Field Device State Monitoring Through Automated Parameter Comparison
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Solution Overview
Problem
Existing solutions for monitoring and validating field device states in process control systems are labor-intensive and inefficient, requiring manual comparison of parameter sets across numerous devices, leading to time-consuming and complex reporting processes, especially in environments with hundreds of field devices.
Innovation Solution
A method and system for monitoring field device parameter state changes by retrieving and comparing reference or prior parameter states with current states, detecting deviations, and displaying results, allowing for automated reporting and configuration adjustments, with the ability to filter and modify reports based on user inputs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual comparison of parameter sets is used across numerous field devices, then monitoring accuracy can be maintained, but the time and effort required for reporting increases significantly
Solution Approach 1:
The system creates a digital copy of field device parameter states and stores them in a database. This copy can be retrieved and compared automatically without manual intervention, maintaining validation accuracy while eliminating the time-consuming manual comparison process. The parameter manager tool queries the database for stored parameter sets and performs automated comparisons.
Solution Approach 2:
The patent replaces the manual mechanical process of comparing parameter sets with an automated electronic system. The parameter manager tool automatically retrieves parameter states, compares them against reference values, and generates reports without human intervention. This substitution of manual operations with automated computing operations resolves the contradiction between accuracy and time consumption.
2Reliability
If comprehensive monitoring of all field devices is performed, then system reliability improves, but the complexity of the monitoring system increases
Solution Approach 1:
The parameter manager tool is designed as a universal system that can monitor multiple field devices with different parameter types through a single interface. It handles various device classes (valves, transmitters, actuators) and parameter categories (configuration, diagnostic, process) uniformly, improving reliability across the entire system while avoiding the need for separate monitoring systems for each device type.
Solution Approach 2:
The monitoring system is segmented into modular components: a database layer for storing parameter data, a query layer for retrieving data, a comparison layer for analyzing deviations, and a reporting layer for presenting results. This segmentation allows comprehensive monitoring of all field devices while managing system complexity through modular architecture, where each component handles a specific aspect of the monitoring task.
3Loss of information
If detailed parameter state data is collected and reported for all devices, then diagnostic capability is enhanced, but the effort required for configuration and reporting increases
Solution Approach 1:
The system performs preliminary actions by automatically collecting, storing, and organizing detailed parameter state data in a database before any analysis or reporting is needed. This pre-processing eliminates the need for manual data collection and configuration efforts when diagnostics are required. The parameter manager tool can then retrieve pre-organized data and generate reports without requiring operators to manually configure data collection or analysis parameters.
Data Source
AI summary
The invention provides methods, systems and computer program products for monitoring field device states within a process control system, and for detecting and responding to state changes associated with one or more field devices. Implementation of the invention involves, for each field device within a selected sub-set of the plurality of field devices, (i) retrieving a reference set or template set of field device parameter state data associated with the field device (ii) retrieving a set of current state data associated with each field device within the selected sub-set of the plurality of field devices, (iii) comparing the two sets of parameter state data for each field device within the selected sub-set of the plurality of field devices and (iv) generating and/or displaying a report representing detected deviations between the two sets of parameter state data for each field device within the selected sub-set of the plurality of field devices.