GB2577860A

GB2577860A - Remote configuration of plant monitoring

Info

Publication number: GB2577860A
Application number: GB1813779.4A
Authority: GB
Inventors: Taylor Jack; Moore Steve; Roberts Lloyd
Original assignee: Spirax Sarco Ltd
Current assignee: Spirax Sarco Ltd
Priority date: 2018-08-23
Filing date: 2018-08-23
Publication date: 2020-04-15
Anticipated expiration: 2038-08-23
Also published as: WO2020038697A1; GB201813779D0; GB2577860B

Abstract

A server remote from an industrial plant defines 120 a configuration profile for connecting 134 a local data collector (eg a hub or gateway) to a monitoring device (eg a sensor) based on monitoring device data received 112 from a survey device and transmits 122 the configuration profile to the local data collector to enable the local data collector to receive a stream 136 of data from the monitoring device. The monitoring device data may include connection data, telemetry metadata, or a device identifier. The server may define or obtain a monitoring template for an operational configuration of the industrial plant. The monitoring template may be obtained from a plurality of monitoring templates based on an operator input. The server may compute a performance data associated with the industrial plant based on telemetry data received from monitoring devices and provide remote access to and display of the performance parameter.

Description

REMOTE CONFIGURATION OF PLANT MONITORING

The disclosure relates to a method of configuring a connection to a monitoring device in an industrial plant.

Industrial plants, such as manufacturing plants, chemical plants or energy plants, may comprise flow systems such as a steam or refrigerant system. By way of example, a flow system such as a steam system may typically comprise both active and passive equipment, such as steam traps, control valves, and sensors for monitoring thermodynamic properties. In particular, steam traps (or condensate drains) are typically installed to discharge condensate to prevent build-up of condensate in a flow system which may impair its proper functioning.

Steam traps, amongst other devices, may be routinely audited by manual inspection to check their status and provide information on the functional state of the flow system. For example, an audit of steam traps may identify those steam traps that are operating normally, those which are failed open or shut, and those which may be leaking.

Some installed devices may operate passively or autonomously such that there is no link with a remote station or controller, whereas other installed devices may link with a remote station or controller via a wired or wireless link, for example to report operational or status data, or receive control instructions.

According to an aspect there is provided a computer implemented method of configuring monitoring connections for an industrial plant, the method comprising: by a server remote from the industrial plant: receiving from a survey device, monitoring device data relating to a monitoring device installed in the industrial plant; defining, based on the monitoring device data, a configuration profile for connecting a local data collector to the monitoring device to receive a data stream from the device; transmitting the configuration profile for receipt by the local data collector, to enable the local data collector to connect with the monitoring device and receive a data stream from the device.

The monitoring device data received from the survey device may comprise connection data for establishing a connection with the local data connector; and telemetry metadata defining a telemetry data type of the monitoring device.

The monitoring device data received from the survey device may comprise a device identifier. The server may obtain connection data for establishing a connection with the local data connector and telemetry metadata defining a telemetry data type of the monitoring device from one or more databases based on the device identifier.

A monitoring device may be configured to output a plurality of different types of telemetry data, and the telemetry metadata may define a plurality of respective telemetry data types of the monitoring device.

For example, the telemetry data type may be a thermodynamic parameter (such as pressure, temperature, dryness, flowrate) or an operational parameter (e.g. steam trap status, such as open, closed, failed open etc.). Flow rate may be considered a thermodynamic property in that the energy flux or flow (e.g. in a circuit or any other control volume) of a fluid is dependent not only on pressure, temperature and dryness, but also on the flow rate, such as a mass flow rate.

When the server receives monitoring device data relating to a plurality of monitoring devices installed in the industrial plant; the method may further comprise the server defining a monitoring template for an operational configuration of the industrial plant based on operator inputs received specifying a plurality of telemetry data inputs; or obtaining a monitoring template for an operational configuration of the industrial plant from a database containing a plurality of monitoring templates, the monitoring template specifying a plurality of telemetry data inputs.

When the server receives monitoring device data relating to a plurality of monitoring devices installed in the monitoring plant, the server may, for each monitoring device for which data is received or for each monitoring device which is associated with a telemetry data input: define a configuration profile for connecting the local data collector to the respective monitoring device to receive a data stream from the device; and transmit the configuration profile for receipt by the local data collector.

The method may further comprise the server, for each telemetry data input of the monitoring template, associating one of the monitoring devices with the telemetry data input based on the respective telemetry metadata. The configuration profile may be defined to connect the local data connector to each monitoring device associated with the telemetry data inputs to receive respective data streams from the monitoring devices.

The method may further comprise the server receiving an operator input specifying an operational aspect of the industrial plant, wherein the monitoring template is selectively obtained from the plurality of monitoring templates based on the operator input.

The method may further comprise the server, for at least one of the telemetry data inputs of the monitoring template, identifying one or more monitoring devices for association with the telemetry data input based on the telemetry metadata relating to the monitoring device.

The method may further comprise the server associating one of a plurality of identified monitoring devices with the telemetry data input of the monitoring template based on an operator selection from the plurality of identified monitoring devices.

The server may computer performance data associated with the industrial plant based on telemetry data received from at least two monitoring devices associated with respective telemetry data inputs of the monitoring template. The server may provide for remote access and display of the performance parameter.

The server may generate a monitoring interface for remote access and display of output data based on the telemetry data, the monitoring interface being generated based on a telemetry display template associated with the monitoring template.

A plurality of telemetry display templates may be stored in a database and correlated to respective monitoring templates. Telemetry display templates may be directly associated with respective monitoring templates, for example by being stored together with them for simultaneous retrieval, or by being defined within the monitoring template.

The telemetry display template may be configured to generate a monitoring interface comprising a plurality of telemetry display elements, and each telemetry display element may be configured to display: telemetry data associated with one or more telemetry data inputs of the monitoring template; or performance data associated with the industrial plant, computed based on telemetry data received from one or more monitoring devices associated with respective telemetry data inputs of the monitoring template.

The method may further comprise a display device remotely accessing the server and displaying the output data in the monitoring interface.

The survey device may receive input data relating to installed devices and transmit installed device data to the server based on the input data. The installed device data may comprise audit data relating to one or more non-transmitting devices; and the monitoring device data relating to the or each monitoring device which is configured to transmit a data stream.

The method may comprise the local data collector: receiving the or each configuration profile from the server for connecting to the or each respective monitoring device; and connecting with the or each monitoring device based on the respective configuration profile to receive a respective data stream from the monitoring device.

The method may further comprise the local data collector receiving a data stream from the or each monitoring device to which it has been connected, and transmitting the data stream to the server.

According to a second aspect there is provided a server comprising: a processor and a memory storing instructions to cause the processor to carry out server actions of a method in accordance with the first aspect.

According to a third aspect there is provided a computer program comprising instructions to cause a server to carry out server actions of a method in accordance with the first aspect.

According to a fourth aspect there is provided a non-transitory computer-readable medium storing a computer program in accordance with the third aspect.

The invention may comprise any combination of the above features, except such features as are mutually exclusive.

The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figures 1 and 2 schematically show an example industrial plant; Figure 3 schematically shows a portion of a flow circuit of the industrial plant including a boiler; Figure 4 is a flow diagram showing a method of configuring monitoring connections and monitoring plant operation Figure 5 is an example of an operator interface for associating monitoring devices with telemetry data inputs for monitoring; and Figure 6 is an example telemetry display template; Figure 1 schematically shows an example industrial plant 10 comprising a flow system, which in this particular example is steam oven circuit. The steam oven circuit comprises a boiler 12 and a steam oven 14. In use, dry steam is generated at the boiler 12 and flows to the steam oven 14 for use. Wet steam exits the steam oven 14 and is recirculated to the boiler 12 for re-heating.

A plurality of monitoring devices are distributed around the steam oven circuit. In this particular example, a steam temperature sensor 16 is provided at the boiler; a flow meter 18 is provided in a steam supply line to the steam oven; an oven temperature sensor 20 is provided within the steam oven 14; and a temperature sensor 22 is provided in a recirculation line extending from the steam oven 14 to the boiler 12.

Each of the monitoring devices 16, 18, 20, 22 are configured to output a data stream of telemetry data to a remote station.

In this example, a local data collector 24 is provided in the plant 10 to receive telemetry data from each of the monitoring devices. In order to receive a data stream from any of the monitoring devices, a connection must be established with each monitoring device.

In known installations, physical connections between a monitoring device and a monitoring station are configured manually, for example using connection data such as a ModBus address for the monitoring device.

In this example, the local data collector 24 is remotely configured to connect (i.e. establish a communication session for data transfer) to each of the monitoring devices based on respective configuration profiles received from a remote server 26. Accordingly, the act of connecting above does not relate to the physical connection between the local data collector and each of the monitoring devices, but rather the connection to establish a communication session for data transfer. The remote server 26 generates the configuration profiles based on monitoring device data received from a survey device 28.

As shown in Figure 1, in this example a survey device 28 is provided which an operator may use to log device information when touring the industrial plant.

In this example, an operator may conduct an audit of installed devices in the industrial plant by touring the plant and recording installed device data in the survey tool (as indicated by the solid arrow in Figure 1). For non-transmitting devices, device data recorded may include device type, operational status (e.g. normal operation, failure mode) and maintenance status (e.g. "OK", in need of service). For transmitting devices such as monitoring devices configured to output a data stream of telemetry data, monitoring device data recorded may include device type; telemetry metadata such as telemetry data type (i.e. the or each type of data that is output by the device) and sampling data (e.g. frequency of data transmission); and connection data (e.g. ModBus address, IP address, communication protocol, port or channel, radio frequency). For either non-transmitting or transmitting devices, device data may include: location, operational function (i.e. the function performed by the device in use), serial number.

The operator may record installed device data using the survey device 28 by completing a template record for each device using a user interface of the survey device, for example a touch screen or keyboard of the device. In other examples, the operator may record installed device data using the survey device 28 by scanning an identifier or coded information of the respective device, for example a barcode or RFID tag.

The survey device 28 may transmit the installed device data to the server 26 continuously, periodically or on demand over a wired or wireless link.

The server 26 receives the installed device data from the survey device 28 (as illustrated by the dashed arrow from the survey device 28 to the server 26). The server 26 generates a configuration profile for connecting the data collector 24 to one or more of the monitoring devices so as to receive a respective data stream. The server 26 transmits the or each configuration profile for receipt by the local data connector (as illustrated by the dashed arrow from the server 26 to the local data collector 24), for example by a wired or wireless link.

In this example, the installed device information for each of the monitoring devices includes connection data for establishing a connection between the local data connector and the respective device, and the configuration profile is defined by the server 26 based on the connection data. For example, the configuration profile may include a ModBus address for the respective device. Optionally, the configuration profile may include sampling data defining a sampling frequency for obtaining a data stream from the respective device.

The local data collector 24 receives the configuration profiles and executes a connection procedure with each respective monitoring device 16, 18, 20, 22 based on each respective configuration profile to establish a connection between the respective monitoring device and the local data collector 24 for transmitting a respective data stream. For example, the local data collector may establish a connection with a monitoring device at a known ModBus address based on the configuration data over a specified communication channel (e.g. Ethernet) or communication protocol (e.g. TCP/IP). For example, the local data collector may establish a connection with a monitoring device at a known IP address based on the configuration data over a wired Ethernet link, and the communication protocol of Transmission Control Protocol and Internet Protocol (TCP/IP), with a communication session being initiated over a specified port number (e.g. 502). Application data is thereby retrieved from a monitoring device using Modbus TCP/IP.

Figure 2 shows data transmission in the industrial plant of Figure 1 once the local data collector 24 has been connected to each of the monitoring device 16, 18, 20, 22. Each monitoring device transmits a respective data stream of telemetry data to the local data collector 24 (as illustrated by the respective arrows in dashed lines). The local data collector 24 transmits the data streams to the server 26 for remote storage and analysis.

The local data collector 24 may re-transmit each data stream in the form it is received. Otherwise, the local data collector 24 may reconfigure the data stream, for example by down-sampling the data stream, converting the data (e.g. from one unit to another, or from an uncalibrated unit to a calibrated (such as converting a voltage output of a temperature sensor to units of °C). In this example, the local data collector 24 has a memory for storing a time history of a data stream, and for periodically transmitting portions of the time history to the server 26. Accordingly, data loss at the server 26 can be avoided despite a temporary failure in a connection between the local data collector 24 and the server 26.

As shown in Figure 2, in this example there are connections between a plurality of display devices 30 and the server 26 for accessing the telemetry data. The server 26 is configured to generate a monitoring interface to display the telemetry data and/or performance data derived from one or more telemetry data types received from the monitoring devices, as will be described in further detail below.

In some examples, a local data collector may be connected to each monitoring device for which monitoring device data is generated and transmitted by a survey device (i.e. each monitoring device surveyed by the survey device). In other examples, a local data collector may be connected to monitoring devices which are required to provide a predetermined set of inputs.

Similarly, in some examples, a monitoring interface may be generated by the server for each respective monitoring device surveyed, or the server may generate monitoring interfaces relating to particular operational aspects of an industrial plant, which may relate to particular functions, configurations or performance features of an industrial plant. For example, the server may generate a monitoring interface relating to start-up of a steam generator (boiler) in an industrial plant. Such a monitoring interface may include a plurality of interface elements configured to display particular data types that are relevant to operational control and monitoring of the respective function or configuration of a the plant. With respect to the example of start-up, interface elements may be provided for displaying data including: steam flow rate, feedwater temperature, and a rate of condensate loss through monitored steam traps.

The server may have access to a plurality of monitoring templates for monitoring various operational aspects of an industrial plant. The server may have access to a plurality of telemetry display templates which specify a layout and content of monitoring interfaces for monitoring such operational aspects of an industrial plant.

Table 'I below defines three example monitoring templates for monitoring boiler efficiency. The monitoring template specifies a plurality of telemetry data inputs, and comprises instructions for generating one or more performance outputs which are calculated based on one or more of the telemetry data inputs. Table 1 shows the telemetry data inputs and the performance output, as follows: Template ID Telemetry Data Inputs Performance Output (*mandatory inputs) 1 Fuel input energy* Boilerhouse Operational Efficiency Feedwater input energy* Steam output energy* 2 Fuel input energy* Boilerhouse Operational Efficiency Boilerhouse Condensate Return Flow Feedwater input energy* Makeup water input energy Steam output energy* 3 Fuel input energy* Boilerhouse Operational Efficiency Boilerhouse Condensate Return Flow Boiler Thermal Efficiency Feedwater input energy* Makeup water input energy Steam output energy* TDS output energy Blowdown output energy 4 Fuel input energy* Boilerhouse Operational Efficiency Make up water flow and energy Boiler Thermal Efficiency Feedwater input energy* Condensate return energy and flow Steam output energy* TDS output energy Blowdown output energy

Table 1

Monitoring devices in an industrial plant may be associated with each of the telemetry data inputs in order to receive telemetry data corresponding to each input and calculate boiler efficiency. As shown in table 1, a monitoring template may be selected dependent on the available inputs. In these examples, the minimum inputs to determine boiler efficiency (otherwise known as "Boilerhouse Operational Efficiency") are fuel input energy, feedwater input energy and makeup water input energy. These inputs are specified in template ID 1. In template ID 2, makeup water input energy is also specified, and the template is also configured to determine the condensate return mass and energy flow based on the balance of input and output energies and mass flow. In template ID 3, the TDS (total dissolved solids) output energy and the blowdown output energy are also monitored, and the template is configured to determine the boiler thermal efficiency.

Template ID 4 is similar to template ID 3, but differs in that the condensate return energy and flow (mass and energy flow) is determined as an input (instead of the makeup water input energy as in template ID 3). In template ID 4, the makeup water flow and energy is determined as an output, based on the balance of input and output energies and mass flow.

Figure 3 schematically shows a portion of an example flow circuit in an industrial plant, such as the steam oven circuit of Figures 1 and 2, including a feedwater tank 32, boiler 12 and blowdown vessel 34. The flow circuit may have a load which is provided with steam from the boiler, and which returns a recirculating flow towards the boiler. For example, the load may be a steam oven such as the steam oven 14 of Figures 1 and 21.

In use, the feedwater tank 32 receives, via a feedwater line 33, a recirculating flow from the load for supply to the boiler 12. In this example, the feedwater tank 32 also receives makeup water on demand from a makeup water supply 36 (e.g. a fresh water supply) in response to demand at the boiler.

The boiler 12 is configured to discharge steam through a steam supply line 38 for use at the load. The boiler 12 is configured to discharge blowdown water to a blowdown vessel 34. In this example the boiler receives a flow of fuel from a fuel supply 40 for combustion in the boiler to generate the steam.

The blowdown vessel is configured to cool the blowdown water and to separate a concentrate flow from the blowdown water having a high level of total dissolved solids (TDS). The blowdown vessel is configured to discharge the concentrate flow and the remaining blowdown water.

A plurality of monitoring devices are provided to monitor thermodynamic parameters associated with flows into and out of the boiler. A feedwater energy monitor 42 is provided in the feedwater line 33 to monitor a parameter relating to the thermal energy of recirculating feedwater into the feedwater tank. A makeup water energy monitor 44 is provided to monitor a parameter relating to the thermal energy of makeup water provided from the makeup water 36 supply to the feedwater tank 32. A fuel energy monitor 46 is provided to monitor a parameter relating to the thermal energy of fuel provided to the boiler. A TDS (total dissolved solids) energy monitor 48 is provided to monitor a parameter relating to the thermal energy of the concentrate flow from the blowdown vessel 34. A blowdown energy monitor 50 is provided to monitor a parameter relating to the thermal energy of the remaining (or "bottom") blowdown water discharged from the blowdown vessel 34. A steam energy monitor 52 is provided in the steam supply line 38 to monitor a parameter relating to the thermal energy of steam discharged from the boiler through the steam supply line 38.

Each of the energy monitors may be configured to monitor a plurality of different telemetry data types relating to the respective flow. For example, each energy monitor may monitor any or all of pressure, temperature, and flow rate. The energy monitor may determine an energy flow rate or an energy total (over a sampling period) relating to the energy flow of the respective fluid. Each monitor may be an energy totalizer configured to determine a total energy of the respective flow over a respective time period.

In this example, each of the monitoring devices may be configured to connect to a local data connector, for example by a wired or wireless link.

Figure 4 is a flow diagram of a method of configuring monitoring connections and monitoring plant operation. The method will be described, by way of example, with reference to the example industrial plant 10, server 26 and survey device 28 of Figures 1 and 2, and the monitoring devices and boiler equipment of the example plant as described above with reference to Figure 3.

Figure 4 shows steps of the method in three columns. The first column relates to steps performed by the survey tool 28. The central column relates to steps performed by the server 26. The third column includes some steps performed by the local data collector 24 (those within the respective box in broken lines), and a further step performed by a remote display device (as indicated by the respective box in broken lines).

In block 102, the survey device 28 receives installed device data. In this example, an operator tours the industrial plant with the survey device 28 and records installed device data relating to both non-transmitting devices and transmitting devices including each of the monitoring devices 42, 44, 46, 48, 50, 52. For example, installed device data may include device type information, location data relating to the location of a device, operational status data relating to an operational status of a device (e.g. normal operation, failure mode) and maintenance data relating to a maintenance status of the device (e.g. "OK", in need of service). For transmitting devices, the installed device data may include monitoring device data.

In this particular example, the operator records the following monitoring device data for each of the monitoring devices: a device type (e.g. "flow totalizer"), connection data (e.g. a ModBus address), a location (e.g. coordinates in the plant installation), a location descriptor (e.g. "in feedwater line feedwater tank for main boiler"), telemetry metadata specifying telemetry data types output by the monitoring device (e.g. pressure, temperature, flow rate, energy flow rate, energy totalised at a specified interval, for example 30 second intervals).

In other examples, the monitoring device data recorded for at least one of the monitoring device may include a monitoring device identifier instead of connection data, telemetry metadata and/or a device. Such data may subsequently be obtained from one or more databases by the server based on the monitoring device identifier.

In block 104, the survey device 28 transmits the installed device data, including the monitoring device data relating to the monitoring devices 42, 44, 46, 48, 50, 52 to the server. The data may be transmitted as it is recorded in the survey device 28, periodically or on demand as initiated by either the operator of the survey device, or the server 26.

The data may be transferred via a wired or wireless link. For example, the data may be transmitted over the Internet.

In block 112, the server 26 receives the installed device data from the survey device 28.

The server 26 stores the installed device data in records for each installed device. The data may be used to audit the installed devices, for example by reporting on devices in need of maintenance, and to report on the operational status of specific devices or the body of installed devices as a whole. Such an audit may be conducted based on data for both non-transmitting and transmitting devices, such as monitoring devices.

In this particular example, the server 26 is configured to specify which of the monitoring devices the local data collector is to be connected based on a monitoring template 115 obtained from a database, which may be stored at the server 26 or remote from the server 26.

In this particular example, the server 26 is configured to receive operator input specifying an operational aspect of the industrial plant which is to be monitored. For example, an operational aspect to be monitored may relate to efficiency of a steam cooking procedure, steam leakage in a start-up phase of an industrial plant, or boiler efficiency, amongst many others.

An operator may select an operational aspect of the industrial plant via a remote workstation. In this example, based on an operator input specifying a predetermined operational aspect to be monitored, the server 26 obtains a monitoring template 115 from a database of monitoring templates.

In other examples, a server may define a monitoring template based on operator input or automatically based on an analysis of monitoring device data received.

The method will be described with reference to the example boiler efficiency monitoring template described above with respect to Table 1.

In block 114, the server associates monitoring devices with each telemetry data input specified in the monitoring template. In this example, the server 26 determines, based on the telemetry metadata corresponding to each of the monitoring devices, which of the monitoring devices are configured to output telemetry data of a type corresponding to each of the telemetry data inputs specified in the monitoring template, thereby identifying candidate monitoring devices for the respective telemetry data input.

Briefly referring to Figure 5, in this example the server is configured to receive operator input specifying which of the candidate monitoring devices should be associated with the respective telemetry data input. In this particular example the operator input is received by user selection in a user interface 116 generated by the server for display at the remote workstation, for example via one or more drop-down selections 118 for each of the telemetry data inputs for which there is more than one candidate monitoring device.

Where there is only a single candidate monitoring device for a respective telemetry data input of the template, this may be automatically associated without requiring operator input.

Referring again to Figure 4, in block 120 the server defines a configuration profile for connecting to each monitoring device associated with any of the telemetry data inputs of the monitoring template 115. In other examples, the server may define a configuration profile for each of the monitoring devices for which data is received from the survey tool 28.

In this particular example, the configuration profile is defined based on the connection data of the monitoring device data received from the survey tool. For example, the configuration profile may specify a ModBus address, IP address, communication protocol, port, channel, and/or radio frequency for connecting to the respective monitoring device. The configuration profile may include further information derived from the monitoring template, for example a sampling period or reporting frequency required, which may be applied by the local data collector. For example, the local data collector, based on the configuration profile, may down-sample a data stream received from a monitoring device to a required reporting frequency, or may instruct the monitoring device to provide a data stream at the specified reporting frequency.

In block 122, the server transmits the or each configuration profile to the local data collector 24 for connecting to the respective monitoring devices, for example via a wired or wireless link (e.g. over the internet).

In block 124, the server 26 generates a monitoring interface for display of telemetry data and/or performance data calculated based on one or more telemetry data inputs, for example at least two monitoring devices In this example, the server 26 obtains a telemetry display template 125 from a database of telemetry display templates corresponding to different operational aspects of an industrial plant. For example, the database of telemetry display templates may comprise one or more templates associated with a monitoring template, such as the boiler efficiency monitoring template of the present example. A telemetry display template may be obtained by the server based on the selected monitoring template.

The monitoring interface is generated to include one or more telemetry display elements configured to display telemetry data or performance data. The monitoring interface is generated for remote display, for example by a remote display device or workstation configured to access the server.

Briefly referring to Figure 6, an example monitoring interface for the boiler efficiency monitoring template comprises four telemetry display elements. By way of example only, a first display element 126 displays performance data (i.e. a calculated output based on one or more telemetry data inputs), in particular boiler efficiency as a percentage of ideal efficiency, averaged over discrete sampling periods corresponding to a totalising period of the respective monitoring devices. In this example, the boiler efficiency is overlaid on a double-axis plot with a plot of (totalised) steam flow by mass. The first display element is at the upper left quadrant of the example display.

Counter clockwise from the first display element 126, a second display element 128 displays volumetric flow rate of fuel (gas) (telemetry data); a third display element 130 displays feedwater mass flow rate (telemetry data) and a fourth display element 132 displays a table of current telemetry data and performance data (i.e. for a current or most recent sampling period).

Referring again to Figure 4, in block 134 the local data collector 24 receives the configuration profiles from the server 26, and executes a connection procedure based on the respective configuration profiles to connect with each of the respective monitoring devices associated with the monitoring template.

In block 136, the local data collector 24 receives data streams from each of the respective monitoring devices, for example at a sampling rate as specified by in the configuration profile and set at the monitoring device by the local data collector 24. The local data collector 24 locally stores a time history of the data streams, as described above, in case of interruption in a connection between the local data collector and the server.

In block 138, the local data collector 24 uploads the data streams to the server. As mentioned above, in other examples the local data collector 24 may process (for example down-sample) a data stream as received from a monitoring device before uploading to the server.

In block 140, the server 26 receives the data streams from the local data collector 24 and stores them. In block 142, the server populates the monitoring interface with telemetry data from the data streams and/or performance data derived from the telemetry data.

In block 144, a display device, for example the remote workstation controlled by the operator, accesses the generated monitoring interface to display the telemetry data and/or performance data.

By remotely configuring a local data collector to connect to installed monitoring devices at an industrial plant remotely using respective configuration profiles transmitted from a server based on monitoring device data obtained by a survey device, the invention enables connections between monitoring devices and the local data connector to be established without manual setup at the local data connector. Accordingly, monitoring device data can be captured during a tour of the industrial plant by an operator, and connections to the respective monitoring devices can be established by remote control after completion of the tour. Where a local data collector is to be installed at the industrial plant, an operator may therefore perform a basic installation of the local data collector without any configuration of connections to monitoring devices, as such connections may be made subsequently by remotely transmitting the configuration profiles. Accordingly, a local data collector may be provided without a complex user interface for operation by an operator at the industrial plant.

A monitoring template and/or a telemetry display template may be generated after a tour of an industrial plant, for example a new display template(s) for visualisation of a particular operational aspect of an industrial plant. A monitoring template and/or a telemetry display template may be defined independently or the definition of a configuration profile by the server, or the monitoring template may define the connections which are to be made, such that the configuration profile is at least partly determined based on the monitoring template.

As the local data collector is configured remotely, monitoring templates may be updated, replaced or added to remotely, for example as new equipment and monitoring devices are installed at the industrial plant. Further, telemetry display templates may be generated remotely from the industrial plant, for example to calculate and display performance data. Accordingly, a monitoring function for an industrial plant can be upgraded without requiring local configuration of the monitoring devices or local data collector.

By capturing monitoring device data together with installed device data for non-transmitting devices, and communicating the monitoring device data to the server, the data can be captured as part of a routine audit of installed devices, and periodically updated to reflect new installations at the industrial plant.

Methods according to the invention and as described (for example with respect to the flow diagrams herein) may be executed by a computer. For example, such methods may be executed by a processor executing computer-readable instructions encoded in a non-transitory machine readable medium, such as a memory, for example a disk drive, CD-ROM or any other suitable medium. A computer program incorporating such instructions may carry out methods as described (for example with respect to the flow diagrams herein).

Claims

CLAIMS1. A computer implemented method of configuring monitoring connections for an industrial plant, the method comprising: by a server remote from the industrial plant: receiving from a survey device, monitoring device data relating to a monitoring device installed in the industrial plant; defining, based on the monitoring device data, a configuration profile for connecting a local data collector to the monitoring device to receive a data stream from the device; transmitting the configuration profile for receipt by the local data collector, to enable the local data collector to connect with the monitoring device and receive a data stream from the device.
2. A method according to claim 1, wherein the monitoring device data received from the survey device comprises: connection data for establishing a connection with the local data connector; and telemetry metadata defining a telemetry data type of the monitoring device.
3. A method according to claim 1, wherein the monitoring device data received from the survey device comprises a device identifier, and wherein the server obtains connection data for establishing a connection with the local data connector and telemetry metadata defining a telemetry data type of the monitoring device from one or more databases based on the device identifier.
4. A method according to claim 2 or 3, wherein the server receives monitoring device data relating to a plurality of monitoring devices installed in the industrial plant; the method further comprising the server: defining a monitoring template for an operational configuration of the industrial plant based on operator inputs received specifying a plurality of telemetry data inputs; or obtaining a monitoring template for an operational configuration of the industrial plant from a database containing a plurality of monitoring templates, the monitoring template specifying a plurality of telemetry data inputs.
A method according to claim 4, further comprising the server: for each telemetry data input of the monitoring template, associating one of the monitoring devices with the telemetry data input based on the respective telemetry metadata; wherein the configuration profile is defined to connect the local data connector to each monitoring device associated with the telemetry data inputs to receive respective data streams from the monitoring devices.
6. A method according to claim 5, further comprising the server: receiving an operator input specifying an operational aspect of the industrial plant, wherein the monitoring template is selectively obtained from the plurality of monitoring templates based on the operator input.
7. A method according to claim 5 or 6, further comprising the server: for at least one of the telemetry data inputs of the monitoring template, identifying one or more monitoring devices for association with the telemetry data input based on the telemetry metadata relating to the monitoring device.
8. A method according to claim 7, further comprising the server: associating one of a plurality of identified monitoring devices with the telemetry data input of the monitoring template based on an operator selection from the plurality of identified monitoring devices.
9. A method according to any of claims 5 to 8, further comprising the server: computing performance data associated with the industrial plant based on telemetry data received from at least two monitoring devices associated with respective telemetry data inputs of the monitoring template; and providing for remote access and display of the performance parameter.
10. A method according to any of claims 5 to 9, further comprising the server: generating a monitoring interface for remote access and display of output data based on the telemetry data, the monitoring interface being generated based on a telemetry display template associated with the monitoring template.
11. A method according to claim 10, wherein the telemetry display template is configured to generate a monitoring interface comprising a plurality of telemetry display elements, each telemetry display element being configured to display: telemetry data associated with one or more telemetry data inputs of the monitoring template; or performance data associated with the industrial plant, computed based on telemetry data received from one or more monitoring devices associated with respective telemetry data inputs of the monitoring template.
12. A method according to claim 10 or 11, further comprising: by a display device: remotely accessing the server and displaying the output data in the monitoring interface.
13. A method according to claim 12, comprising, by the survey device: receiving input data relating to installed devices transmitting installed device data to the server based on the input data, comprising: audit data relating to one or more non-transmitting devices; and the monitoring device data relating to the or each monitoring device, wherein the or each monitoring device is configured to transmit a data stream.
14. A method according to any preceding claim, further comprising, by the local data collector: receiving the or each configuration profile from the server for connecting to the or each respective monitoring device; and connecting with the or each monitoring device based on the respective configuration profile to receive a respective data stream from the monitoring device.
15. A method according to claim 14, further comprising the local data collector receiving a data stream from the or each monitoring device to which it has been connected, and transmitting the data stream to the server.
16. A server comprising: a processor; and a memory storing instructions to cause the processor to carry out a method in accordance with any of claims 1-11.
17. A computer program comprising instructions to cause a server to carry out a method in accordance with any of claims 1-11.
18. A non-transitory computer-readable medium storing a computer program in accordance with claim 17.