Configuration system and method for abnormal situation prevention in a process plant

• US 20050197806A1
• Filed: 10/22/2004
• Published: 09/08/2005
• Est. Priority Date: 03/03/2004
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Miller, John P., Eryurek, Evren, Kavaklioglu, Kadir
• Granted Patent: US 7,676,287 B2
• Time in Patent Office: Days
• US Class Current: 702/188
• CPC Class Codes: G05B 23/0221 Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods

Abstract

A system for gathering data associated with a process plant, in which parameters are generated by a plurality of signal processing data collection blocks, automatically determines parameters to be monitored. The signal processing data collection blocks may generate data such as statistical data, frequency analysis data, auto regression data, wavelets data, etc. Then, the system monitors the determined parameters.

Claims

1. A method for gathering data associated with a process plant, the method comprising:

analyzing process plant hierarchy data to determine a plurality of parameters to be monitored, the plurality of parameters to be generated by a plurality of signal processing data collection blocks, each signal processing data collection block of the plurality of signal processing data collection blocks communicatively coupled to a network associated with the process plant;

storing data indicative of the plurality of parameters to be monitored; and

monitoring the plurality of parameters indicated by the stored data.

2. A method according to claim 1, wherein analyzing the process plant hierarchy data to determine the plurality of parameters to be monitored comprises:

analyzing the process plant hierarchy data to identify the plurality of signal processing data collection blocks; and

determining the plurality of parameters to be generated by the plurality of signal processing data collection blocks.

3. A method according to claim 2, wherein analyzing the process plant hierarchy data to identify the plurality of signal processing data collection blocks comprises:

analyzing the process plant hierarchy data to identify a plurality of devices capable of implementing signal processing data collection; and

determining signal processing data collection blocks implemented by the plurality of devices capable of implementing signal processing data collection.

4. A method according to claim 1, wherein the plurality of parameters comprises at least one of statistical data, frequency analysis data, auto regression data, wavelets data, data generated using a neural network, and data generated using fuzzy logic.

5. A method according to claim 1, wherein the plurality of signal processing data collection blocks comprises at least one statistical data collection block.

6. A method according to claim 1, wherein the plurality of signal processing data collection blocks comprises at least one signal processing data collection block implemented by a field device.

7. A method according to claim 1, wherein the plurality of signal processing data collection blocks comprises signal processing data collection blocks implemented by at least one of a process controller, a data historian, and a workstation.

8. A method according to claim 1, wherein analyzing process plant hierarchy data comprises analyzing names of nodes of a process plant hierarchy.

9. A method according to claim 8, wherein analyzing names of nodes of the process plant hierarchy comprises analyzing names of all the nodes of the process plant hierarchy.

10. A method according to claim 8, wherein analyzing names of nodes of the process plant hierarchy comprises analyzing names of a subset of the nodes of the process plant hierarchy.

11. A method according to claim 8, wherein analyzing process plant hierarchy data further comprises determining whether a name of a node is indicative of a device associated with the node having a capability to implement at least one signal processing data collection block.

12. A method according to claim 1, wherein analyzing process plant hierarchy data further comprises determining whether a name of a sub-node is indicative of the device having the capability to implement at least one signal processing data collection block if the name of the node is indicative of the device having the capability.

13. A method according to claim 11, further comprising analyzing data transmitted by the device via the network to determine whether the device has the capability to implement at least one signal processing data collection block if the name of the node is indicative of the device associated with the node having the capability.

14. A method according to claim 1, wherein analyzing the process plant hierarchy data to determine the plurality of parameters to be monitored comprises determining a set of signal processing data collection blocks configured to generate signal processing data.

15. A method according to claim 14, further comprising automatically configuring at least some signal processing data collection blocks not configured to generate signal processing data.

16. A method according to claim 14, wherein analyzing the process plant hierarchy data to determine the plurality of parameters to be monitored comprises determining a set of one or more parameters to be generated by each signal processing data collection block in the set of signal processing data collection blocks configured to generate signal processing data.

17. A method according to claim 16, wherein determining the set of one or more parameters comprises receiving data indicative of the set of one or more parameters via a user interface.

18. A method according to claim 14, wherein analyzing the process plant hierarchy data to determine the plurality of parameters to be monitored comprises determining a set of one or more parameters to be generated by each signal processing data collection block in a subset of the set of signal processing data collection blocks configured to generate signal processing data.

19. A method according to claim 18, wherein determining the set of one or more parameters comprises receiving data indicative of the set of one or more parameters via a user interface.

20. A method according to claim 14, analyzing the process plant hierarchy data to determine the plurality of parameters to be monitored comprises determining one or more parameters to be generated by an individual signal processing data collection block.

21. A method according to claim 20, wherein determining the set of one or more parameters comprises receiving data indicative of the set of one or more parameters via a user interface.

22. A method according to claim 14, wherein storing data indicative of the plurality of parameters to be monitored comprises:

storing data indicative of the set of signal processing data collection blocks configured to generate signal processing data; and

storing data indicative of one or more parameters generated by each signal processing data collection block of the set of signal processing data collection blocks already configured to generate signal processing data.

23. A method according to claim 22, further comprising generating a set of Object Linking &

Embedding for Process Control (OPC) items based on the data indicative of the set of signal processing data collection blocks and the data indicative of one or more parameters generated by each signal processing data collection block of the set of signal processing data collection blocks.

24. A method according to claim 1, further comprising storing data indicative of a plurality of devices that implement signal processing data collection blocks.

25. A method according to claim 1, wherein analyzing process plant hierarchy data comprises analyzing hierarchy data generated by at least one of an Object Linking &

Embedding for Process Control (OPC) server, a process controller, a data historian, and a workstation associated with asset management in a process plant.

26. A method according to claim 1, wherein monitoring the plurality of parameters comprises receiving data generated by a field device that conforms with at least one of the Foundation Fieldbus protocol, the HART protocol, the Profibus protocol, the WORLDFIP protocol, the, Device-Net protocol, the AS-Interface protocol, and the CAN protocol.

27. A method according to claim 1, wherein monitoring the plurality of parameters comprises receiving data via at least one of a wired network and a wireless network.

28. A method according to claim 1, wherein monitoring the plurality of parameters comprises receiving data via at least one of a wired connection, a wireless connection, and an intermittent connection.

29. A method according to claim 1, wherein monitoring the plurality of parameters comprises:

receiving an indication that data corresponding to at least one parameter of the plurality of parameters has changed; and

in response to receiving the indication, retrieving at least the data corresponding to the at least one parameter.

30. A method according to claim 1, wherein monitoring the plurality of parameters comprises:

polling to determine whether data corresponding to at least one parameter of the plurality of parameters has changed; and

retrieving at least the data corresponding to the at least one parameter if the polling indicates that data corresponding to at least one parameter of the plurality of parameters has changed.

31. A method according to claim 1, wherein nonitoring the plurality of parameters comprises periodically retrieving data corresponding to at least one parameter of the plurality of parameters.

32. A method according to claim 1, wherein monitoring the plurality of parameters comprises retrieving data corresponding to at least one parameter of the plurality of parameters at particular times.

33. A method according to claim 1, wherein monitoring the plurality of parameters comprises receiving data, corresponding to at least one parameter of the plurality of parameters sent by a device in the process plant upon the device detecting a change in the at least one parameter.

34. A signal processing data gathering system associated with a process plant, the signal processing data gathering system comprising:

at least one processor communicatively coupled to a network associated with the process plant;

at least one computer readable memory communicatively coupled to the at least one processor;

a first routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to analyze process plant hierarchy data to determine a plurality of parameters to be monitored, the plurality of parameters to be generated by a plurality of signal processing data collection blocks, each signal processing data collection block of the plurality of signal processing data collection blocks communicatively coupled to a network associated with the process plant;

a second routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to store data indicative of the plurality of parameters to be monitored; and

a third routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to monitor the plurality of parameters indicated by the stored data.

35. A signal processing data gathering system for gathering signal processing data associated with a process plant, the signal processing data gathering system comprising:

a computer readable medium;

a first routine stored on the computer readable memory and adapted to be executed on the at least one processor to analyze process plant hierarchy data to determine a plurality of parameters to be monitored, the plurality of parameters to be generated by a plurality of signal processing data collection blocks, each signal processing data collection block of the plurality of signal processing data collection blocks communicatively coupled to a network associated with the process plant;

a second routine stored on the computer readable memory and adapted to be executed on the at least one processor to store data indicative of the plurality of parameters to be monitored; and

a third routine stored on the computer readable memory and adapted to be executed on the at least one processor to monitor the plurality of parameters indicated by the stored data.

36. A method for configuring signal processing data collection blocks associated with a process plant, the method comprising:

analyzing process plant hierarchy data to determine a plurality of signal processing data collection blocks, each of the signal processing data collection blocks of the plurality of signal processing data collection blocks communicatively coupled to a network associated with the process plant;

analyzing data retrieved from the plurality of signal processing data collection blocks via the network to determine at least a subset of signal processing data collection blocks that are not enabled, if any; and

configuring at least some of the signal processing data collection blocks in the at least the subset of signal processing data collection blocks to enable signal processing data collection by the at least some of the signal processing data collection blocks.

37. A method according to claim 36, wherein analyzing data retrieved from the plurality of signal processing data collection blocks comprises analyzing data received from an Object Linking &

Embedding for Process Control (OPC) server.

38. A method according to claim 36, wherein analyzing data retrieved from the plurality of signal processing data collection blocks comprises analyzing data received from a field device that conforms with at least one of the Foundation Fieldbus protocol, the HART protocol, the Profibus protocol, the WORLDFIP protocol, the Device-Net protocol, the AS-Interface protocol, and the CAN protocol.

39. A method according to claim 36, wherein analyzing data retrieved from the plurality of signal processing data collection blocks comprises analyzing data received via at least one of a wired network and a wireless network.

40. A method according to claim 36, wherein analyzing data retrieved from the plurality of signal processing data collection blocks comprises analyzing data received via at least one of a wired connection, a wireless connection, and an intermittent connection.

41. A method according to claim 36, wherein analyzing process plant hierarchy data comprises analyzing process plant hierarchy data to determine a plurality of devices capable of implementing signal processing data collection, each device of the plurality of devices communicatively coupled to the network associated with the process plant;

the method further comprising analyzing data retrieved from the plurality of devices capable of implementing signal processing data collection via the network to determine at least a subset of devices in the plurality of devices that are not enabled for signal processing data collection, if any; and

wherein configuring at least some of the signal processing data collection comprises configuring at least one signal processing data collection block implemented by each device in the subset to enable signal processing data collection.

42. A method according to claim 41, wherein configuring at least one signal processing data collection block implemented by each device in the subset comprises, for each device in the subset, configuring at least one signal processing data collection block to generate signal processing data associated with one of a primary analog input of the corresponding device or a primary analog output of the corresponding device.

43. A method according to claim 41, further comprising receiving, via a user interface, data indicative of process variables corresponding to at least some of the devices;

wherein configuring at least one signal processing data collection block implemented by each device in the subset comprises, for each device in the subset, configuring at least one signal processing data collection block to generate signal processing data associated with one process variable indicated by the data indicative of process variables.

44. A method according to claim 41, further comprising retrieving stored data indicative of process variables corresponding to at least some of the devices based on process;

wherein configuring at least one signal processing data collection block implemented by each device in the subset comprises, for each device in the subset, configuring at least one signal processing data collection block to generate signal processing data associated with one process variable indicated by the data indicative of process variables.

45. A method according to claim 36, wherein the plurality of signal processing data collection blocks comprises at least one signal processing data collection block capable of generating at least one of statistical data, frequency analysis data, auto regression data, wavelets data, data generated using a neural network, and data generated using fuzzy logic.

46. A method according to claim 36, wherein the plurality of signal processing data collection blocks comprises at least one statistical data collection block.

47. A method according to claim 36, wherein the plurality of signal processing data collection blocks comprises at least one signal processing data collection block implemented by a field device.

48. A method according to claim 36, wherein the plurality of signal processing data collection blocks comprises signal processing data collection blocks implemented by at least one of a process controller, a data historian, and a workstation.

49. A system for configuring devices associated with a process plant to generate signal processing data associated with the process plant, the system comprising:

at least one processor communicatively coupled to a network associated with the process plant;

at least one computer readable memory communicatively coupled to the at least one processor;

a first routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to analyze process plant hierarchy data to determine a plurality of signal processing data collection blocks, each of the signal processing data collection blocks of the plurality of signal processing data collection blocks communicatively coupled to a network associated with the process plant;

a second routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to analyze data retrieved from the plurality of signal processing data collection blocks via the network to determine at least a subset of signal processing data collection blocks that are not enabled, if any; and

a third routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to configure at least some of the signal processing data collection blocks in the at least the subset of signal processing data collection blocks to enable signal processing data collection by the at least some of the signal processing data collection blocks.

50. A system for configuring devices associated with a process plant to generate signal processing data associated with the process plant, the system comprising:

a computer readable medium;

a first routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to analyze process plant hierarchy data to determine a plurality of signal processing data collection blocks, each of the signal processing data collection blocks of the plurality of signal processing data collection blocks communicatively coupled to a network associated with the process plant;

a second routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to analyze data retrieved from the plurality of signal processing data collection blocks via the network to determine at least a subset of signal processing data collection blocks that are not enabled, if any; and

a third routine stored on the at least one computer readable memory and adapted to be executed on the at least one processor to configure at least some of the signal processing data collection blocks in the at least the subset of signal processing data collection blocks to enable signal processing data collection by the at least some of the signal processing data collection blocks.