Process Control Testing Automation via Routine Monitoring

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Solution Overview

Problem

Process control systems face inefficiencies in testing due to independent control routines and test procedures, leading to unverified modifications and potential failures, as well as time-consuming manual verification processes that require system shutdowns, resulting in productivity losses and potential quality declines.

Innovation Solution

A method and apparatus that combine process control routines with corresponding test procedures to optimize testing by generating a test application from the control strategy, monitoring operations for similar events, and updating the test application to indicate verification, thereby reducing manual intervention and ensuring timely verification during normal system operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual verification process is used to verify process control system, then verification accuracy is improved, but testing time increases and productivity decreases

Engineering Contradiction:

Improveverification accuracyVSAvoidtesting efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent creates a test application that is a copy or representation of the process control routine, allowing verification to be performed on the copied structure without affecting the actual system operation. This enables automated comparison and verification while maintaining system productivity.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces manual mechanical verification processes with automated electronic monitoring and comparison systems. The system automatically monitors routine operations, compares them against test criteria, and updates verification status without manual intervention, thereby improving both accuracy and efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If manual verification process is used to verify process control system, then verification thoroughness is improved, but system shutdown is required resulting in productivity loss

Engineering Contradiction:

Improveverification thoroughnessVSAvoidsystem availability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent performs verification actions preliminarily by continuously monitoring routine operations and automatically comparing them against test criteria in the background. This preliminary automated verification eliminates the need for subsequent system shutdowns while maintaining thorough verification standards.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent enables continuous verification of the process control system during normal operation. The monitoring and comparison processes run continuously in the background, maintaining system availability while ensuring thorough verification without interruption.

Inventive Principle:

Principle #20Continuity of useful action

3Adaptability or versatility

If independent control routines and test procedures are used, then system operation flexibility is improved, but verification reliability decreases due to unverified modifications

Engineering Contradiction:

Improvesystem operation flexibilityVSAvoidverification reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent merges the control routine and test procedure into a unified verification system. The test application is generated from and linked to the process control routine, creating an integrated system where modifications to the routine automatically update the test criteria, ensuring verification reliability while maintaining flexibility.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent implements feedback mechanisms where the monitoring system continuously compares routine operations against test criteria and automatically updates verification status. This feedback loop ensures that modifications are immediately verified, maintaining reliability while allowing operational flexibility.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS9874870B2Methods and apparatus to manage testing of a process control system

Publication Date: 2018.01.23 FISHER ROSEMOUNT SYST INC

AI summary

Example methods and apparatus to manage testing of a process control system are disclosed. A disclosed example method includes generating a test application from a process control routine, the test application including at least one test that is to be performed within a time period, monitoring an operation of the process control routine, determining if the operation of the process control routine during the time period includes an execution of a portion of the process control routine that is substantially similar to the at least one test, and updating the test application by indicating that the at least one test has been performed within the time period.