Automatic verification of field installed systems

Abstract

A method and system to improve commissioning and start-up up of systems in the field, where operational data from the system is analyzed to produce a result that can be used as a verifiable check to confirm the system is installed and operating correctly. Also disclosed are enhancements to the system and method to ensure proper ongoing function of the system. A system to verify satisfactory installation and operation of a field installed system can include sensors and a controller, and the system can be configured to operate the system for a set period to time while capturing sensor data; process the sensor data; compare the processed sensor data to desired operating parameters; and produce a verification result.

Description

AUTOMATIC VERIFICATION OF FIELD INSTALLED SYSTEMSRELATED APPLICATION

[0001] This application claims benefit of priority of U.S. Provisional Application Serial No. 63 / 532,185, filed August 11, 2023, entitled Automatic Verification of Field Installed Systems. The above-identified related application is incorporated herein by reference.FIELD OF THE INVENTION

[0002] The present invention relates generally to improving the commissioning and start-up up of systems in the field; and more particularly where operational data from the system is analyzed to produce a result that can be used as a verifiable check to confirm proper system installation and operation.BACKGROUND OF THE INVENTION

[0003] Many systems depend heavily on correct installation in the field to ensure proper function. For a subset of these systems, it can be difficult to verify that the installation was done correctly. In other cases, verification is possible, but may require a burdensome manual process that is often skipped or not completed.

[0004] In some cases, manual verification steps may be done incorrectly or even falsified to ensure installation is completed on time. Even when manual verification is done correctly, records of these steps can be difficult to track, and this information is often lost.

[0005] Many of these systems are commissioned with less than satisfactory installation and are left to operate as is until a problem occurs and is noticed. A better method of system verification that does not require manual measurements is needed. In addition, in many cases it is difficult to diagnose a problem with a system during installation. Diagnosing and fixing problems often requires manual measurements and can be error prone resulting in wasted time, imperfect fixes, and users simply living with problematic systems.

[0006] The following is a list of challenges when installing, commissioning, and operating field installed systems.• Difficult to verify installation.o Buried or inaccessible systems, hard to measure, no method exists. o Manual verification is burdensome, done incorrectly, records not kept, falsified. o Verification required for work to continue, buried pipes etc.• Difficult to track system performance. o Lack of records on initial verification o Potential for damage or shift from desired set up. o Difficulty in determining if problem was present at installation or caused later.• Difficult to spot failed or out of range system components. o Systems made up of several nodes such as distributed heaters or batteries make it difficult to check for a single bad node. o Improper configuration of system components can mask failed or out of range nodes. o Degradation of a single component or node at a later date can be difficult to spot.• Difficult to commission a system o Pressure to sign off and get stuff done encourages “do the minimum’ . o Requirement to visit a system in person is burdensome and encourages quick fixes to avoid repeat trips to a site. o Lack of information can lead to extensive time spent trouble shooting installation errors. o Installer may not be responsible after system hand-off encouraging them to do the minimum to achieve sign off. o When multiple parties are involved, each party aims to only verify that the problem was not caused by their portion of the work.• Difficulty in system design o Designer cannot ensure system will work as required due to improper installation. o Difficult to communicate required setpoints and operating parameters. o Difficult for the installer to notice when systems are not installed per the design.• Difficulty in failure analysis at later date o No record of initial “good” operation. o Cannot distinguish installation issue from later damage or shift.• Difficult to fix system configuration after installation is completeo Lack of access to the system after installation may make fixes difficult in cases where the system is hidden behind a wall, buried underground, or otherwise inaccessible. o This can include proper sensor location. For example, a system where a temperature sensor needs to be placed on a buried pipe but is not placed correctly before the pipe is buried.• Difficult to verify operation at all stages of system life o Lack of as-built design drawings. o Lack of system performance records.SUMMARY OF THE INVENTION

[0007] The present disclosure provides a system and method to improve commissioning and start-up up of systems in the field, where operational data from the system is analyzed to produce a result that can be used as a verifiable check to confirm the system is installed and operating correctly. The disclosure further describes enhancements to methods to ensure proper function of the system over its lifetime.

[0008] In certain embodiments, the disclosure describes a system that includes a controller with sensors that operate the system and that capture data from the sensors during a test run. A microprocessor on the controller or a connected cloud platform (the data processing engine), processes the data from the test run and compares the data to the desired operating parameters for the specific type and model of system and controller to provide a verification report or other output indicating whether the system is operating correctly.

[0009] In one embodiment, a system to verify satisfactory installation and operation of a field installed system is disclosed, where the system includes sensors and a controller, and where the system is configured to operate the system for a set period to time while capturing sensor data; process the sensor data; compare the processed sensor data to desired operating parameters; and produce a verification result.

[0010] In certain aspects, the system can send sensor data to a cloud platform where the sensor data is processed in the cloud, and where the verification result is either sent back to the controller or disseminated via the cloud platform. In another aspect, a user can initiate the verification ofsatisfactory installation and operation process from the cloud platform allowing for a completely remote set up of the system.

[0011] In other aspects, the system can be configured so that one or more of the external sensors are configured to sense temperature, where the controller uses weather data from a cloud platform as a comparison to verify correct operation of the external sensors sensing temperature. In a further aspect, one or more of the sensors are configured to sense temperature, where sensor data is recorded with the heating system off, then the heating system is turned on for a set period and the temperature response is recorded and processed to verify an effect of the heating system on the one or more sensors sensing temperature, whereby a result is used to determine if the one or more sensors is installed in a correct location in the system or if the heating system meets a specified heat up time period.

[0012] In another embodiment, a method to verify satisfactory installation and operation of a field installed system is disclosed, where a controller runs the system and the system includes sensors, and where the method steps comprise operating the system for a set period of time while capturing sensor data; processing the sensor data; comparing the processed sensor data to desired operating parameters; and producing a verification result.BRIEF DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[0013] The present invention will be better understood with reference to the following description taken in combination with the drawings. For the purpose of illustration, there are shown in the drawings certain embodiments of the present invention. In the drawings, like numerals indicate like elements throughout. It should be understood, however, that the invention is not limited to the precise arrangements, dimensions, and instruments shown:

[0014] FIG. 1 is an illustrated system diagram with controller, gateway, mobile tester, and sensors, in accordance with an embodiment of this disclosure; and

[0015] FIG. 2 illustrates an exemplary result report including test result, controller information, test conditions, contextualized test values, expected operating ranges, highlighted issues, troubleshooting recommendations and test identifier, all in accordance with an embodiment of this disclosure.DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[0016] It is to be understood that the figures and descriptions of the present invention may have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for purposes of clarity, other elements found in a typical system environment. Those of ordinary skill in the art will recognize that other elements may be desirable and / or required in order to implement the present disclosure. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements is not provided herein. It is also to be understood that the drawings included herewith only provide diagrammatic representations of the presently preferred structures of the present disclosure and that structures falling within the scope of the present disclosure may include structures different than those shown in the drawings. Reference will be made to the drawings wherein like structures are provided with like reference designations.

[0017] Before explaining at least one embodiment in detail, it should be understood that the inventive concepts set forth herein are not limited in their application to the construction details or component arrangements set forth in the following description or illustrated in the drawings. It should also be understood that the phraseology and terminology employed herein are merely for descriptive purposes and should not be considered limiting.

[0018] It should further be understood that any one of the described features may be used separately or in combination with other features. Other invented devices, systems, methods, features, and advantages will be or become apparent to one with skill in the art upon examining the drawings and the detailed description herein. It is intended that all such additional devices, systems, methods, features, and advantages be protected by the accompanying claims.

[0019] This disclosure provides a system that includes a controller with sensors that operates the system and captures data from the sensors during a test run. A microprocessor on the controller, or on a connected cloud platform (the data processing engine), processes the data from the test run and compares the data to the desired operating parameters for a specific type and model of system and controller to provide a verification report or other output indicating whether the system is operating correctly.

[0020] When the system is known prior to running the check, the data processing engine can provide an expected operating range based on the captured data and the typical operating range forthe type of system. For example, with a specific model of air handling unit that has a known fan motor and flow rate. For this system, prior testing could be used to establish parameters that indicate proper airflow, such as fan speed, fan power draw, airflow measurement, temperature measurements, etc. The data collected during the verification check can then be compared to these known values to determine if there are any issues that may be causing a deviation from the expected values.

[0021] For example, if the system consists of a controller and heat trace, the expected operating range may be determined as follows. Temperature is a principal factor in heat trace load. The verification check can report both the measured temperature and the expected range. It does this by first determining an expected operating temperature range, possibly taking into account the type of system and location. Then it looks at the typical range for self-regulating heater cable current and inrush current which is based on operating temperature. Since the temperature at the time of test is known, the result can be placed in the range and the maximum and minimum expected values calculated and presented to the user. If the type of heating cable is known, this process can be done more accurately.

[0022] The method can be used to ensure sensors are placed in the proper location and configured correctly. For example, in a pipe heating system where it is important that the temperature sensor is placed in contact with the pipe that needs to be heated. In this case, the check could turn on the heater once or multiple times to elicit a temperature response in the target sensor. Data analysis would then show whether the temperature sensor showed an increase in temperature during the heating cycle indicating that the sensor was, in fact, placed on the pipe. This feature could be extended for systems with known expected behavior. In this case, the rate of temperature increase measured by the sensor could be compared to an expected value to further ensure proper sensor placement.

[0023] The system could also take into account data from external sources such as weather data from either a connected weather station or an information service or API. The weather data could be used in the verification check to establish test conditions and flag instances where operation conditions may differ from test conditions. The weather information could also be used in individual verification checks. For example, if a system measures ambient temperature using a local sensor, the temperature from the local sensor and the temperature from the weather data couldbe compared, and if the difference is out of an established range this issue could be flagged. For systems where the operating behavior is dependent on weather conditions, the result could include a range of expected operating values based on the test value (measured during the check), the test conditions (measured during the test or taken from an external data source), and known operating characteristics of the system.

[0024] The verification check may also be conducted again at any time after the installation of the system. If the results of the initial check and all subsequent checks are recorded and stored in a database, they may be used as a baseline for the system to identify changes or faults in the system. Verification checks can be automatically run at some set interval or according to a pre-determined schedule to ensure proper function over the lifetime of the system. For example, a system could be set to run a check once a day. In the case of a freeze protection system which must function through the winter months, the check could be run each fall to ensure the system is ready to go for the winter heating season. In the case of a snow-melting system that is designed to run during a winter storm, the system could be programed to run prior to an expected winter storm event. The result could then be provided to the user along with either an assurance that the system is ready, or with a warning that there are issues that need to be resolved prior to the storm event.

[0025] The verification check result can include additional information that may be helpful to the various users of the system. For example, a check could help identify installation conditions that do not match the design drawings. To do this, an engineer or system designer would upload the expected system design including verifiable parameters such as expected heater load, in the case of a heating system, or number of nodes, in the case of a battery system. If the check does not align with the expected design values, this would be flagged in the result. In the case of a heat trace system where multiple pieces of heat trace are connected to a single control circuit, this method could be used to determine that the correct number of pieces of the correct length are connected to each circuit. A knowledgeable user could use the information from a number of circuits to correct the case where a piece of heat trace was connected to the wrong circuit.

[0026] In the case where the verification check indicates issues with the system under test, the result could include recommendations to fix or improve the issues. For example, if the check identifies abnormally high ground-fault current in a heat tracing system. It could provide arecommendation to check the heat trace connections which are a common source for ground fault current issues.

[0027] For a system with an existing set of sensors and controls that include communication, the check could be completed by an external device that gathers information from the controller and either processes the data locally or passes the data to a cloud-platform or local data processing engine. Using this method, existing systems can be fitted with an external module that allows for a verification check. Alternatively, the external tester could be a mobile device that a technician brings to the site during installation or start up to record and process a test run. The mobile tester could record the data and store it. The data would then be uploaded to the processing engine at some later time and processed to create a test result. This method would allow systems in high security areas to be tested without any cloud connection. As another approach, the mobile tester could include the processing engine and the result could be generated locally.

[0028] For systems that require a user to program various control settings there are several advantages to this invention. First, the data from the verification run can be used to suggest certain control or alarm parameters. For example, a low-current alarm on a heat-trace system could be automatically programed based on the expected current range established during the verification run. Second, the system could flag troublesome control configurations either during start-up or at any other point during the system’s lifetime. This would help reduce programming errors, problems due to tampering, and improper control configurations set by unknowledgeable users.

[0029] In order to ensure the veracity of a test result, an identifier, such as an identification code, could be included with the test result. A user could enter the identification code via a web portal to access the result and ensure that it matches the result that they have. This method would deter miscreants from falsifying results and would allow users to ensure they have a correct result. The test identifier or some other test ID could also be used to locate test results. For example, a log of test runs could be kept on the controller including a test identifier. This would allow someone with access to the controller to determine if any tests had been run and provide them with a way to track down the results of any tests.

[0030] FIG. 1 illustrates one example of a system where this type of check could be used. FIG.l shows a heat trace system with a controller and a system with nodes. The system could alsoinclude external sensors, internal sensors, an internet connection, a gateway connection, and an optional mobile tester, as shown in FIG. 1.

[0031] Overall, exemplary FIG. 1 illustrates a system under test 1; a controller 2; a wireless (or wired) connection to a cloud platform 3; a wired external sensor (whether permanent or temporary) 4; an internal sensor located in the controller 5; a wireless external sensor (whether permanent or temporary) 6; a power feed to the system 7; wiring to the wired external sensor 8; a node within the system 9; a wireless connection to a wireless sensor 10; a controller display and human machine interface (HMI) 11; a gateway 12; a mobile tester 13; a permanently wired connection to the gateway 14; and a temporary connection to the mobile tester 15.

[0032] FIG. 2 illustrates an example result check report 21 for a check run on a system. The result could include the overall result summary with recommendations for any issues found during the test, device information including system and model identifiers, test condition information including a summary of how test conditions may affect results, specific check criteria including contextualized test values, and a result identifier. The result could also include all the settings as programmed at the time of the check and recommended settings such as a recommended low current alarm threshold based on the steady-state operating current and the expected operating range. The result could also include other information about the system or system design such as the type or heater or heat trace, the length of heat trace, the power output of the heater or heat trace, the number of pieces of heat trace, the installation method, the insulation type, if the system is located outside, and any other relevant system information. For failed tests, the result could include the reason for the failure and partial result of any information that is available on other criteria. The exemplary result check report 21 shown in FIG. 2 could be hosted on a web platform, presented as a PDF, emailed to a user, viewed on a mobile device, or otherwise presented to users in a useful way.

[0033] The specific embodiment of the result check report 21 of FIG. 2 provides an overall test result 22; including a test result 22a; showing that issues were identified indicating that these issues should be addressed prior to system operation; a description of result including recommendation 22b; troubleshooting recommendations for issues identified during the test 22c; specific issues identified during the test 22d; and recommendation(s) for a specific issue identified during the test 22e. The result check report 21 also notes the system information for the deviceunder test 23; the device under test identifier 23a; the device under test model identifier 23b; the device under test name 23c; and the device under test group 23d.

[0034] The specific embodiment of the result check report 21 of FIG. 2 further provides test conditions 24; temperature and weather conditions 24a; test start time 24b; test location information 24c; and description of how test conditions may affect test results 24d. Also included are individual checks 25; with check criteria 25a; test value 25b; a result for specific check criteria 25c, showing “in range,” indicating the specific check is within the recommended range and the check has passed; a result for specific check criteria 25d, showing “higher than normal,” indicating the specific check is outside of the recommended range, but the system may be functional; a result for specific check criteria 25e, showing “out of range,” indicating the specific check is well out of range and the system is likely not functional; a context bar showing the test value within a context range 25f; a context bar marker showing the limits of the recommended, higher / lower, and out of range sections of the context bar 25g; a recommended range shown in green to indicate good 25h; a higher than recommended range shown in yellow to indicate caution 25i; an out of range shown in red to indicate significant problem 25j; an expected range showing the expected operating range of check criteria 25k; and expected range marker showing the limits of the expected operating range 251; a snippet providing description of the result for the check criteria including recommendations for improvement 25m; and a check criteria description including check summary, context, and information to help the user better understand the test value and result 25n. Lastly, the result check report 21 also includes a result identifier to ensure results are traceable and cannot easily be tampered with 26.

[0035] The individual checks for a heat trace system could include the following:• A ground fault system test to check the built-in ground fault equipment protection (GFEP) circuit. If failed, the overall result would be a test failure.• The average voltage for the test system including how close the voltage is to the nominal operating voltage of the system, with values out of the recommended range flagged.• The voltage drop when the heating system turns on, with values out of the recommended range flagged.• In-rush current, with values out of the recommended range flagged.• Steady-state current, with values out of the recommended range flagged.• In-rush ground-fault current, with values out of the recommended range flagged.• Steady-state ground-fault current, with values out of the recommended range flagged.• Ambient temperature sensor reading, with values compared to an ambient temperature reading from weather data. Values that differ significantly from the ambient temperature would be flagged to indicate the sensor is likely in a location with external heating or cooling such as a position in the sun that could negatively affect operation.• Heating system temperature sensor reading with a rate of temperature increase. If the rate of temperature increase is lower than expected, this criterion would be flagged to indicate that the sensor may not be located in the correct position.• Network connectivity showing a metric for connection health with poor connectivity flagged.• Alarm check to detect whether there are any other alarms on the device.• Local communications check for systems using Modbus, BACnet, or some other protocol to communicate with other devices on a local network.

[0036] A heat tracing system check designed to run on a longer test cycle could also include the following check criteria:• Total number of heater cycles within the test period with abnormally high cycle counts flagged to indicate improper system configuration or settings.• Heater duty cycle with values compared to the expected duty cycle for the system based on the system type and design.• Power usage within the period with a comparison to typical systems of the same type.• Duty cycle / Power usage with operating conditions to understand how the system operates under different weather conditions.• Efficiency metric indicating how efficient the system is compared to similar systems including recommendations on how to improve system efficiency.

[0037] Fields of use for embodiments of the systems and methods of the above presented disclosure include industrial control, building system control, heating systems, process heating systems, heat trace systems, freeze protection systems, grease waste systems, cooling towers, snowmelting and deicing systems, cooling systems, HVAC systems, air-conditioning systems, heatpump systems, mini-split systems, residential systems, plumbing systems, electrical systems, battery systems, energy systems, solar power systems, charging stations.

[0038] The method steps in any of the embodiments described herein are not restricted to being performed in any particular order. Also, structures mentioned in any of the method embodiments may utilize structures mentioned in any of the device embodiments. Such structures may be described in detail with respect to the device embodiments only but are applicable to any of the method embodiments.

[0039] Features in any of the embodiments described in this disclosure may be employed in combination with features in other embodiments described herein, such combinations are considered to be within the spirit and scope of the present invention.

[0040] The contemplated modifications and variations specifically mentioned in this disclosure are considered to be within the spirit and scope of the present invention.

[0041] More generally, even though the present disclosure and exemplary embodiments are described above with reference to the examples according to the accompanying drawings, it is to be understood that they are not restricted thereto. Rather, it is apparent to those skilled in the art that the disclosed embodiments can be modified in many ways without departing from the scope of the disclosure herein. Moreover, the terms and descriptions used herein are set forth by way of illustration only and are not meant as limitations. Those skilled in the art will recognize that many variations are possible within the spirit and scope of the disclosure as defined in the following claims, and their equivalents, in which all terms are to be understood in their broadest possible sense unless otherwise indicated.

Claims

What is claimed is:

1. A system to verify satisfactory installation and operation of a field installed system, wherein the system includes sensors and a controller, where the system is configured to: operate for a set period to time while capturing sensor data; process the sensor data; compare the processed sensor data to desired operating parameters; and produce a verification result.

2. The system of claim 1, wherein the sensor data is sent to a cloud platform and processed in the cloud, and wherein the verification result is either sent back to the controller or disseminated via the cloud platform.

3. The system of claim 2, wherein a user can initiate the verification of satisfactory installation and operation process from the cloud platform allowing for completely remote set up of the system.

4. The system of claim 1 , wherein the sensor data is compared to pre-programmed settings specific to the system.

5. The system of claim 1 , wherein the verification result is recorded and kept in a database; and is later compared to a second result from the same system to provide a comparison of system performance over time.

6. The system of claim 1, wherein the sensor data is used to automatically determine certain settings that are then programmed on the controller.

7. The system of claim 1, wherein the sensor data is used to provide feedback to a user, wherein the feedback provides troubleshooting guidance directed to correcting a failed verification result or to improve a system that is passing but can still be improved.

8. The system of claim 1 , wherein the sensor data captured includes operating voltage and operating current of the system.

9. The system of claim 1, wherein the sensor data from external sensors is used to determine whether the external sensors are connected correctly and functioning properly.

10. The system of claim 9, wherein one or more of the external sensors are configured to sense temperature, and wherein the controller uses weather data from a cloud platform as a comparison to verify correct operation of the external sensors sensing temperature.

11. The system of claim 1 , wherein the sensors are temporary sensors, not a permanent part of the system, and are connected to the controller to provide sensor data during a verification step only.

12. The system of claim 1, where a set period of sensor data capture extends several days or weeks, whereby complex long running system behavior can be included in the verification result.

13. The system of claim 1, where the system is a heating system.

14. The system of claim 13, where one or more of the sensors are configured to sense temperature, where sensor data is recorded with the heating system off, then the heating system is turned on for a set period and the temperature response is recorded and processed to verify an effect of the heating system on the one or more sensors sensing temperature, whereby a result is used to determine if the one or more sensors is installed in a correct location in the system or if the heating system meets a specified heat up time period.

15. The system of claim 13, where the system is a heat trace system.

16. The system of claim 1, where the verification of satisfactory installation and operation can be run at any time during a lifetime of the system.

17. The system of claim 1, where the verification of satisfactory installation and operation is run at a regular interval or according to a pre-determined schedule to ensure proper system function over time.

18. The system of claim 1, where the verification result requires sign-off or approval from a system designer or engineer to ensure the system is not commissioned with improper configuration.

19. The system of claim 1, where the sensor data is recorded by the controller and passed to a gateway that sends the sensor data to a cloud-platform or local data processing engine.

20. The system of claim 1, where the verification result includes an identifier providing that a user could identify a digitally verified result via a web portal or via other method and ensure the verification result has not been tampered with.

21. The system of claim 1, where the verification result includes recommendations to correct or improve issues identified in the verification result.

22. The system of claim 1, where weather data from an external source is used as part of the comparing to produce a verification result.

23. The system of claim 1, where the system is a battery system.

24. A method to verify satisfactory installation and operation of a field installed system, wherein a controller runs the system and the system includes sensors, the method steps comprising: operating the system for a set period of time while capturing sensor data; processing the sensor data; comparing the processed sensor data to desired operating parameters; and producing a verification result.

Images