Methods and apparatus to manage testing of a process control system

• US 9,874,870 B2
• Filed: 08/26/2009
• Issued: 01/23/2018
• Est. Priority Date: 08/26/2009
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Law, Gary Keith, Sherriff, Godfrey R., Nixon, Mark
• Primary Examiner(s): COYER, RYAN D
• Application Number:
  US12/548,197
• Publication Number:
  US 20110054643A1
• Time in Patent Office: 3,072 Days
• Field of Search: 717125, 717131
• CPC Class Codes: G05B 23/0256 injecting test signals and analyzing monitored process response, e.g. injecting the test signal while interrupting the normal operation of the monitored system; superimposing the test signal onto a control signal during normal operation of the monitored system
• CPC Class Codes: G06F 11/3636 by tracing the execution of the program

Abstract

Example methods and apparatus to manage testing of a process control system are disclosed. A disclosed example method includes generating a test application from a process control routine, the test application including at least one test that is to be performed within a time period, monitoring an operation of the process control routine, determining if the operation of the process control routine during the time period includes an execution of a portion of the process control routine that is substantially similar to the at least one test, and updating the test application by indicating that the at least one test has been performed within the time period.

Claims

1. A method to manage testing of a process control system, the method comprising:

generating, via a processor, a test application from a process control routine, the test application including a test to be performed during suspension of an operation of the process control routine;

monitoring, via the processor, the operation of the process control routine;

reducing a time consumed by the test application for performing the test by determining, via the processor, if the operation of the process control routine during operation of the process control system includes an execution of a portion of the process control routine that is within a threshold range of the test;

when the execution of the portion results in a first mitigation event indicative of a successful correction based on the threshold range, updating, via the processor, the test application with a first status indicative of a verified test; and

when the execution of the portion results in a second mitigation event indicative of an unsuccessful correction based on the threshold range, updating, via the processor, the test application with a second status indicative of an unverified test.

2. A method as defined in claim 1, further comprising:

when the execution of the portion results in the first mitigation event, indicating that the test is to be performed within a future time period.

3. A method as defined in claim 1, wherein the first mitigation event includes a specified process control response to correct an issue within the process control system.

4. A method as defined in claim 1, further comprising:

when the execution of the portion results in the first mitigation event, time-stamping the test; and

storing to a test record at least one of the first mitigation event, the time-stamp of the test, or the test.

5. A method as defined in claim 1, wherein generating the test application from the process control routine includes at least one of:

determining a test limit based on at least one parameter within the process control routine;

ordering a sequence of the test based on an order of instructions within the process control routine;

or

ordering the sequence of the test based on a type of a function within the process control routine.

6. A method as defined in claim 1, further comprising:

receiving a modification to the process control routine;

modifying the test application based on the modification; and

storing the modified test application as another version of the test application.

7. A method as defined in claim 1, further comprising:

generating a test plan from the test application including the test;

prompting an operator to execute the test included within the test plan;

receiving at least one of data associated with the test plan or data associated with the test application;

determining if the received data corresponds to the first mitigation event; and

updating the test plan with the first status.

8. A method as defined in claim 7, further comprising:

prompting the operator for an identification value;

receiving the identification value;

accessing a database of personnel training records;

determining if a training record corresponding to the identification value includes an indication the operator is allowed to perform the test plan; and

allowing the operator to execute the test plan.

9. A method as defined in claim 7, further comprising:

combining results of the test plan with the test application to create a test record;

time-stamping the test record with a time at which the test was completed;

determining if the test associated with the test application has been completed; and

if the test has not been completed, updating the test application with the second status.

31. A method as defined in claim 1, further comprising optimizing test time by skipping the test when the test application is associated with the second status.

33. A method as defined in claim 3, further comprising determining whether the first mitigation event includes the specified process control response to correct the issue within the process control system by determining if an indication of the issue has been reset by the process control routine.

34. A method as defined in claim 1, wherein a successful correction comprises adjusting a parameter value associated with the process control routine within the threshold range.

35. A method of claim 34, wherein the parameter value is an input measured by a field device associated with the process control routine.

36. A method as defined in claim 1, wherein the threshold range includes a first range and a second range, and further comprising updating the test application with the first status when the execution of the portion results in the first mitigation event indicative of the successful correction based on the threshold range satisfying both the first range and the second range.

37. A method as defined in claim 1, wherein the test includes a first test and a second test and the determining further includes determining if the execution of the portion of the process control routine results in an input that is within a threshold range of the first test or a threshold range of the second test.

10. An apparatus to manage testing of a process control system, the apparatus comprising:

a routine monitor to monitor an operation of a process control routine;

a test application comparer to reduce a time consumed by a test application for performing a test that is included within the test application, the test to be performed during suspension of the operation of the process control routine, by determining if the operation of the process control routine during operation of the process control system includes an execution of a portion of the process control routine that is within a threshold range of the test; and

a test application modifier to;

when the execution of the portion results in a first mitigation event indicative of a successful correction based on the threshold range, update the test application with a first status indicative of a verified test; and

when the execution of the portion results in a second mitigation event indicative of an unsuccessful correction based on the threshold range, update the test application with a second status indicative of an unverified test, at least one of the routine monitor, the test application comparer, or the test application modifier comprising a logic circuit.

11. An apparatus as defined in claim 10, further comprising a test application generator to generate the test application from the process control routine.

12. An apparatus as defined in claim 11, wherein the test application generator is to generate the test application from the process control routine by at least one of:

determining a test limit based on at least one parameter within the process control routine;

ordering a sequence of the test based on an order of instructions within the process control routine;

or

ordering the sequence of the test based on a type of a function within the process control routine.

13. An apparatus as defined in claim 11, wherein the test application generator is to generate a test plan from the test application including the test.

14. An apparatus as defined in claim 13, further comprising:

a test application processor to;

prompt an operator to execute the test included within the test plan;

prompt the operator for an identification value;

receive the identification value; and

a test execution verifier to receive at least one of data associated with the test plan or data associated with the test application.

15. An apparatus as defined in claim 14, wherein the test application comparer is to:

determine if the received data corresponds to the first mitigation event;

access a database of personnel training records;

determine if a training record corresponding to the identification value includes an indication the operator is allowed to perform the test plan;

allow the operator to execute the test plan;

combine results of the test plan with the test application to create a test record; and

determine if the test associated with the test application has been completed.

16. An apparatus as defined in claim 15, wherein the test application modifier is to:

update the test plan with the first status if the test application has been completed; and

time-stamp the test record with a time at which the test was completed.

17. An apparatus as defined in claim 16, wherein the test application modifier is to update the test application with the second status if the test has not been completed.

18. An apparatus as defined in claim 10, wherein the test application comparer is to optimize test time by skipping the test when the test application is associated with the second status.

19. An apparatus as defined in claim 10, wherein when the execution of the portion results in the first mitigation event, the test application modifier is to at least one of:

indicate that the test is to be performed within a future time period;

time-stamp the test;

or

store to a test record at least one of the first mitigation event, the time-stamp of the test, or the test.

20. An apparatus as defined in claim 10, wherein the first mitigation event includes a specified process control response to correct an issue within the process control system.

21. An apparatus as defined in claim 10, wherein the test application modifier is to:

receive a modification to the process control routine;

modify the test application based on the modification; and

store the modified test application as another version of the test application.

22. A non-transitory machine readable storage device or storage disc having instructions stored thereon that, when executed, cause a machine to:

generate a test application from a process control routine, the test application including a test that is to be performed during suspension of an operation of the process control routine;

monitor the operation of the process control routine;

reduce a time consumed by the test application for performing the test by determining if the operation of the process control routine during operation of the process control system includes an execution of a portion of the process control routine that is within a threshold range of the test;

when the execution of the portion results in a first mitigation event indicative of a successful correction based on the threshold range, update the test application with a first status indicative of a verified test; and

when the execution of the portion results in a second mitigation event indicative of an unsuccessful correction based on the threshold range, update the test application with a second status indicative of an unverified test.

23. A machine readable storage device or storage disc as defined in claim 22, wherein the instructions, when executed, cause the machine to:

when the execution of the portion results in the first mitigation event, indicate that the test is to be performed within a future time period.

24. A machine readable storage device or storage disc as defined in claim 22, wherein the first mitigation event includes a specified process control response to correct an issue within the process control system.

25. A machine readable storage device or storage disc as defined in claim 23, wherein the instructions, when executed, cause the machine to:

when the execution of the portion results in the first mitigation event, time-stamp the test; and

store to a test record at least one of the first mitigation event, the time-stamp of the test, or the test.

26. A machine readable storage device or storage disc as defined in claim 22, wherein the instructions, when executed, cause the machine to generate the test application from the process control routine by at least one of:

determining a test limit based on at least one parameter within the process control routine;

ordering a sequence of the test based on an order of instructions within the process control routine;

or

ordering the sequence of the test based on a type of a function within the process control routine.

27. A machine readable storage device or storage disc as defined in claim 22, wherein the instructions, when executed, cause the machine to:

receive a modification to the process control routine;

modify the test application based on the modification; and

store the modified test application as another version of the test application.

28. A machine readable storage device or storage disc as defined in claim 22, wherein the instructions, when executed, cause the machine to:

generate a test plan from the test application including the test;

prompt an operator to execute the test included within the test plan;

receive at least one of data associated with the test plan or data associated with the test application;

determine if the received data corresponds to the first mitigation event; and

if the received data corresponds to the first mitigation event, update the test plan with the first status.

29. A machine readable storage device or storage disc as defined in claim 28, wherein the instructions, when executed, cause the machine to:

prompt the operator for an identification value;

receive the identification value;

access a database of personnel training records;

determine if a training record corresponding to the identification value includes an indication the operator is allowed to perform the test plan; and

allow the operator to execute the test plan.

30. A machine readable storage device or storage disc as defined in claim 28, wherein the instructions, when executed, cause the machine to:

combine results of the test plan with the test application to create a test record;

time-stamp the test record with a time at which the test was completed;

determine if the test associated with the test application has been completed; and

if the test has not been completed, update the test application with the second status.

32. A machine readable storage device or storage disc as defined in claim 22, wherein the instructions, when executed, cause the machine to optimize test time by causing the machine to skip the test when the test application is associated with the second status.