Monitoring of field devices via a communication network

• US 10,197,996 B2
• Filed: 03/08/2016
• Issued: 02/05/2019
• Est. Priority Date: 09/29/2015
• Status: Active Grant

• Current Assignee: Bristol (Emerson Electric Company)
• Original Assignee: Bristol (Emerson Electric Company)
• Inventors: Cincea, Corneliu, Toporan, Bogdan Ionut
• Primary Examiner(s): Nguyen, Viet Q
• Application Number:
  US15/064,456
• Publication Number:
  US 20170090467A1
• Time in Patent Office: 1,064 Days
• Field of Search: 700 9, 700 11, 700310
• CPC Class Codes: G05B 23/0205 by means of a monitoring system capable of detecting and responding to faults
• CPC Class Codes: H04L 12/40013 Details regarding a bus controller
• CPC Class Codes: H04L 2012/40208 characterized by the use of a particular bus standard
• CPC Class Codes: H04L 2012/4026 Bus for use in automation systems
• CPC Class Codes: H04L 43/065 related to network devices
• CPC Class Codes: H04L 43/0805 by checking availability
• CPC Class Codes: H04L 43/0817 by checking functioning
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A system for monitoring field devices operating in process plants includes a remote terminal unit (RTU) coupled to several field devices, each configured to perform a respective function in a process plant, and a host disposed remotely from the RTU and coupled to the RTU via a communication network. The RTU includes (i) a first interface module configured to communicate according to a digital industrial automation protocol, via which the RTU receives data indicative of respective statuses of the field devices, (ii) a memory to store the received data, and (iii) a second interface module configured to communicate with remote hosts via a communication network. The host is configured to (i) request the statutes of the field devices and (ii) receive, from the RTU, indications of the status based on the data stored in the memory of the RTU.

Claims

1. A method for monitoring status of field devices operating in a process plant, the method comprising:

receiving, at a remote terminal unit (RTU) coupled to a field device, data indicative of a status of the field device;

storing the received information in a memory of the RTU;

receiving, at the RTU from a remote host via a communication network, a request for the status of the field device;

providing, from the RTU to the remote host in response to the request, an indication of the status of the field device based the data stored in the memory of the of the RTU, including providing a bit mask to the remote host;

checking, at the remote host, a status of the bit mask to determine whether additional information is available; and

requesting, from the remote host via the RTU, additional information from the field device.

2. The method of claim 1, wherein the request is one of a plurality of requests received at the RTU from the remote host via the communication network, the method further comprising transmitting the plurality of requests according to a schedule configurable by an operator at the remote host.

3. The method of claim 1, wherein requesting the additional information includes tunneling a request to the field device via the RTU.

4. The method of claim 1, further comprising providing, from the remote host, the indication of the status of the field device to a third-party system using a non-proprietary standard.

5. The method of claim 1, further comprising storing, at the remote host, the indication of the status of the field device in a database accessible by a plurality of services.

6. The method of claim 1, wherein the remote terminal unit communicates with the field device via a digital industrial automation protocol.

7. The method of claim 6, wherein the digital industrial automation protocol is HART.

8. The method of claim 1, wherein the communication network is a supervisory control and data acquisition (SCADA) network.

9. A system for monitoring status of field devices operating in process plants, the system comprising:

a remote terminal unit (RTU) coupled to a plurality of field devices, each configured to perform a respective function in a process plant, wherein the RTU includes;

a first interface module configured to communicate according to a digital industrial automation protocol, via which the RTU receives data indicative of respective statuses of the field devices,

a memory to store the received data, and

a second interface module configured to communicate with remote hosts via a communication network;

the system further comprising;

a host disposed remotely from the RTU and coupled to the RTU via a communication network, wherein the host is configured to (i) request the statutes of the field devices, (ii) receive, from the RTU, indications of the statuses based on the data stored in the memory of the RTU, (iii) check a status of the bit mask to determine whether additional information is available at the corresponding field device, and (iv) request, via the RTU, additional information from the field device.

10. The system of claim 9, further comprising a database to store alarms and events related to the field device, wherein the host is further configured to (i) generate alarms or events based on the received indications and (ii) store the generated alarms or events in the database.

11. The system of claim 9, wherein the host is configured to request the statutes of the field devices according to a schedule configurable by an operator of the host.

12. The system of claim 9, wherein the remote terminal unit communicates with the field devices via a digital industrial automation protocol.

13. The system of claim 9, wherein the communication network is a supervisory control and data acquisition (SCADA) network.

14. The system of claim 9, wherein the RTU periodically polls the field devices to obtain the statuses.

15. A remote terminal unit (RTU) for use in a process plant, the RTU comprising:

a first interface module configured to exchange data with field devices according to a digital industrial automation protocol;

a memory to store data indicative of respective statuses of the field devices, the data including respective bit masks reported by the field devices;

a second interface module configured to communicate with a remote host via a communication network; and

a processing module configured to;

provide, via the second interface module, indications of respective statuses of the field devices based on the data stored in the memory in response to commands from the remote host, wherein a status for one of the field devices indicates that further information is available at the corresponding field device,

tunnel a command from the remote host addressed to the one of the field devices, and

tunnel a response from the one of the field devices to the remote host.

16. The RTU of claim 15, wherein the processing module is configured to provide the indications of respective statuses in response to commands from the remote host.

17. The RTU of claim 15, wherein the communication network is a supervisory control and data acquisition (SCADA) network.