitory computer readable medium of claim 11, wherein the applications comprise both native applications embedded within the execution environment and custom applications added to the execution environment;

and further comprising computer readable program code for causing the at least one processing device to support a real-time data service between the native and custom applications.

14. The non-transitory computer readable medium of claim 11, further comprising:

computer readable program code implementing an asset manager that is configured to use the layers of the framework to monitor operation of the equipment, the asset manager configured to monitor the operation of the equipment by receiving real-time field data from one or more sensors associated with the equipment and processing the real-time field data to identify one or more fault conditions of the equipment.

15. The non-transitory computer readable medium of claim 14, further comprising:

computer readable program code for causing the at least one processing device to provide a graphical user interface (GUI) for the asset manager, the GUI identifying the equipment and statuses of the equipment;

wherein the GUI comprises a tree map comprising multiple blocks, each block associated with a piece of equipment, an indicator of each block identifying the status of the associated piece of equipment and the equipment'"'"'s sub-components.

16. A system comprising:

at least one interface configured to receive data associated with equipment in at least one industrial facility; and

at least one processing device configured to;

use one or more graphical function blocks in a graphical application to identify relationships between input variables and output variables of multiple real-time applications associated with a framework, generate a variable dependency matrix for each application, and combine the variable dependency matrices for the applications to generate a final variable dependency matrix defining a hierarchy of variables, the variable dependency matrices used to identify data dependencies, the real-time applications comprising applications for monitoring or controlling the equipment, each application having at least one input variable and at least one output variable that are stored in at least one memory, the framework comprising an execution environment, an input/output (IO) environment, and a data cache;

store, in the data cache, data being transported between the execution environment and the IO environment in real-time, wherein the data is stored in an address format defined by a data model configured by a user for the framework; and

after the data cache has received a change to at least one of the input or output variables, identify at least one of the applications associated with the at least one changed variable based on the data dependencies and publish the at least one changed variable to the at least one identified application to support data driven operation of the framework;

wherein the data-driven operation of the framework is configured to provide the data to the applications to support at least one of;

performance monitoring of the equipment, analysis of the equipment'"'"'s operation, and identification of abnormal equipment conditions,

wherein the framework further comprises multiple layers, the layers comprising;

a data collector layer configured to receive the at least one changed variable from data sources;

a data validation layer configured to validate the received at least one changed variable;

an extraction layer configured to identify key process indicators associated with the equipment using the at least one changed variable;

a fault diagnosis layer configured to identify faults associated with sub-components of the equipment; and

a health index integration layer configured to identify health index values for the equipment using the identified faults.

17. The system of claim 16, wherein the at least one processing device comprises multiple processing devices configured to execute the framework in a distributed manner.

18. The system of claim 17, wherein the processing devices are configured to execute real-time data services to enable data access in a transparent manner.