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WO2014060024A1 - Guiding a maintenance engineer to a process control device - Google Patents

Guiding a maintenance engineer to a process control device Download PDF

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Publication number
WO2014060024A1
WO2014060024A1 PCT/EP2012/070502 EP2012070502W WO2014060024A1 WO 2014060024 A1 WO2014060024 A1 WO 2014060024A1 EP 2012070502 W EP2012070502 W EP 2012070502W WO 2014060024 A1 WO2014060024 A1 WO 2014060024A1
Authority
WO
WIPO (PCT)
Prior art keywords
process control
engineer
wireless terminal
control device
location
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2012/070502
Other languages
French (fr)
Inventor
Elina Vartiainen
Jonas BRÖNMARK
Martin Olausson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ABB Research Ltd Switzerland
Original Assignee
ABB Research Ltd Switzerland
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ABB Research Ltd Switzerland filed Critical ABB Research Ltd Switzerland
Priority to PCT/EP2012/070502 priority Critical patent/WO2014060024A1/en
Publication of WO2014060024A1 publication Critical patent/WO2014060024A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • GPHYSICS
    • G06COMPUTING OR CALCULATING; COUNTING
    • G06QINFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00Administration; Management
    • G06Q10/06Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
    • G06Q10/063Operations research, analysis or management
    • GPHYSICS
    • G06COMPUTING OR CALCULATING; COUNTING
    • G06QINFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q50/00Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism
    • G06Q50/04Manufacturing
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/30Computing systems specially adapted for manufacturing

Definitions

  • the present invention generally relates to process control systems. More particularly the present
  • invention relates to a method, data presentation control arrangement and a computer program product for enabling a maintenance engineer of a process control system to obtain details of a process control device.
  • a process control system may be provided in process plant. Such a system normally comprises a number of process control devices involved in the control of the process. The operation of these devices is typically monitored by plant operators via operator terminals of the system.
  • Plant operators are normally busy maintaining the process, making sure the operation at the plant runs as effective as possible. As alarms occur in the plant it is the responsibility of the process operator to decide if the alarm needs attention of a plant maintenance engineer. If that is the case, the operator must first locate the plant maintenance engineer and after that direct the engineer to the process control device that raised the alarm.
  • Valuable time may thus be lost when routing service engineers to the source of the problem, while operators are needed for other tasks.
  • the operators may have more alarms to take care of and make sure that the process is running as effective as possible.
  • the operator should dedicate his or her time on the operation of the process instead of addressing the plant maintenance engineer .
  • a number of documents describe how a maintenance engineer may be located.
  • WO 2012/069814 discloses an industrial system where a handheld device of a plant engineer receives a
  • US 2007/0245169 discloses a system where a diagnosis is made as an engineer is in a vicinity of an object and then the results are sent to the engineer. The engineer is also selected based on qualification. However, there is still room for improvement within the field, especially concerning the timing of when a maintenance engineer is to receive data that is of use in handling an issue of a process control device.
  • the present invention addresses the problem of timing the provision of relevant data for a maintenance engineer.
  • This object is according to a first aspect of the invention solved through a method of guiding a maintenance engineer to a process control device present in a process control system, the method being performed by a data presentation control arrangement and comprising the steps of:
  • selecting a maintenance engineer for handling the alarm having a wireless terminal and being at a second location, sending guiding data to the wireless terminal for moving from the second to the first location, monitoring the progress of the wireless terminal in moving from the second to the first location, determining if the wireless terminal is within a distance d from the first location, and
  • This object is according to a second aspect of the invention solved through a data presentation control arrangement data presentation control arrangement for enabling a maintenance engineer of a process control system to obtain details of a process control device, the data presentation control arrangement comprising: a engineer selecting unit configured to
  • the selected maintenance engineer having a wireless terminal and being at a second location
  • a progress monitoring unit configured to
  • This object is according to a third aspect of the invention solved through a computer program product for enabling a maintenance engineer of a process control system to obtain details of a process control device, the computer program product being provided on a data carrier comprising computer program code configured to cause a data presentation control arrangement to, when the computer program code is loaded into at least one device providing the data presentation control
  • the selected maintenance engineer having a wireless terminal and being at a second location, send guiding data to the wireless terminal for moving from the second to the first location, monitor the progress of the wireless terminal in moving from the second to the first location, determine if the wireless terminal is within a distance d from the first location, and
  • the present invention has a number of advantages. It presents a way to automatically direct plant
  • the invention will also allow for faster response time since plant maintenance engineers are automatically contacted and requested by the process control system to ensure quick examination of the source of the alarm.
  • FIG. 1 schematically shows an industrial plant with a process control system operating an industrial process together with a first and second wireless terminal associated with corresponding maintenance engineers
  • Fig. 2 schematically shows a front view of the first wireless terminal
  • Fig. 3 schematically shows a block schematic of the first wireless terminal
  • Fig. 4 shows premises of the industrial plant with a number of rooms, where the first and second wireless terminals are provided with a first process control device,
  • Fig. 5 shows a flow chart of a number of method steps being performed in a first variation of a method of enabling a user in a process control system to obtain details of a process control object
  • Fig. 6 schematically shows a data carrier with computer program code, in the form of a CD-ROM disc, for
  • Fig. 1 schematically shows an industrial plant where a process control system 10 is provided.
  • the process control system 10 is a computerized process control system for controlling an industrial process.
  • the process can be any type of industrial process, such as electrical power generation, transmission and
  • a process may be monitored through one or more process monitoring computers, which communicate with a server handling monitoring and control of the process.
  • the process control system 10 therefore includes a number of process monitoring computers 12 and 14. These computers may here also be considered to form operator terminals and are connected to a first data bus Bl .
  • the wireless network WN may be a local network, such as a wireless local area network (WLAN) . It may also be a Bluetooth network, i.e. a network with a number of interconnected Bluetooth nodes.
  • WLAN wireless local area network
  • Bluetooth network i.e. a network with a number of interconnected Bluetooth nodes.
  • the network may
  • PLMN public land mobile communication network
  • a second data bus B2 and between the first and second data busses Bl and B2 there are connected a server 18 providing control and protection of the process and a database 20 where data relating to control and protection of the process is stored.
  • data relating to control and protection may here comprise process data such as measurements and control commands, while data relating to protection may
  • alarm and event data as well as data on which alarms and events can be generated, such as
  • the engineer locating server 22 comprises an engineer selecting unit 21 and a progress monitoring block 23.
  • a first field device is a first process control device 24, as an example a tank and the second field device is a second process control device 26, as an example a centrifuge.
  • Fig. 2 schematically shows a front view of the first wireless terminal 32. It simply comprises a display 34.
  • the display 34 is in some variations of the invention a touch screen via which data can be presented for the user of the wireless terminal 32 as well as via which data can be entered by the user, such as selections of various features in applications. It should be realized that in other variations of the invention the display may only be a display and the inputs provided through a keypad or a keyboard, a trackball, a joystick or some other buttons .
  • Fig. 3 shows a block schematic of the first wireless terminal 32.
  • the first wireless terminal 32 comprises a bus 36 and to this bus there is connected the display 34, a processor 38, a program memory 40 as well as a first radio communication circuit 42.
  • the first radio communication circuit 42 is furthermore connected to a first antenna 44.
  • the first radio communication unit 42 and first antenna 44 are provided for communication with the wireless network WN.
  • the progress monitoring element 41 is merely a slave entity presenting process data under the control of the progress monitoring block 23 of the engineer locating server 22, which server then forms the data presentation control arrangement and where the progress monitoring block 23 then forms a progress monitoring unit.
  • the progress monitoring elements 41 is a progress monitoring unit of a presentation control arrangement, which arrangement then comprises the engineer selecting unit 21 of the engineer locating server 22 as well as the progress monitoring element 41 of the wireless terminal 32.
  • Fig. 4 schematically shows a facility 49 of the
  • the facility 49 is here in the form of a building where the first process control device 24 is located at a first location LI.
  • a first wireless access point 48 of the wireless network with which the first wireless terminal 32 communicates In the facility 49 there is also a second wireless access point 50 of the wireless network with which the second wireless terminal 33 communicates.
  • the first wireless terminal 32 is shown as being at a second location L2 and having a first path PI to the first process control device 24.
  • the second wireless terminal 33 is shown having second path P2 to the first process control device 24.
  • the second wireless terminal 33 is physically closer to the first process control device 24 than the first wireless terminal 32.
  • the second path P2 is longer than the first path PI.
  • the positions of the wireless access points 48 and 50 are typically known and because of this also the positions or locations of the wireless terminals and consequently the maintenance engineers may be known. Also the layout of the premises may be known. This means that the locations of the walls may be known in the engineer locating server.
  • fig. 5 shows a flow chart of a number of method steps being performed in a method of enabling a maintenance engineer in the process control system to obtain details of a process control device.
  • the wireless terminals available today are equipped with a lot of different sensors, such as Global
  • GPS Positioning System
  • Bluetooth Bluetooth
  • NFC Near Field Communication
  • process control system 10 is also aware of the physical position of process control devices then it is possible to calculate the distance between a wireless terminal and the surrounding process control devices.
  • a user of the first wireless terminal 32 may thus typically be a maintenance engineer performing some activity in the premises. If an alarm that needs to be handled by a plant
  • the method starts with the engineer locating server 22 receiving an alarm from a faulty process control device, for instance the first process control device 24 at location LI, step 60. An alarm is thus generated by the first process control device 24. The alarm may then be presented for an operator at the operator terminal 12, step 62. The operator may then decide the severity of the alarm and if the alarm requires service, the operator may select to forward the alarm to a plant maintenance engineer. In some variations of the invention alarms may be pre-configured to be automatically forwarded to a plant maintenance engineer. The operator may then invoke an engineer locating function of the engineer locating server 22, which function may be implemented through the engineer selecting unit 21. Alternatively the alarm is directly forwarded to the engineer
  • the engineer selecting unit 21 selects a suitable maintenance engineer for servicing the process control device 24, step 64.
  • the engineer selecting unit 21 may use an algorithm to locate the closest available plant maintenance engineer with proper knowledge to be able to handle the problem. This may involve locating an engineer having the right qualification.
  • maintenance engineer database 19 may comprise data about maintenance engineers, their qualifications as well as data concerning their availability and
  • the engineer selecting unit 21 may therefore send a query to the engineer database 19 to find out the wireless terminals of the maintenance engineers that have the right qualifications and are indicated as being available, i.e. not busy with some other task. It may then be informed that the engineer of the first and second wireless terminals 32 and 33 have the right
  • the engineer selecting unit 21 may thereafter automatically calculate which of the maintenance engineers of the plant to contact. As seen in Figure 4, the plant maintenance engineer associated with the first wireless terminal 32 would be contacted since the maintenance engineer associated with the second wireless terminal 33 has to travel a longer path to get to the process control device 24 that triggered the alarm.
  • the engineer selecting unit 21 may select a second closest engineer in case the closest engineer is busy and sends a request to the wireless terminal of this second closes engineer .
  • the type of process control device 24 and fault may be compared with the different plant
  • the engineer selecting unit 21 thus investigates the positions of the wireless terminals of the maintenance engineers and selects the wireless terminal of the engineer that is closest to the first process control device 24. In this determination of which is closest it is possible that the path from the wireless terminal to the process control device is considered.
  • the engineer selecting unit 21 may consider the distance between the location of the engineer and the location of the process control device 24. However it may also consider such things as the locations of obstacles such as walls that would force the maintenance engineer to take a longer route to the object. It may therefore select the first wireless terminal 32 instead of the second wireless terminal 33, even though the second wireless terminal is closer to the process control device 24.
  • the engineer selection may furthermore be presented to the operator at the operator terminal 12. The operator may then be able to change maintenance engineer.
  • the operator selects the first wireless terminal 32, which is provided at the second location L2.
  • the operator may then be presented with the selection and he or she may then push a request to the wireless terminal 32.
  • the request may be
  • a request may thus be sent to the plant maintenance engineer having the first wireless terminal 32, which request may be received by the progress monitoring element 41 and presented via the display 34.
  • the engineer may then select to accept the request.
  • the plant maintenance engineer thus gets the request notification on his wireless terminal 32, and may be immediately able to read selected data such as which process control devices are related to the alarm that is the root cause of the request.
  • the plant control system When an alarm or other event that requires attention is generated in the plant control system, a request may thus be automatically sent to the plant maintenance engineer that is located closest to the device that needs to be maintained. Thereafter the first wireless terminal 32 is provided with guiding instructions for guiding the first
  • the engineer selecting unit 21 may therefore obtain the positions of the first and second locations and thereafter send guiding instructions for guiding the maintenance engineer from the second location L2 to the first location LI.
  • the progress monitoring element 41 may therefore be provided with detailed instructions to guide the engineer to the correct process control device, which instructions may comprise maps, process schemes and photos. As the request contains proper instruction to locate the process control device, the plant maintenance engineer locates it and is able to take immediate action on the problem.
  • the engineer selecting unit 21 may more particularly create guiding instructions for guiding the selected maintenance engineer to the vicinity of the first process control device 24.
  • the guiding instructions may for instance be based on the second location L2 of the first wireless terminal 32 and comprise a number of instructions guiding the maintenance engineer from this second location L2 to the first location LI of the first process control device 24.
  • the first wireless terminal 32 thus receives the guiding instructions. All this data may in this first embodiment be received by the first radio circuit 42 via the first antenna 44 and then forwarded to the progress monitoring element 41. It is here as an alternative possible that the progress monitoring element 41 itself has a set of instructions for guiding the user to the vicinity of the first process control device 24 and then it itself determines its own
  • the progress of the selected maintenance engineer may be presented to the operator at the operator terminal 12. It may also at this stage be possible for the operator to change maintenance engineer. In this case a revoking instruction may be sent to the
  • the progress monitoring element 41 presents the guiding instructions to the maintenance engineer for guiding him or her to the first process control device 24.
  • directions may furthermore be dynamically updated based on the position of the maintenance engineer.
  • the position of the maintenance engineer may be any position of the maintenance engineer.
  • the first location LI of the first process control device 24 may be stationary and known
  • the progress monitoring unit may monitor the progress of the first wireless terminal 32, step 67, i.e. keep track of the positions as it moves from the second location L2 towards the first location LI of the first process control device 24.
  • the progress monitoring unit may then ensure that the first wireless terminal displays further relevant data of the object, step 70.
  • the further data may comprise the real time values of the process control device, notes written by operators regarding the process control device, trends and faceplates. All may be adapted in suitable format and layout of the wireless terminal to guarantee effective problem solving.
  • the progress monitoring block 23 is the progress monitoring unit, then this will compare the distance with the distance threshold d and the relevant further data may be sent to the progress monitoring element of the first wireless terminal as it is selected and then an order may be sent to the progress monitoring element 41 to display the data when the distance is below the distance threshold d. Alternatively the progress monitoring block 23 may send the further data to be presented as it finds that the wireless terminal 32 is within the distance threshold d. If the progress monitoring element 41 is the progress monitoring unit, it may have received the further data with the notification and thereafter determined if the distance to the first process control device is below the distance threshold d. it may then receive
  • This information or further data could comprise, but is not restricted to, alarm details, trends, process displays and faceplates of the process control device - adapted in proper format and layout for the plant maintenance engineer.
  • the wireless terminal With this information it is possible to dynamically update the user interface on the wireless terminal depending on the proximity of a maintenance engineer to a faulty process control device.
  • the wireless terminal When a maintenance engineer approaches a process control device, the wireless terminal he or she is carrying will then automatically update its display to present the correct process graphics. This includes, but is not limited to, highlighting the corresponding process control device on the wireless terminal display 34.
  • the process control device may then be located in the center of the display with extended information such as real time values, object name, alarms etc.
  • the amount of further data being presented may also be, after the distance threshold has been passed, dependent on the distance between the wireless terminal and the first process control device.
  • the amount of information being presented may increase with decreasing distance to the first process control device. This means that the closer the maintenance engineer gets to the first process control device, the more further data is presented .
  • This invention has a number of advantages. It presents a way to automatically direct plant maintenance
  • the invention will save time as no manual routing of personnel is required. Operators located in the control room do not have to worry about routing the plant maintenance engineers, and can instead concentrate on operation. The invention will also allow for faster response time since plant maintenance engineers are automatically contacted and requested by the process control system to ensure quick examination of the source of the alarm. Plant maintenance engineers will be able to quickly address service requests and alarms and do not need to depend on support from process operators. Equipping maintenance engineers with wireless terminals and keeping track of their current location will improve safety as in emergency situations the position of the plant maintenance engineers is known. With handheld wireless terminals, the plant maintenance engineers could check valuable information whenever necessary - it will be possible to look up necessary data without having to rely on support from other personnel .
  • the engineer selecting unit and progress monitoring block may, as was previously described, be provided in the form of one or more processors together with computer program memory including computer program code for performing their functions. As an alternative they may be provided in the form of a Application Specific Integrated Circuit (ASIC) or Field-Programmable Gate Array (FPGA) . Also the progress monitoring element may be provided in the same way.
  • This computer program code may also be provided on one or more data carriers which perform the functionality of the present invention when the program code thereon is being loaded into a engineer locating server or a wireless terminal.
  • One such data carrier 72 with computer program code 74, in the form of a CD ROM disc, is schematically shown in fig. 6.
  • Such computer program may as an alternative be provided on another server and downloaded therefrom into the presentation control server and/or the

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Abstract

The invention relates to a method, presentation control arrangement and a computer program product enabling a maintenance engineer of a process control system (10) to obtain details of a process control device (24). The arrangement comprises an engineer selecting unit (21) that receives an alarm from a process control device (24), which is placed at a first location of the process control system, selects a maintenance engineer for handling the alarm, where the selected engineer has a wireless terminal (32) at a second location (L2), and sends guiding data to the wireless terminal for moving from the second to the first location, where the arrangement also comprises a progress monitoring unit (23; 41) that monitors the progress of the wireless terminal, determines if it is within a distance d from the first location and ensures that the wireless terminal presents detailed data of the process control device if it is.

Description

GUIDING A MAINTENANCE ENGINEER TO A PROCESS CONTROL
DEVICE
FIELD OF THE INVENTION
The present invention generally relates to process control systems. More particularly the present
invention relates to a method, data presentation control arrangement and a computer program product for enabling a maintenance engineer of a process control system to obtain details of a process control device.
BACKGROUND A process control system may be provided in process plant. Such a system normally comprises a number of process control devices involved in the control of the process. The operation of these devices is typically monitored by plant operators via operator terminals of the system.
In process control systems there are furthermore maintenance engineers that are most of the time working on the process floor close to these process control devices, which is typically far away from control rooms with work stations and other computers from which the system is monitored. The maintenance engineers make sure the process runs as smooth as possible by both preventive and direct maintenance.
User studies conducted in different type of process plants have indicated that the daily work tasks of operators and plant maintenance engineers can be stressful, especially when there are a lot of events that require quick intervention.
Plant operators are normally busy maintaining the process, making sure the operation at the plant runs as effective as possible. As alarms occur in the plant it is the responsibility of the process operator to decide if the alarm needs attention of a plant maintenance engineer. If that is the case, the operator must first locate the plant maintenance engineer and after that direct the engineer to the process control device that raised the alarm.
Handling the responsibility in such a way is not very effective as the process operators are distracted from other events that might occur in the process: alarms within the category of abnormal situation normally populate other alarms that also need immediate
handling .
When an alarm that needs to be handled by a plant maintenance engineer occurs, the operators spend significant time in locating the plant maintenance engineer that is closest to the process device, has relevant knowledge to fix the problem and thereafter direct him to the process device provoking the alarm.
In the case of alarm cascade due to abnormal
situations, plant maintenance engineers might be busy on other alarms and the operators must sometimes contact several plant maintenance engineers to find out who is closest to the process device in need of
service . Valuable time may thus be lost when routing service engineers to the source of the problem, while operators are needed for other tasks. The operators may have more alarms to take care of and make sure that the process is running as effective as possible. Hence the operator should dedicate his or her time on the operation of the process instead of addressing the plant maintenance engineer . A number of documents describe how a maintenance engineer may be located.
WO 2012/069814 discloses an industrial system where a handheld device of a plant engineer receives a
notification of a device needing maintenance based on qualification, proximity to device and availability. The instructions may include details of fault and location . US 2007/0245169 discloses a system where a diagnosis is made as an engineer is in a vicinity of an object and then the results are sent to the engineer. The engineer is also selected based on qualification. However, there is still room for improvement within the field, especially concerning the timing of when a maintenance engineer is to receive data that is of use in handling an issue of a process control device. SUMMARY OF THE INVENTION
The present invention addresses the problem of timing the provision of relevant data for a maintenance engineer.
This object is according to a first aspect of the invention solved through a method of guiding a maintenance engineer to a process control device present in a process control system, the method being performed by a data presentation control arrangement and comprising the steps of:
receiving an alarm from a process control device, the process control device being placed at a first location of the process control system,
selecting a maintenance engineer for handling the alarm, the selected maintenance engineer having a wireless terminal and being at a second location, sending guiding data to the wireless terminal for moving from the second to the first location, monitoring the progress of the wireless terminal in moving from the second to the first location, determining if the wireless terminal is within a distance d from the first location, and
- ensuring that the wireless terminal presents
detailed data of the process control device if the terminal is within said distance d.
This object is according to a second aspect of the invention solved through a data presentation control arrangement data presentation control arrangement for enabling a maintenance engineer of a process control system to obtain details of a process control device, the data presentation control arrangement comprising: a engineer selecting unit configured to
receive an alarm from a process control device, the process control device being placed at a first location of the process control system,
select a maintenance engineer for handling the alarm, the selected maintenance engineer having a wireless terminal and being at a second location, and
send guiding data to the wireless terminal for moving from the second to the first location, a progress monitoring unit configured to
monitor the progress of the wireless terminal in moving from the second to the first location, determine if the wireless terminal is within a distance d from the first location, and
ensure that the wireless terminal presents detailed data of the process control device if the terminal is within said distance d.
This object is according to a third aspect of the invention solved through a computer program product for enabling a maintenance engineer of a process control system to obtain details of a process control device, the computer program product being provided on a data carrier comprising computer program code configured to cause a data presentation control arrangement to, when the computer program code is loaded into at least one device providing the data presentation control
arrangement, receive an alarm from a process control device, the process control device being placed at a first location of the process control system,
select a maintenance engineer for handling the alarm, the selected maintenance engineer having a wireless terminal and being at a second location, send guiding data to the wireless terminal for moving from the second to the first location, monitor the progress of the wireless terminal in moving from the second to the first location, determine if the wireless terminal is within a distance d from the first location, and
order the wireless terminal to present detailed data of the process control device if the terminal is within said distance d.
The present invention has a number of advantages. It presents a way to automatically direct plant
maintenance engineers based on their position and availability to the source of a problem. It also enables the plant maintenance engineers to view process graphics directly on the wireless terminal as the engineer approaches the process control device, which facilitates the maintenance of the process control device. This invention will save time as no manual routing of personnel is required. Operators located in the control room do not have to worry about routing the plant maintenance engineers, and can instead
concentrate on operation. The invention will also allow for faster response time since plant maintenance engineers are automatically contacted and requested by the process control system to ensure quick examination of the source of the alarm.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will in the following be
described with reference being made to the accompanying drawings, where Fig. 1 schematically shows an industrial plant with a process control system operating an industrial process together with a first and second wireless terminal associated with corresponding maintenance engineers, Fig. 2 schematically shows a front view of the first wireless terminal,
Fig. 3 schematically shows a block schematic of the first wireless terminal,
Fig. 4 shows premises of the industrial plant with a number of rooms, where the first and second wireless terminals are provided with a first process control device,
Fig. 5 shows a flow chart of a number of method steps being performed in a first variation of a method of enabling a user in a process control system to obtain details of a process control object, and
Fig. 6 schematically shows a data carrier with computer program code, in the form of a CD-ROM disc, for
performing the steps of the method. DETAILED DESCRIPTION OF THE INVENTION
In the following, a detailed description of preferred embodiments of a method, data presentation control arrangement and a computer program product for enabling a maintenance engineer of a process control system to obtain details of a process control device will be given .
Fig. 1 schematically shows an industrial plant where a process control system 10 is provided. The process control system 10 is a computerized process control system for controlling an industrial process. The process can be any type of industrial process, such as electrical power generation, transmission and
distribution processes as well as water purification and distribution processes, oil and gas production and distribution processes, petrochemical, chemical, pharmaceutical and food processes, and pulp and paper production processes. These are just some examples of processes where the system can be applied. There exist countless other industrial processes. The processes may also be other types of industrial processes such as the manufacturing of goods. A process may be monitored through one or more process monitoring computers, which communicate with a server handling monitoring and control of the process. In fig. 1 the process control system 10 therefore includes a number of process monitoring computers 12 and 14. These computers may here also be considered to form operator terminals and are connected to a first data bus Bl . There is also a gateway 16 connected to this first data bus Bl, which gateway 16 is connected to at least one wireless network WN. To the wireless network WN there is connected a first and a second wireless terminal 32 and 33. It should be realized that it is possible with more wireless terminals in the wireless network WN. However, only two are shown for simplifying the understanding of the present invention. The wireless network WN may be a local network, such as a wireless local area network (WLAN) . It may also be a Bluetooth network, i.e. a network with a number of interconnected Bluetooth nodes. The network may
furthermore be a mobile communication network, such as a public land mobile communication network (PLMN) .
There is furthermore a second data bus B2 and between the first and second data busses Bl and B2 there are connected a server 18 providing control and protection of the process and a database 20 where data relating to control and protection of the process is stored. Such data relating to control and protection may here comprise process data such as measurements and control commands, while data relating to protection may
comprise alarm and event data as well as data on which alarms and events can be generated, such as
measurements made in the process. There is furthermore a maintenance engineer database 19 provided in the system, as well as an engineer locating server 22 connected between the two buses Bl and B2. The engineer locating server 22 comprises an engineer selecting unit 21 and a progress monitoring block 23.
To the second data bus B2 there is furthermore
connected a number of further devices 24, 26, 28 and 30. These further devices 24, 26, 28 and 30 are field devices, which are devices that are interfaces to the process being controlled. A field device is typically an interface via which measurements of the process are being made and to which control commands are given. Because of this the field devices are furthermore process control devices. In one variation of the invention a first field device is a first process control device 24, as an example a tank and the second field device is a second process control device 26, as an example a centrifuge.
Fig. 2 schematically shows a front view of the first wireless terminal 32. It simply comprises a display 34. The display 34 is in some variations of the invention a touch screen via which data can be presented for the user of the wireless terminal 32 as well as via which data can be entered by the user, such as selections of various features in applications. It should be realized that in other variations of the invention the display may only be a display and the inputs provided through a keypad or a keyboard, a trackball, a joystick or some other buttons .
Fig. 3 shows a block schematic of the first wireless terminal 32. The first wireless terminal 32 comprises a bus 36 and to this bus there is connected the display 34, a processor 38, a program memory 40 as well as a first radio communication circuit 42. The first radio communication circuit 42 is furthermore connected to a first antenna 44. The first radio communication unit 42 and first antenna 44 are provided for communication with the wireless network WN.
In the program memory 40 there is provided software code which when being run by the processor forms a progress monitoring element 41. In some embodiments of the invention the progress monitoring element 41 is merely a slave entity presenting process data under the control of the progress monitoring block 23 of the engineer locating server 22, which server then forms the data presentation control arrangement and where the progress monitoring block 23 then forms a progress monitoring unit. In other variations the progress monitoring elements 41 is a progress monitoring unit of a presentation control arrangement, which arrangement then comprises the engineer selecting unit 21 of the engineer locating server 22 as well as the progress monitoring element 41 of the wireless terminal 32.
Fig. 4 schematically shows a facility 49 of the
industrial plant. The facility 49 is here in the form of a building where the first process control device 24 is located at a first location LI. In the facility 49 there is a first wireless access point 48 of the wireless network with which the first wireless terminal 32 communicates. In the facility there is also a second wireless access point 50 of the wireless network with which the second wireless terminal 33 communicates. In this figure also the first wireless terminal 32 is shown as being at a second location L2 and having a first path PI to the first process control device 24. Also the second wireless terminal 33 is shown having second path P2 to the first process control device 24. The second wireless terminal 33 is physically closer to the first process control device 24 than the first wireless terminal 32. However, there are a number of walls between the second wireless terminal 33 and the first process control device 24 and therefore the second path P2 is longer than the first path PI. Furthermore the positions of the wireless access points 48 and 50 are typically known and because of this also the positions or locations of the wireless terminals and consequently the maintenance engineers may be known. Also the layout of the premises may be known. This means that the locations of the walls may be known in the engineer locating server. A first embodiment of the invention will now be
described with reference also being made to fig. 5, which shows a flow chart of a number of method steps being performed in a method of enabling a maintenance engineer in the process control system to obtain details of a process control device.
The wireless terminals available today are equipped with a lot of different sensors, such as Global
Positioning System (GPS) , Bluetooth, and Near Field Communication (NFC) . Using these sensors as well as other communication systems it would be possible to detect the position of the wireless terminal. This may be used in a number of different situations. For instance, in locating maintenance engineers to make service of faulty process control devices.
If the process control system 10 is also aware of the physical position of process control devices then it is possible to calculate the distance between a wireless terminal and the surrounding process control devices. A user of the first wireless terminal 32 may thus typically be a maintenance engineer performing some activity in the premises. If an alarm that needs to be handled by a plant
maintenance engineer occurs, the operators at the work stations 12 and 14 spend significant time in locating the plant maintenance engineer that is closest to the process control device, has relevant knowledge to fix the problem and thereafter direct him to the process control device that provokes the alarm.
In the case of alarm cascade due to abnormal
situations, plant maintenance engineers may be busy on other alarms and the operators may sometimes have to contact several plant maintenance engineers to find out who is closest to the process control device in need of service . Valuable time is lost when routing maintenance
engineers to the source of the problem, while operators are needed for other tasks. The operators may have more alarms to take care of and make sure that the process is running as effective as possible. Hence an operator should dedicate his or her time on the operation of the process instead of addressing the plant maintenance engineer. The present invention is provided for
addressing this and other related issues. The method starts with the engineer locating server 22 receiving an alarm from a faulty process control device, for instance the first process control device 24 at location LI, step 60. An alarm is thus generated by the first process control device 24. The alarm may then be presented for an operator at the operator terminal 12, step 62. The operator may then decide the severity of the alarm and if the alarm requires service, the operator may select to forward the alarm to a plant maintenance engineer. In some variations of the invention alarms may be pre-configured to be automatically forwarded to a plant maintenance engineer. The operator may then invoke an engineer locating function of the engineer locating server 22, which function may be implemented through the engineer selecting unit 21. Alternatively the alarm is directly forwarded to the engineer
selecting unit 21.
Thereafter the engineer selecting unit 21 selects a suitable maintenance engineer for servicing the process control device 24, step 64. The engineer selecting unit 21 may use an algorithm to locate the closest available plant maintenance engineer with proper knowledge to be able to handle the problem. This may involve locating an engineer having the right qualification. The
maintenance engineer database 19 may comprise data about maintenance engineers, their qualifications as well as data concerning their availability and
identifiers of their wireless terminals. The engineer selecting unit 21 may therefore send a query to the engineer database 19 to find out the wireless terminals of the maintenance engineers that have the right qualifications and are indicated as being available, i.e. not busy with some other task. It may then be informed that the engineer of the first and second wireless terminals 32 and 33 have the right
qualifications and are available for performing
servicing. By use of a path finding algorithm the engineer selecting unit 21 may thereafter automatically calculate which of the maintenance engineers of the plant to contact. As seen in Figure 4, the plant maintenance engineer associated with the first wireless terminal 32 would be contacted since the maintenance engineer associated with the second wireless terminal 33 has to travel a longer path to get to the process control device 24 that triggered the alarm.
As the system may keep track of if plant maintenance engineers are allocated on other duties, the engineer selecting unit 21 may select a second closest engineer in case the closest engineer is busy and sends a request to the wireless terminal of this second closes engineer . In addition, the type of process control device 24 and fault may be compared with the different plant
maintenance knowledge to make sure that a plant
engineer is only assigned to a specific process control device if he or she has relevant knowledge.
The engineer selecting unit 21 thus investigates the positions of the wireless terminals of the maintenance engineers and selects the wireless terminal of the engineer that is closest to the first process control device 24. In this determination of which is closest it is possible that the path from the wireless terminal to the process control device is considered. The engineer selecting unit 21 may consider the distance between the location of the engineer and the location of the process control device 24. However it may also consider such things as the locations of obstacles such as walls that would force the maintenance engineer to take a longer route to the object. It may therefore select the first wireless terminal 32 instead of the second wireless terminal 33, even though the second wireless terminal is closer to the process control device 24. The engineer selection may furthermore be presented to the operator at the operator terminal 12. The operator may then be able to change maintenance engineer.
In this example it selects the first wireless terminal 32, which is provided at the second location L2. The operator may then be presented with the selection and he or she may then push a request to the wireless terminal 32. Alternatively the request may be
automatically pushed by the server 22.
A request may thus be sent to the plant maintenance engineer having the first wireless terminal 32, which request may be received by the progress monitoring element 41 and presented via the display 34. The engineer may then select to accept the request. The plant maintenance engineer thus gets the request notification on his wireless terminal 32, and may be immediately able to read selected data such as which process control devices are related to the alarm that is the root cause of the request.
When an alarm or other event that requires attention is generated in the plant control system, a request may thus be automatically sent to the plant maintenance engineer that is located closest to the device that needs to be maintained. Thereafter the first wireless terminal 32 is provided with guiding instructions for guiding the first
maintenance engineer to the process control device 24, step 66. The engineer selecting unit 21 may therefore obtain the positions of the first and second locations and thereafter send guiding instructions for guiding the maintenance engineer from the second location L2 to the first location LI. The progress monitoring element 41 may therefore be provided with detailed instructions to guide the engineer to the correct process control device, which instructions may comprise maps, process schemes and photos. As the request contains proper instruction to locate the process control device, the plant maintenance engineer locates it and is able to take immediate action on the problem.
The engineer selecting unit 21 may more particularly create guiding instructions for guiding the selected maintenance engineer to the vicinity of the first process control device 24. The guiding instructions may for instance be based on the second location L2 of the first wireless terminal 32 and comprise a number of instructions guiding the maintenance engineer from this second location L2 to the first location LI of the first process control device 24.
The first wireless terminal 32 thus receives the guiding instructions. All this data may in this first embodiment be received by the first radio circuit 42 via the first antenna 44 and then forwarded to the progress monitoring element 41. It is here as an alternative possible that the progress monitoring element 41 itself has a set of instructions for guiding the user to the vicinity of the first process control device 24 and then it itself determines its own
position .
Also the progress of the selected maintenance engineer may be presented to the operator at the operator terminal 12. It may also at this stage be possible for the operator to change maintenance engineer. In this case a revoking instruction may be sent to the
currently selected maintenance engineer and a new request sent to a new maintenance engineer, perhaps together with guiding instructions.
After this has been done the progress monitoring element 41 presents the guiding instructions to the maintenance engineer for guiding him or her to the first process control device 24. The guiding
instructions may thus provide directions. These
directions may furthermore be dynamically updated based on the position of the maintenance engineer.
The position of the maintenance engineer may be
obtained using the wireless access points 48 and 50. If the process control device is outdoors then also GPS is an option. The first location LI of the first process control device 24 may be stationary and known
beforehand and may for instance be fetched from a database with process control device information. The progress monitoring unit may monitor the progress of the first wireless terminal 32, step 67, i.e. keep track of the positions as it moves from the second location L2 towards the first location LI of the first process control device 24.
It may for instance compare the distance between the first wireless terminal 32 and the first process control device 24 with a distance threshold d, step 68. If the distance is below the distance threshold d, the progress monitoring unit may then ensure that the first wireless terminal displays further relevant data of the object, step 70. The further data may comprise the real time values of the process control device, notes written by operators regarding the process control device, trends and faceplates. All may be adapted in suitable format and layout of the wireless terminal to guarantee effective problem solving.
If the progress monitoring block 23 is the progress monitoring unit, then this will compare the distance with the distance threshold d and the relevant further data may be sent to the progress monitoring element of the first wireless terminal as it is selected and then an order may be sent to the progress monitoring element 41 to display the data when the distance is below the distance threshold d. Alternatively the progress monitoring block 23 may send the further data to be presented as it finds that the wireless terminal 32 is within the distance threshold d. If the progress monitoring element 41 is the progress monitoring unit, it may have received the further data with the notification and thereafter determined if the distance to the first process control device is below the distance threshold d. it may then receive
information about the first location LI from the progress monitoring block 23 and determine the own position through communicating with the wireless access points .
Whenever the plant maintenance engineer is close to the process control device that is in need of service, the process displays with relevant information for
correcting the problem are thus automatically shown on the display 34 of the wireless terminal 32. This information or further data could comprise, but is not restricted to, alarm details, trends, process displays and faceplates of the process control device - adapted in proper format and layout for the plant maintenance engineer.
With this information it is possible to dynamically update the user interface on the wireless terminal depending on the proximity of a maintenance engineer to a faulty process control device. When a maintenance engineer approaches a process control device, the wireless terminal he or she is carrying will then automatically update its display to present the correct process graphics. This includes, but is not limited to, highlighting the corresponding process control device on the wireless terminal display 34. The process control device may then be located in the center of the display with extended information such as real time values, object name, alarms etc.
The amount of further data being presented may also be, after the distance threshold has been passed, dependent on the distance between the wireless terminal and the first process control device. The amount of information being presented may increase with decreasing distance to the first process control device. This means that the closer the maintenance engineer gets to the first process control device, the more further data is presented .
This invention has a number of advantages. It presents a way to automatically direct plant maintenance
engineers based on their position and availability to the source of a problem. It also enables the plant maintenance engineers to view process graphics directly on the wireless terminal as the engineer approaches the process control device, which facilitates the
maintenance of the process control device. This
invention will save time as no manual routing of personnel is required. Operators located in the control room do not have to worry about routing the plant maintenance engineers, and can instead concentrate on operation. The invention will also allow for faster response time since plant maintenance engineers are automatically contacted and requested by the process control system to ensure quick examination of the source of the alarm. Plant maintenance engineers will be able to quickly address service requests and alarms and do not need to depend on support from process operators. Equipping maintenance engineers with wireless terminals and keeping track of their current location will improve safety as in emergency situations the position of the plant maintenance engineers is known. With handheld wireless terminals, the plant maintenance engineers could check valuable information whenever necessary - it will be possible to look up necessary data without having to rely on support from other personnel .
There are a number of further benefits that may be add:
• The downtime in the plant can be reduced as the plant maintenance engineer available, with correct knowledge and currently closest to the process control device will be assigned to the problem immediately. This therefore increases productivity.
• The stress on the operators in the process control room is reduced as they no longer have to direct plant maintenance engineers to alarms and service requests.
The engineer selecting unit and progress monitoring block may, as was previously described, be provided in the form of one or more processors together with computer program memory including computer program code for performing their functions. As an alternative they may be provided in the form of a Application Specific Integrated Circuit (ASIC) or Field-Programmable Gate Array (FPGA) . Also the progress monitoring element may be provided in the same way. This computer program code may also be provided on one or more data carriers which perform the functionality of the present invention when the program code thereon is being loaded into a engineer locating server or a wireless terminal. One such data carrier 72 with computer program code 74, in the form of a CD ROM disc, is schematically shown in fig. 6. Such computer program may as an alternative be provided on another server and downloaded therefrom into the presentation control server and/or the
wireless terminal.

Claims

1. A method of guiding a maintenance engineer to a process control device (24) present in a process control system (10), the method being performed by a data presentation control arrangement and comprising the steps of:
receiving (60) an alarm from a process control device (24), said process control device being placed at a first location (LI) of the process control system,
selecting (62) a maintenance engineer for handling the alarm, the selected maintenance engineer having a wireless terminal (32) and being at a second location (L2 ) ,
sending (64) guiding data to the wireless terminal for moving from the second to the first location, monitoring (67) the progress of the wireless terminal in moving from the second to the first location,
determining (68) if the wireless terminal is within a distance d from the first location, and
ensuring (70) that the wireless terminal presents detailed data of the process control device if the terminal is within said distance d.
2. The method according to claim 1, wherein the selecting comprises selecting a maintenance engineer that is qualified for performing service.
3. The method according to claim 1 or 2, wherein the selected maintenance engineer is an available maintenance engineer.
4. The method according to any previous claim, wherein the selected maintenance engineer is the closest maintenance engineer.
5. The method according to claim 4, wherein the closest maintenance engineer is the maintenance engineer having the shortest path to travel to the first location.
6. The method according to any previous claim, wherein detailed data comprises real-time data of the process control device.
7. The method according to any previous claim, further comprising presenting, by the wireless terminal, said further data when being within said distance d.
8. A data presentation control arrangement for enabling a maintenance engineer of a process control system (10) to obtain details of a process control device, the data presentation control arrangement comprising :
a engineer selecting unit (21) configured to
receive an alarm from a process control device (24), said process control device being placed at a first location (LI) of the process control system,
select a maintenance engineer for handling the alarm, the selected maintenance engineer having a wireless terminal (32) and being at a second location (L2), and send guiding data to the wireless terminal for moving from the second to the first location, a progress monitoring unit (23; 41) configured to monitor the progress of the wireless terminal in moving from the second to the first location, determine if the wireless terminal is within a distance d from the first location, and
ensure that the wireless terminal presents detailed data of the process control device if the terminal is within said distance d.
9. The data presentation control arrangement according to claim 8, wherein the engineer selecting unit (21) is configured to select a maintenance
engineer that is qualified for performing service.
10. The data presentation control arrangement according to claim 8 or 9, wherein the engineer
selecting unit (21) is configured to select an
available maintenance engineer.
11. The data presentation control arrangement according to any of claims 8 - 10, wherein the engineer selecting unit (21) is configured to select a closest maintenance engineer.
12. The data presentation control arrangement according to claim 11, wherein the closest maintenance engineer is the maintenance engineer having the
shortest path to travel to the first location.
13. The data presentation control arrangement according to any of claims 8 - 12, wherein the detailed data comprise real-time data of the process control device .
14. The data presentation control arrangement according to any of claims 8 - 13, wherein the engineer selecting unit (21) is implemented in an engineer locating server of the process control system.
15. The data presentation control arrangement according to claim 14, wherein the progress monitoring unit is implemented in the engineer locating server.
16. The data presentation control arrangement according to claim 14, the progress monitoring unit is implemented in the wireless terminal.
17. A computer program product for enabling a maintenance engineer of a process control system (10) to obtain details of a process control device (24), said computer program product being provided on a data carrier (72) comprising computer program code (74) configured to cause a data presentation control arrangement to, when said computer program code is loaded into at least one device providing the data presentation control arrangement,
receive an alarm from a process control device (24), said process control device being placed at a first location (LI) of the process control system,
select a maintenance engineer for handling the alarm, the selected maintenance engineer having a wireless terminal (32) and being at a second
location (L2 ) , send guiding data to the wireless terminal for moving from the second to the first location, monitor the progress of the wireless terminal in moving from the second to the first location,
- determine if the wireless terminal is within a
distance d from the first location, and
order the wireless terminal to present detailed data of the process control device if the terminal is within said distance d.
PCT/EP2012/070502 2012-10-16 2012-10-16 Guiding a maintenance engineer to a process control device Ceased WO2014060024A1 (en)

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GB2532848B (en) * 2014-10-03 2019-06-12 Fisher Rosemount Systems Inc Methods and apparatus to filter process control system alarms based on alarm source type and/or alarm purpose
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