Methods and systems for detecting deviation of a process variable from expected values
First Claim
1. A method, implemented in one or more computer processors, for facilitating detection of abnormal operation of a process in a process plant, comprising:
- collecting first data sets for the process while the process is in a first operating region, the first data sets generated from process variables of the process in the first operating region;
generating, in one of the processors, a first regression model of the process in the first operating region using the first data sets;
determining, in one of the processors, a first range in which the first regression model is valid;
generating, in one of the processors, a model of the process to include the first regression model;
collecting second data sets for the process while the process is in a second operating region, the second data sets generated from process variables of the process in the second operating region;
generating, in one of the processors, a second regression model of the process in the second operating region using the second data sets;
determining, in one of the processors, a second range in which the second regression model is valid;
revising, in one of the processors, the model of the process to include the first regression model for the first range and the second regression model for the second range;
receiving, in one of the processors, process variable data, the process variable data generated by a device in a process plant;
receiving, in one of the processors, statistical data regarding the process variable data;
receiving, in one of the processors, at least one parameter associated with at least one threshold based on the received statistical data;
determining at least one threshold based on the received statistical data and the received at least one parameter;
generating, in one of the processors, predicted process variable data using the model of the process;
analyzing, in one of the processors, the received process variable data, the predicted process variable data, and the at least one threshold to determine if the received process variable data significantly deviates from the predicted process variable data; and
generating an indicator of abnormal operation if it is determined that the received process variable data significantly deviates from the predicted process variable data,wherein analyzing the received process variable data, the predicted process variable data, and the at least one threshold to determine if the received process variable data significantly deviates from the predicted process variable data comprises;
generating a difference signal based on the received process variable data and the predicted process variable data; and
detecting whether the difference signal is increasingly deviating from zero by doing at least one of;
determining, in one of the processors, whether Zk1>
Zk2>
. . . >
ZkB>
X, wherein Zk1, Zk2, . . . , ZkB are at least a subset of B values within a set of A consecutive values of the difference signal at time indexes k1, k2, . . . kB, wherein A is a positive integer greater than 2, B is a positive integer less than or equal to A and greater than 2, wherein X is a first threshold, and wherein k1>
k2 . . . >
kB; and
determining, in one of the processors, whether Zk1<
Zk2<
. . . <
ZkB<
Y, wherein Y is a second threshold.
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Abstract
In methods and systems that may facilitate detecting abnormal operation in a process plant, values of a process variable are analyzed to determine whether they significantly deviate from expected values. If there is a significant deviation, an indicator may be generated. Analyzing the process variable may include, for example, utilizing a plurality of thresholds determined based on statistics of the process variable. Analyzing the process variable may also include, for example, determining whether a first number of values of the process variable are in a first region, and whether a second number of values are in a second region.
196 Citations
28 Claims
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1. A method, implemented in one or more computer processors, for facilitating detection of abnormal operation of a process in a process plant, comprising:
-
collecting first data sets for the process while the process is in a first operating region, the first data sets generated from process variables of the process in the first operating region; generating, in one of the processors, a first regression model of the process in the first operating region using the first data sets; determining, in one of the processors, a first range in which the first regression model is valid; generating, in one of the processors, a model of the process to include the first regression model; collecting second data sets for the process while the process is in a second operating region, the second data sets generated from process variables of the process in the second operating region; generating, in one of the processors, a second regression model of the process in the second operating region using the second data sets; determining, in one of the processors, a second range in which the second regression model is valid; revising, in one of the processors, the model of the process to include the first regression model for the first range and the second regression model for the second range; receiving, in one of the processors, process variable data, the process variable data generated by a device in a process plant; receiving, in one of the processors, statistical data regarding the process variable data; receiving, in one of the processors, at least one parameter associated with at least one threshold based on the received statistical data; determining at least one threshold based on the received statistical data and the received at least one parameter; generating, in one of the processors, predicted process variable data using the model of the process; analyzing, in one of the processors, the received process variable data, the predicted process variable data, and the at least one threshold to determine if the received process variable data significantly deviates from the predicted process variable data; and generating an indicator of abnormal operation if it is determined that the received process variable data significantly deviates from the predicted process variable data, wherein analyzing the received process variable data, the predicted process variable data, and the at least one threshold to determine if the received process variable data significantly deviates from the predicted process variable data comprises; generating a difference signal based on the received process variable data and the predicted process variable data; and detecting whether the difference signal is increasingly deviating from zero by doing at least one of; determining, in one of the processors, whether Zk1>
Zk2>
. . . >
ZkB>
X, wherein Zk1, Zk2, . . . , ZkB are at least a subset of B values within a set of A consecutive values of the difference signal at time indexes k1, k2, . . . kB, wherein A is a positive integer greater than 2, B is a positive integer less than or equal to A and greater than 2, wherein X is a first threshold, and wherein k1>
k2 . . . >
kB; anddetermining, in one of the processors, whether Zk1<
Zk2<
. . . <
ZkB<
Y, wherein Y is a second threshold. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A tangible, non-transitory medium storing machine readable instructions, the machine readable instructions capable of causing one or more machines to:
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collect first data sets for the process while the process is in a first operating region, the first data sets generated from process variables of the process in the first operating region; generate a first regression model of the process in the first operating region using the first data sets; determine a first range in which the first regression model is valid; generate a model of the process to include the first regression model; collect second data sets for the process while the process is in a second operating region, the second data sets generated from process variables of the process in the second operating region; generate a second regression model of the process in the second operating region using the second data sets; determine a second range in which the second regression model is valid; revise the model of the process to include the first regression model for the first range and the second regression model for the second range; receive process variable data, the process variable data generated by a device in a process plant; receive statistical data regarding the process variable data; receive at least one parameter associated with at least one threshold based on the received statistical data; determine at least one threshold based on the received statistical data and the received at least one parameter; generate predicted process variable data using the model of the process; analyze the received process variable data, the predicted process variable data, and the at least one threshold to determine if the received process variable data significantly deviates from the predicted process variable data; and generate an indicator of abnormal operation if it is determined that the received process variable data significantly deviates from the predicted process variable data, wherein the instructions for analyzing the received process variable data, the predicted process variable data, and the at least one threshold to determine if the received process variable data significantly deviates from the predicted process variable data comprise instructions capable of causing the one or more machines to; generate a difference signal based on the received process variable data and the predicted process variable data; and detect whether the difference signal is increasingly deviating from zero by doing at least one of; determine whether Zk1>
Zk2>
. . . >
ZkB>
X, wherein Zk1, Zk2, . . . , ZkB are at least a subset of B values within a set of A consecutive values of the difference signal at time indexes k1, k2, . . . kB, wherein A is a positive integer greater than 2, B is a positive integer less than or equal to A and greater than 2, wherein X is a first threshold, and wherein k1>
k2 . . . >
kB; anddetermine whether Zk1<
Zk2<
. . . <
ZkB<
Y, wherein Y is a second threshold.
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12. A method, implemented in one or more computer processors, for facilitating detection of abnormal operation of a process in a process plant, comprising:
-
collecting first data sets for the process while the process is in a first operating region, the first data sets generated from process variables of the process in the first operating region; generating, in one of the processors, a first regression model of the process in the first operating region using the first data sets; determining, in one of the processors, a first range in which the first regression model is valid; generating, in one of the processors, a model of the process to include the first regression model; collecting second data sets for the process while the process is in a second operating region, the second data sets generated from process variables of the process in the second operating region; generating, in one of the processors, a second regression model of the process in the second operating region using the second data sets; determining, in one of the processors, a second range in which the second regression model is valid; revising, in one of the processors, the model of the process to include the first regression model for the first range and the second regression model for the second range; receiving, in one of the processors, process variable data associated with a process plant; generating, in one of the processors, expected process variable data using the model of the process; determining, in one of the processors, whether a first number of values of the received process variable data are within a first region based on the expected process variable data; generating an indicator of significant deviation if it is determined that the first number of values of the received process variable data is within the first region; determining, in one of the processors, whether a second number of values of the received process variable data is within a second region based on the expected process variable data, wherein the second number is greater than the first number, wherein the second region is different than the first region; and generating the indicator of significant deviation if it is determined that the second number of values of the received process variable data is within the second region, wherein generating the indicator of significant deviation comprises analyzing a difference signal generated based on received process variable data and the expected process variable data and detecting whether the difference signal is increasingly deviating from zero by doing at least one of; determining, in one of the processors, whether Zk1>
Zk2>
. . . >
ZkB>
X wherein Zk1, Zk2, . . . , ZkB are at least a subset of B values within a set of A consecutive values of the difference signal at time indexes k1, k2, . . . kB, wherein A is a positive integer greater than 2, B is a positive integer less than or equal to A and greater than 2, wherein X is a first threshold, and wherein k1>
k2 . . . >
kB; anddetermining, in one of the processors, whether Zk1<
Zk2<
. . . <
ZkB<
Y, wherein Y is a second threshold. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20)
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21. A tangible, non-transitory medium storing machine readable instructions, the machine readable instructions capable of causing one or more machines to:
-
collect first data sets for the process while the process is in a first operating region, the first data sets generated from process variables of the process in the first operating region; generate a first regression model of the process in the first operating region using the first data sets; determine a first range in which the first regression model is valid; generate a model of the process to include the first regression model; collect second data sets for the process while the process is in a second operating region, the second data sets generated from process variables of the process in the second operating region; generate a second regression model of the process in the second operating region using the second data sets; determine a second range in which the second regression model is valid; revise the model of the process to include the first regression model for the first range and the second regression model for the second range; receive process variable data associated with a process plant; generate expected process variable data using the model of the process; determine whether a first number of values of the received process variable data are within a first region based on the expected process variable data; generate an indicator of significant deviation if it is determined that the first number of consecutive values of the received process variable data is within the first region; determine whether a second number of values of the received process variable data is within a second region based on the expected process variable data, wherein the second number is greater than the first number, wherein the second region is different than the first region; and generate the indicator of significant deviation if it is determined that the second number of consecutive values of the received process variable data is within the second region, wherein the machine readable instructions operable to cause the one or more processors to generate the indicator of significant deviation comprises instructions operable to cause the one or more processors to analyze a difference signal generated based on received process variable data and the expected process variable data and detect whether the difference signal is increasingly deviating from zero by doing at least one of; determining whether Zk1>
Zk2>
. . . >
ZkB>
X, wherein Zk1, Zk2, . . . , ZkB are at least a subset of B values within a set of A consecutive values of the difference signal at time indexes k1, k2, . . . kB, wherein A is a positive integer greater than 2, B is a positive integer less than or equal to A and greater than 2, wherein X is a first threshold, and wherein k1>
k2 . . . >
kB; anddetermining whether Zk1<
Zk2<
. . . <
ZkB<
Y, wherein Y is a second threshold.
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22. A system for facilitating detection of abnormal operation of a process in a process plant, comprising:
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a configurable model of the process in the process plant, the configurable model including a first regression model in a first range corresponding to a first operating region of the process, the configurable model capable of being subsequently configured to include a second regression model in a second range corresponding to a second operating region different than the first operating region; the system further comprising a deviation detector coupled to the configurable model, the deviation detector configured to determine if the process significantly deviates from an output of the model a threshold generator to receive process variable statistical data and to generate a plurality of thresholds based on the process variable statistical data; a comparator coupled to the configurable model, the comparator configured to; receive process variable data and the plurality of thresholds, determine whether a first number of values of the received process variable data are within a first region based on a first threshold of the plurality of thresholds and based on an output of the configurable model, generate an indicator of significant deviation if it is determined that the first number of values of the received process variable data is within the first region, determine whether a second number of values of the received process variable data is within a second region based on a second threshold of the plurality of thresholds and based on the output of the configurable model, wherein the second number is greater than the first number, wherein the second region is different than the first region, and generate the indicator of significant deviation if it is determined that the second number of values of the received process variable data is within the second region, wherein generating the indicator of significant deviation comprises analyzing a difference signal generated based on received process variable data and the expected process variable data and detecting whether the difference signal is increasingly deviating from zero by doing at least one of; determining whether Zk1>
Zk2>
. . . >
ZkB>
X, wherein Zk1, Zk2, . . . , ZkB are at least a subset of B values within a set of A consecutive values of the difference signal at time indexes k1, k2, . . . kB, wherein A is a positive integer greater than 2, B is a positive integer less than or equal to A and greater than 2, wherein X is a first threshold, and wherein k1>
k2 . . . >
kB; anddetermining whether Zk1<
Zk2<
. . . <
ZkB<
Y, wherein Y is a second threshold. - View Dependent Claims (23, 24, 25, 26, 27, 28)
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Specification