Safety instrumented system interface

Abstract

The present disclosure relates to a safety instrumented system interface. A two-tier interface with a safety instrumented system (SIS) in an industrial plant. A diagnostic state aggregator having an established connection with the SIS collects and stores health and diagnostic state data from the SIS. An interface processing engine, communicatively coupled to the diagnostic state aggregator and a user device, receives a new request from the user device for information related to the SIS. A memory stores processor-executable instructions that, when executed, configure the interface processing engine to parse the new request to identify one or more particular keywords associated with the requested information related to the SIS, generate a query based on the identified keywords, retrieve state data from the diagnostic state aggregator responsive to the query that was collected from the SIS, and provide the state data retrieved from the diagnostic state aggregator to the user device.

Description

Background Technology

[0001] In process control systems, fault tolerance enables the system to continue operating in the event of component failure or transient failures from various sources. A common aspect of fault-tolerant systems involves the concept of redundancy, which can be simply defined as a backup component that becomes operational in the event of a failure, thus allowing the system to continue operating as intended. Safety Instrumented Systems (SIS), such as those available from Schneider Electric Systems USA, Inc. Safety controllers, etc., are known in the art for continuing operation in a “safe state” to avoid adverse safety and health consequences by using fault-tolerant controllers. Such fault-tolerant controllers are often used in hazardous protection systems (i.e., systems regulating the operation of nuclear power plants, turbomachinery, fire and gas sensing systems, etc.).

[0002] Safety requirements for control systems vary by industry and application. While all applications generally need to maintain operating parameters within desired ranges over time, control systems used in industries such as oil and gas, chemicals, and power also ensure that controlled systems and subsystems avoid conditions that could pose a danger to the plant and / or its internal environment (e.g., fire, explosion, release of hazardous materials, equipment damage, personal injury, or loss of life). Typical SISs installed in processes are programmed to identify impending high-risk unsafe events and respond immediately to drive the process to a safe condition. This is typically done independently of the process control system, but can sometimes be coordinated with it. Simultaneously, these “safety systems” are expected to provide high availability while avoiding erroneous trips that could result in system or subsystem shutdown (or downgrade) in response to erroneous sensor readings and / or situations where safety is not actually at risk. Field devices, controllers, workstations, and other devices supporting preferred safety systems are provided by their assignees. Manufacturing and selling brand labels, etc. Summary of the Invention

[0003] In short, aspects of this disclosure provide efficient monitoring of a security system by delivering information to the end user from any location via a dual-interface layer. The dual-interface layer does not interact directly with the SIS, ensuring security and safety when processing information requests. In operation, the user uses a mobile device (such as a smartphone) to request access to the desired information via voice or text.

[0004] Various aspects of this disclosure further enhance interaction between users and security systems through remote maintenance capabilities, such as handheld applications, chatbots, and voice-based interfaces with natural speech processing. For location-based requests, equipment can be externally identified by including machine-readable code (readable by mobile devices). The state of the security system is shared using a unidirectional interface for information flow, preventing remote access components from directly interacting with the SIS. Instead, a two-layer interaction mechanism exists.

[0005] On one hand, a method for interfacing with at least one SIS in a factory includes receiving a new request for SIS-related information from a user equipment via an interface processing engine. The user equipment is communicatively coupled to the interface processing engine, and the interface processing engine is communicatively coupled to a diagnostic status aggregator. The diagnostic status aggregator has an established connection with the SIS and stores at least one of health and diagnostic status data collected from the SIS. The method further includes parsing the new request to identify one or more specific keywords associated therewith with the requested SIS-related information, generating a query based on the identified keywords, retrieving status data collected from the SIS in response to the query, and providing the status data retrieved from the diagnostic status aggregator to the user equipment. On the other hand, the diagnostic status aggregator is configured to continuously collect health and diagnostic status data from the SIS.

[0006] On the other hand, the two-layer interface with SIS includes a diagnostic status aggregator that has an established connection with the SIS, which collects and stores health and diagnostic status data from the SIS. An interface processing engine communicatively coupled to the diagnostic status aggregator and the user equipment receives new requests for SIS-related information from the user equipment. Memory stores processor-executable instructions that, when executed, configure the interface processing engine to parse the new request to identify one or more specific keywords associated with the requested SIS-related information, generate a query based on the identified keywords, retrieve status data collected from the SIS in response to the query, and provide the status data retrieved from the diagnostic status aggregator to the user equipment. On the other hand, the diagnostic status aggregator is configured to continuously collect health and diagnostic status data from the SIS.

[0007] Other features will be partially clear and partially pointed out below. Attached Figure Description

[0008] Figure 1 This is a process control network architecture according to an embodiment.

[0009] Figure 2 This is a block diagram of the safety instrumented system interface according to an embodiment.

[0010] Figure 3 yes Figure 2The interface processing engine block diagram.

[0011] Throughout the accompanying drawings, the corresponding reference numerals indicate the corresponding parts. Detailed Implementation

[0012] Figure 1 Various aspects of a factory network 100 are illustrated in the form of an example process control network architecture. As shown, the factory network 100 is divided into multiple zones, such as a business network 102, a monitoring network 104, and a control network 106. In the illustrated embodiment, the control network 106 provides real-time control to devices or equipment communicating on either a secure network 110 or a non-secure network (e.g., a field device network 112). One or more firewalls 114 separate each zone of the factory network 100.

[0013] The control network 106 carries communication with the process control devices of the basic process control system (BPCS) 118. Furthermore, the BPCS 118, coupled to the field device network 112, interacts with field devices and other I / O devices, their controllers, etc.

[0014] The safety network 110 includes at least one safety system 120, such as a safety instrumented system (SIS). As described above, the safety system 120 is configured to drive the process to a safe state when it is unsafe.

[0015] Now for reference Figure 2 Safety system 120 is a critical protective layer against industrial accidents in a factory. Safety system 120 includes at least one safety programmable logic controller (PLC) main processor module 202 and at least one safety PLC input / output (IO) module 204. As shown, the main processor module 202 can be housed in a main chassis and the IO module 204 can be housed in a separate remote IO chassis. In embodiments, the components of safety system 120 can be located in a control room or distributed throughout the factory. Figure 2 In the embodiments, the safety PLC main processor module 202 and the safety PLC IO module 204 are distributed far apart from each other (e.g., up to 70 kilometers).

[0016] End users (e.g., asset owners, plant maintenance personnel) typically operate and maintain safety systems 120 for over 120 years during plant operations. Plant maintenance personnel generally perform daily health monitoring and health status reporting for the plant safety system 120. Furthermore, when a component of safety system 120 fails, plant operators must alert plant maintenance personnel to perform repairs. Maintenance personnel typically use maintenance software to perform primary maintenance functions by identifying which component of safety system 120 has failed, enabling in-process repairs by replacing the faulty component. In some cases, plant maintenance personnel may request support and must first gather information related to the failure to provide to the safety system vendor.

[0017] Various aspects of this disclosure provide efficient monitoring of the security system 120 by providing information to the user 206 from any location via a dual interface layer consisting of an interface processing engine 210 and a diagnostic state aggregator 212. For example... Figure 2 As shown, user 206 uses mobile device 214, such as a smartphone, to request desired information via speech or text. For example, user 206 may simply ask mobile device 214 via conventional means, chat, or natural voice (e.g., “What is the overall status of the security system?”). Mobile device 214 executes mobile application 216, which provides a speech / text interface through which user 206 requests information about security system 120. The speech / text interface of mobile application 216 sends queries from text or natural voice to interface processing engine 210 based on voice commands from user 206.

[0018] Further reference Figure 2 For example, a diagnostic status aggregator 212, implemented by a cloud data storage device, collects real-time status information indicating the health status of security system 120. The collected status information is preferably coupled with system metadata (e.g., area, equipment, Safety Instrumented Function (SIF), predefined room / site location, etc.). This represents a one-way collection of data from security system 120. The state of security system 120 is shared using a one-way interface for information flow, preventing remote access components from directly interacting with security system 120. Instead, a two-layer interaction exists. Interface processing engine 210 is configured to send requests to and receive responses from diagnostic status aggregator 212.

[0019] For security reasons, there is no direct or indirect interaction between user 206 or interface processing engine 210 and security system 120. Furthermore, coupling metadata with state information used by security system 120 provides a higher level of confidence in the security and reliability of the interaction, as well as improved natural workflows and productivity.

[0020] like Figure 3As shown, mobile application 216 provides a speech-to-text interface through which user 206 can request information about security system 120. Mobile application 216 sends a query, converted from natural speech to text, to interface processing engine 210. In an embodiment, interface processing engine 210 uses artificial intelligence or machine learning to determine what information to retrieve and in what context based on the text query. Interface processing engine 210 references a database of questions / intents related to security system 120 with reference to specific keywords and performs machine learning or artificial intelligence to train and parse user requests for a given set of system configurations for user 206, using specific keywords and their variations to identify a set of questions / intents related to the security system 120 of interest. For example, the trained interface processing engine 210 compares a new request with previous requests using specific keywords and their variations to determine whether the new request corresponds to or is related to previous requests related to security system 120. Therefore, interface processing engine 210 can accurately formulate appropriate contextual queries and determine the correct command from user 206. In an alternative embodiment, interface processing engine 210 additionally requests confirmation of the determined command from user 206. The interface processing engine 210 then transmits the command to the diagnostic status aggregator 212 to retrieve the requested information. In an embodiment, the mobile application 216 converts the retrieved status information from text into natural speech for the user 206.

[0021] Refer again Figure 2 Various aspects of this disclosure further enhance the interaction between user 206 and security system 120 through remote maintenance capabilities, such as handheld applications, chatbots, and voice-based interfaces with natural speech processing performed on mobile device 214. For location-based requests, the equipment can be externally identified via a machine-readable code 220, which can be read by mobile device 214. Figure 2 The illustration depicts a unique, individual, scannable machine-readable code 220 applied to or attached to the main chassis of the safety PLC main processor module 202 and / or the I / O chassis of the safety PLC I / O module 204. The machine-readable code 220 can be one or more of the following: a QR (Quick Response) two-dimensional barcode; a data matrix two-dimensional barcode; an RFID tag or code; a unique pattern or graphic that can be uniquely identified (e.g., an image of a person that can be identified by facial recognition software); an infrared code; a linear barcode; and / or other scannable identification markers, visible or invisible within the visible spectrum. In this way, the dual interface layer does not directly interact with the safety system 120, ensuring security and safety when processing information requests.

[0022] Mobile device 214 executes mobile application 216 to scan machine-readable code 220 from the chassis of selected safety PLC modules 202, 204. In one embodiment, the scanned code 220 identifies the location and / or context of the selected safety PLC modules 202, 204. In another embodiment, in addition to or instead of code scanning, mobile device 214 also executes mobile application 216 to provide a speech / text interface through which user 206 can request information about safety system 120. As described above, the speech / text interface sends queries from text or natural speech to interface processing engine 210 based on voice commands from user 206.

[0023] The following is an example use case where the diagnostic status aggregator 212 continuously collects health and diagnostic status information from the security system 120. The natural language questions used in the example are illustrative, and it is anticipated that the end user 206 will use natural language to ask variations or different questions.

[0024] Use Case #1: Locate the overall status of security system 120 from a remote location.

[0025] User 206 asks in natural speech, “What is the overall status?” Application 216, running on mobile device 214, translates the natural speech question into text and sends the text query to interface processing engine 210 for processing. Interface processing engine 210 determines the best match for the query and sends a data request to diagnostic data aggregator 212 to retrieve the requested information. Diagnostic data aggregator 212 sends the requested data back to interface processing engine 210. Interface processing engine 210 then assembles a response in the correct context format and sends it back to mobile device 214, which executes mobile application 216 to convert the response into user 206's natural speech. In an alternative embodiment, mobile device 214 displays the information from interface processing engine 210 in text format. The dual interface layer for processing requests eliminates direct interaction between user 206 and security system 120, thereby ensuring security and safety. Moreover, providing contextual notifications to user 206 in the event of a failure improves productivity.

[0026] Use Case #2: Locate the status of a specific component of security system 120.

[0027] Using mobile device 214, user 206 scans machine-readable code 220 on the exterior of one of the selected chassis of the safety PLC main processor module 202 of interest and the I / O chassis of the safety PLC I / O module 204 to obtain identification information. User 206 then asks “What’s wrong?” in natural speech via application 216 running on mobile device 214. Mobile application 216 translates the natural speech request into text and sends the text query along with the machine-readable identifier obtained from the specific safety system 120 to interface processing engine 210. Interface processing engine 210 determines the best match with the voice request and sends a data request to diagnostic data aggregator 212 to obtain status information corresponding to the identified system components. Diagnostic data aggregator 212 sends the requested data back to interface processing engine 210, which assembles a response in the correct context format and sends the response to mobile device 214. Furthermore, interface processing engine 210 assembles the response in the correct context format and sends it back to mobile device 214, which executes mobile application 216 to convert the response into user 206’s natural speech. In an alternative embodiment, the mobile device 214 displays information from the interface processing engine 210 in text format.

[0028] Use Case #3: Contact Customer Support.

[0029] At the conclusion of use case #2 above, user 206 may decide to seek assistance from a third party (e.g., the vendor of security system 120). User 206 instructs "Contact customer support" in natural language. Application 216, executing on mobile device 214, translates the natural language instruction into text and sends the specific user request / message to customer support along with machine-readable identifier 220 to interface processing engine 210. Interface processing engine 210 collects relevant information from diagnostic data aggregator 212, compiles the collected information with the user request / message, and sends the information and request to customer support via email. Advantageously, aspects of this disclosure improve the efficiency of maintenance requests to vendor customer support by facilitating contact and relevant fault information from security system 120.

[0030] Commonly assigned U.S. Patent No. 9,582,376 (the entire contents of which are incorporated herein by reference) discloses a fault-tolerant controller that allows flexible communication between safety instrumented systems implementing the aforementioned “safe state.” For example, in addition to actuators and sensors, the networked control device includes one or more controllers, as modified herein, for monitoring and controlling relevant aspects of the process. The controller may include a mainframe computer, workstation, personal computer, dedicated hardware, or other digital data processing device capable of performing monitoring and control functions. The controller may operate in a manner known in the art, as modified herein. Preferably, the controller is constructed and operated in a manner similar to a control processor (“CP”) commercially available from its assignee, such as… (Also known as "Tricon") and Trident TM Controller.

[0031] Embodiments of this disclosure may include a dedicated computer, which includes various computer hardware, as described in more detail below.

[0032] For illustrative purposes, programs and other executable program components may be shown as discrete blocks. However, it should be understood that such programs and components reside in different storage components of the computing device at different times and are executed by one or more data processors of the device.

[0033] While described in conjunction with exemplary computing system environments, embodiments of various aspects of the invention may operate with other dedicated computing system environments or configurations. The computing system environment is not intended to imply any limitation on the scope or functionality of any aspect of the invention. Furthermore, the computing system environment should not be construed as having any dependency or requirement associated with any one or a combination of the components shown in the exemplary operating environment. Examples of computing systems, environments, and / or configurations to which various aspects of the invention may be applied include, but are not limited to, personal computers, server computers, handheld or laptop devices, multiprocessor systems, microprocessor-based systems, set-top boxes, programmable consumer electronics, mobile phones, network PCs, minicomputers, mainframe computers, distributed computing environments including any of the systems or devices described above, etc.

[0034] Embodiments of aspects of the invention can be described in the general context of data and / or processor-executable instructions (such as program modules) stored on one or more tangible, non-transitory storage media and executed by one or more processors or other devices. Generally, program modules include, but are not limited to, routines, programs, objects, components, and data structures that perform specific tasks or implement specific abstract data types. Aspects of the invention can also be practiced in distributed computing environments, where tasks are performed by remote processing devices linked via a communication network. In distributed computing environments, program modules can reside in both local and remote storage media, including memory storage devices.

[0035] In operation, processors, computers, and / or servers can execute processor-executable instructions (e.g., software, firmware, and / or hardware) such as those shown herein to implement aspects of the invention.

[0036] Embodiments of various aspects of the present invention can be implemented using processor-executable instructions. These processor-executable instructions can be organized into one or more processor-executable components or modules on a tangible processor-readable storage medium. Various aspects of the present invention can be implemented using any number and organization of such components or modules. For example, various aspects of the present invention are not limited to specific processor-executable instructions or specific components or modules shown in the figures and described herein. Other embodiments of various aspects of the present invention may include different processor-executable instructions or components having more or fewer functions than those shown and described herein.

[0037] Unless otherwise stated, the order in which operations are performed or carried out in the embodiments of the various aspects of the invention described herein is not essential. That is, operations may be performed in any order unless otherwise stated, and embodiments of the various aspects of the invention may include more or fewer operations than those disclosed herein. For example, it is contemplated that a particular operation may be performed before, simultaneously with, or after another operation within the scope of the aspects of the invention.

[0038] In describing the elements of various aspects of the invention or embodiments thereof, the articles “a,” “the,” and “described” are intended to mean that one or more elements are present. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be other elements in addition to those listed.

[0039] Not all components described or illustrated may be essential. Furthermore, some implementations and embodiments may include additional components. Changes may be made to the arrangement and type of components without departing from the spirit or scope of the claims set forth herein. Additional, different, or fewer components may be provided, and components may be combined. Alternatively or additionally, a component may be implemented from several components.

[0040] The foregoing description illustrates aspects of the invention by way of example and not limitation. This description enables those skilled in the art to make and use aspects of the invention, and describes various embodiments, modifications, variations, substitutions, and uses of aspects of the invention, including modes currently considered best for carrying out aspects of the invention. Furthermore, it should be understood that aspects of the invention are not limited to the construction details and arrangements of the components set forth in the following description or shown in the accompanying drawings. Aspects of the invention can be used in other embodiments and can be practiced or performed in various ways. Moreover, it should be understood that the wording and terminology used herein are for descriptive purposes and should not be construed as limiting.

[0041] Having described various aspects of the invention in detail, it will be clear that modifications and variations are possible without departing from the scope of the invention as defined in the appended claims. Various changes to the above-described structures, products, and processes are contemplated without departing from the scope of the invention. Various preferred embodiments have been described in the foregoing description with reference to the accompanying drawings. However, it is clear that various modifications and changes can be made thereto, and additional embodiments can be implemented without departing from the broader scope of the invention as set forth in the following claims. The description and drawings are accordingly considered illustrative rather than restrictive.

[0042] In view of the above, several advantages of implementing the various aspects of the present invention will be seen and other advantageous results will be obtained.

[0043] The abstract and summary are provided to help readers quickly determine the nature of the technical disclosure. They are submitted with the understanding that they are not intended to interpret or limit the scope or meaning of the claims. The summary is provided to introduce, in a simplified form, a series of concepts further described in the detailed embodiments. The summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to serve as an aid in identifying the claimed subject matter.

Claims

1. A method for interfacing with at least one safety instrumented system (SIS) in a plant, the method comprising: A one-way connection is established from the SIS to the diagnostic status aggregator, the SIS being configured to supply at least one of health and diagnostic status data to the diagnostic status aggregator via the one-way connection, the diagnostic status aggregator storing the status data supplied by the SIS. The interface processing engine is communicatively coupled to the diagnostic state aggregator. The interface processing engine is configured to communicate with the user equipment. The interface processing engine and the diagnostic state aggregator form a dual interface layer. The unidirectional connection from the SIS to the diagnostic state aggregator of the dual interface layer prevents the user equipment from interacting directly with the SIS. The user equipment receives new requests for SIS-related information, and the user equipment is communicatively coupled to the interface processing engine. The interface processing engine receives new requests from the user equipment and is communicatively coupled to the diagnostic state aggregator. The interface processing engine parses the new request to identify one or more specific keywords associated with the requested SIS-related information; The interface processing engine generates queries based on the identified keywords; The interface processing engine retrieves the status data collected from the SIS in response to the query from the diagnostic status aggregator; and The interface processing engine provides the user device with the status data retrieved from the diagnostic status aggregator. The interface processing engine refers to one or more specific keywords to access a database of SIS-related questions or intents, and performs machine learning or artificial intelligence to train against a user’s given system configuration set, parse the new request, and use the one or more specific keywords and their variations to identify a set of SIS-related questions or intents.

2. The method of claim 1, wherein parsing a new request includes determining whether the new request corresponds to one or more previous requests associated with the SIS by using specific keywords and their variants.

3. The method of claim 2, wherein retrieving state data collected from the SIS comprises: In response to determining that a new request corresponds to one or more previous requests, status data is retrieved based at least in part on information obtained from the one or more previous requests.

4. The method according to claim 3, further comprising: In response to determining that a new request does not correspond to one or more of the previous requests, the interface processing engine retrieves the status data collected from the SIS in response to the query from the diagnostic status aggregator. as well as The interface processing engine is trained using information related to new requests and state data retrieved from the diagnostic state aggregator.

5. The method according to any one of claims 1 to 4, wherein receiving a new request from a user equipment includes performing a speech-to-text application to convert the new natural speech request into a text-based request.

6. The method of claim 1, wherein the status data is stored by a diagnostic status aggregator together with metadata associated with the SIS from which the status data is collected, and wherein the metadata includes at least one of the following: the location of the SIS; the identifier of the SIS; and the safety instrumented function (SIF) associated with the SIS.

7. The method according to claim 1, further comprising: The interface processing engine receives the identifier associated with the SIS from the user equipment, which is obtained by the user equipment by scanning the machine-readable code associated with the SIS.

8. A system comprising: At least one Safety Instrumented System (SIS) within the factory; A diagnostic status aggregator is communicatively coupled to the SIS via an established unidirectional connection from the SIS to the diagnostic status aggregator, the diagnostic status aggregator being configured to collect at least one of health and diagnostic status data from the SIS and store the collected status data, wherein the SIS has an established unidirectional connection to the diagnostic status aggregator to supply status data to the diagnostic status aggregator. An interface processing engine, communicatively coupled to the diagnostic state aggregator and the user equipment, is configured to receive new requests for SIS-related information from the user equipment. The interface processing engine and the diagnostic state aggregator constitute a dual interface layer, wherein a unidirectional connection from the SIS to the dual interface layer's diagnostic state aggregator prevents direct interaction between the user equipment and the SIS. A memory that stores processor-executable instructions, which, when executed, also configure an interface processing engine for: Parse the new request to identify one or more specific keywords associated with the requested SIS-related information; Generate queries based on the identified keywords; Retrieve status data collected from SIS in response to queries from the diagnostic status aggregator; and Provide the user equipment with status data retrieved from the diagnostic status aggregator. The interface processing engine refers to one or more specific keywords to access a database of SIS-related questions or intents, and performs machine learning or artificial intelligence to train against a given set of system configurations for the user, parse the new request, and use the one or more specific keywords and their variations to identify a set of SIS-related questions or intents.

9. The system of claim 8, wherein parsing a new request includes determining whether the new request corresponds to one or more previous requests associated with the SIS by using specific keywords and variations thereof.

10. The system of claim 9, wherein retrieving state data collected from the SIS comprises: In response to determining that a new request corresponds to one or more previous requests, status data is retrieved based at least in part on information obtained from the one or more previous requests.

11. The system of claim 10, wherein the memory stores processor-executable instructions, which, when executed, also configure the interface processing engine for: In response to determining that a new request does not correspond to one or more previous requests, the interface processing engine retrieves the status data collected from the SIS in response to the query from the diagnostic status aggregator; and The interface processing engine is trained using information related to new requests and state data retrieved from the diagnostic state aggregator.

12. The system of claim 8, wherein the user equipment is configured to perform a speech-to-text application to convert a new request in natural language into a text-based request, and wherein the new request received by the interface processing engine is a text-based request.

13. The system of claim 8, wherein the state data is stored by the diagnostic state aggregator together with metadata associated with the SIS from which the state data is collected.

14. The system of claim 13, wherein the metadata includes at least one of the following: the location of the SIS; the identifier of the SIS; and the safety instrumented function (SIF) associated with the SIS.

15. The system of claim 8, further comprising machine-readable code associated with the SIS, wherein the interface processing engine is configured to receive from the user equipment an identifier associated with the SIS obtained by the user equipment through scanning the machine-readable code.

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