WO2013170871A1

WO2013170871A1 - Method and industrial control system for industrial process equipment maintenance

Info

Publication number: WO2013170871A1
Application number: PCT/EP2012/058882
Authority: WO
Inventors: Jonas BRÖNMARK; Martin Olausson; Elina Vartiainen
Original assignee: Abb Research Ltd
Priority date: 2012-05-14
Filing date: 2012-05-14
Publication date: 2013-11-21

Abstract

It is presented a method for facilitating the maintenance of a process component of an industrial process. The method comprises receiving (S1), from a mobile terminal, a process component image of a process component and identification data (marker, QR code or barcode) of the process component, comparing (S2) the identification data with identification data of process components included in process graphics representing the industrial process, associating (S3) the process component image with a process component of the process graphics that matches the identification data, and displaying (S4) the process component image together with the process component of the process graphic in the process graphics. A computer program product and an industrial control system are also presented herein.

Description

METHOD AND INDUSTRIAL CONTROL SYSTEM FOR

INDUSTRIAL PROCESS EQUIPMENT MAINTENANCE

TECHNICAL FIELD

The present disclosure generally relates to industrial process maintenance and in particular to a method and an industrial control system for facilitating maintenance operations of process

components of an industrial process.

BACKGROUND

Industrial processes in fields such as pulp and paper, oil and gas, heat and power generation, and the chemical industry generally comprise a plurality of process components, i .e. process

equipment, for carrying out the various process steps.

Typically, one or more operators supervise the industrial process, for example in an operator room, by means of monitoring displays and controllers. In case of maintenance work of a process

component is necessary, the operator may send a maintenance engineer to the process component to carry out the maintenance work. WO2008067236 discloses a portable asset inspection device for inspection of assets in a processing environment. Assets include valves, motors, pipes, gauges, vessels etc. The portable asset inspection device has a camera for taking photographs of assets being inspected. Collected data can be transmitted in either real- time or non-real time to an external system. The external system could associate photographs with specific assets, such as by automatically storing the data in records associated with the correct asset. However, there is still a need to simplify maintenance work of process components of an industrial process. SUMMARY

In view of the above, a general object of the present disclosure is to provide a method and an industrial control system that

facilitates maintenance operations of process components in an industrial process. In particular, it would be desirable to improve the communication between an operator and a maintenance engineer during maintenance work.

Hence, according to a first aspect of the present disclosure there is provided a method for facilitating the maintenance of a process component of an industrial process, wherein the method

comprises: receiving, from a mobile terminal, a process component image of a process component and identification data of the process component; comparing the identification data with identification data of process components included in process graphics representing the industrial process; associating the process component image with a process component of the process graphics that matches the identification data associated with the process component image; and displaying the process component image together with the process component of the process graphic in the process graphics.

By associating a process component image, sent from a mobile terminal and taken on-site, with the corresponding process component in the process graphics and by displaying the process component image together with the process component of the process graphics in the process graphics, an operator in the control room viewing the process graphics can communicate efficiently regarding maintenance matters with a maintenance engineer located by that specific process component on-site. In particular, an operator, who may possess special or complementary

knowledge of the process components with respect to that of the maintenance engineer, may be able to assist/help the maintenance engineer during maintenance work. Especially, the operator, who typically does not have the knowledge of how a process component displayed in the process graphics looks like in reality, can be certain that the process component image displayed in the process graphics is an image of the actual process component subject to maintenance by the maintenance engineer. Thereby the risk of the operator on one hand discussing maintenance of a first process component and the maintenance engineer on the other hand discussing the maintenance of a second process component, can be eliminated. Hence, more efficient maintenance work may be provided. Moreover, if a process component is replaced by another process component or if a part of a process component is replaced, the operator can be ensured of that the latest version of the process component in question is displayed in the process graphics when discussing the matter with a maintenance engineer on-site. Hence, the present disclosure provides means for automatic update and display of process components in an industrial process.

One embodiment comprises, prior to displaying the process component image, receiving a user selection of the process component in the process graphics associated with the process component image. Thus, the process component image can be displayed upon request by an operator so as not to obscure the view of the process graphics when not necessary.

One embodiment comprises indicating in the process graphics that the step of associating has been carried out. Thereby, an operator will become aware of each time when a process component image has been associated with a process component of the process graphics.

According to one embodiment the identification data of the process component is embedded into the process component image. The process component image may for example include a barcode such as a matrix code for identification purposes of the process component in the process component image.

One embodiment comprises processing the process component image to thereby obtain the identification data of the process component. For example, if the identification data is contained in a barcode included in the process component image, the barcode can be processed so as to obtain the identification data to thereby identify the process component of the process component image. One embodiment comprises sending process component data relating to that process component which is depicted in the process component image to the mobile terminal. The mobile terminal may thereby be able to display the process component data to the maintenance engineer. Such process component data may for example be process variable values associated with the process component.

According to one embodiment the process component image comprises identification data of several process components of the industrial process. Thus, a process component image may depict several process components.

According to one embodiment the step of associating comprises associating the process component image with each process component of the process graphics that matches the identification data of the process component image. Hence, if for example several process components are depicted in the same process component image, each depicted process component having a unique identifier i.e. unique identification data, that process component image may be associated with each process component of the process graphics depicted in the process component image.

According to a second aspect of the present disclosure there is provided a computer program product comprising computer- executable components for causing a device to perform the steps according to the first aspect presented herein when the computer- executable components are run on a processor included in the device.

According to a third aspect of the present disclosure, there is provided an industrial control system for facilitating the

maintenance of a process component of an industrial process, wherein the industrial control system comprises: a memory arranged to store identification data of process components included in process graphics representing the industrial process; a processor arranged to receive, from a mobile terminal, a process component image of a process component and identification data of the process component, wherein the processor is arranged to compare identification data received from the mobile terminal with the identification data stored in the memory, and wherein the processor is arranged to associate the process component image with a process component of the process graphics that matches the identification data associated with the process component image; and a display device arranged to display the process component image together with its associated process component of the process graphic in the process graphics. According to one embodiment the display device is arranged to indicate in the process graphics that a process component image has been associated with a process component in the memory.

According to one embodiment the identification data of the process component is embedded into the process component image.

According to one embodiment the processor is arranged to send process component data relating to that process component which is depicted in the process component image to the mobile terminal.

According to one embodiment the process component image comprises identification data of several process components of the industrial process.

According to one embodiment the processor is arranged to associate the process component image with each process

component of the process graphics that matches the identification data of the process component image.

Generally, all terms used in the claims are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein. All references to "a/an/the element, apparatus, component, means, etc. are to be interpreted openly as referring to at least one instance of the element, apparatus, component, means, etc., unless explicitly stated otherwise. Moreover, any step in a method need not necessarily have to be carried out in the presented order, unless explicitly stated otherwise. BRIEF DESCRIPTION OF THE DRAWINGS

The specific embodiments of the inventive concept will now be described, by way of example, with reference to the accompanying drawings, in which : Fig. 1 is a schematic diagram of an industrial process and a therewith associated industrial control system;

Fig. 2 depicts a mobile terminal for facilitating maintenance work in an industrial process;

Fig. 3a is a schematic view of a maintenance engineer using the mobile terminal in Fig. 2 in an industrial process environment;

Fig. 3b is a front view of a display device displaying process graphics including a process component image; and

Fig. 4 is a flowchart of a method for facilitating the maintenance of a process component of an industrial process. DETAILED DESCRIPTION

The inventive concept will now be described more fully hereinafter with reference to the accompanying drawings, in which

exemplifying embodiments are shown. The inventive concept may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of example so that this disclosure will be thorough and complete, and will fully convey the scope of the inventive concept to those skilled in the art. Like numbers refer to like elements throughout the description. Fig. 1 schematically shows an example of an industrial process 3, and an industrial control system 1 for monitoring and controlling the industrial process 3. The industrial process 3 usually involves various process steps carried out by one or more process

component 5-A, 5-B, 5-C and 5-D. The process flow according to the example of Fig. 1 is in a direction from left to right, as indicated by arrows A. The industrial control system 1 may, for example, be a distributed industrial control system (DCS). The industrial control system may also be of supervisory control and data acquisition (SCADA) type or a combination of SCADA and DCS. An example of an industrial control system in this context is the ABB® 800xA control system.

An industrial process is to be understood to mean a procedure that involves chemical, electrical or mechanical steps to aid in

manufacturing, production, power generation, fabrication, or refining. Examples of such industrial processes are processes relating to the refining of oil and gas, the petrochemical industry, power generation, power transmission, power distribution, metals and mining, chemical industry, pulp and paper, or automation in e.g. the manufacturing industry or food industry. It is to be noted that the present inventive concept can be utilised for maintenance of many different types of industrial processes, with only a few examples having been given above.

A process component may for instance be a tank, a valve, a turbine, a roller or a cluster or rollers for a pulp and paper mill, drying equipment, a refiner, a generator, a motor, a transformer or a boiler.

According to the present disclosure, each process component 5-A, 5-B, 5-C, 5-D of the industrial process 3 is provided with an identifier arranged to enable identification of the process

components to which it is attached by means of a device such as a mobile terminal. Such an identifier may for example be a visual identifier, e.g. a barcode. The barcode may for example be a matrix barcode such as a Quick Response (QR) code. By capturing the process component, including the visual identifier, by means of a camera of the mobile terminal, the captured process component may be identified by means of identification data embedded in the visual identifier in the process component image.

The proper functioning of process components is typically the responsibility of one or more operators and maintenance engineers supervising the industrial process via an industrial control system for example in a control room. To that end, the industrial control system 1 may comprise a plurality of control units 7-1, 7-2, 7-3, 7- 4 such as Remote Terminal Units (RTU) or Programmable Logic Controllers (PLC), and a plurality of sensors 9-1, 9-2, 9-3, 9-4 associated with a respective control unit 7-1, 7-2, 7-3, 7-4.

Alternatively, several sensors may be associated with each control unit. Each sensor may be comprised in a respective control unit, or the control units and sensors may be physically separate units. Each sensor 9-1, 9-2, 9-3, 9-4 of the plurality of sensors is arranged to measure one or more process variable(s) of a process component 5-A, 5-B, 5-C, 5-D. The control units 7-1, 7-2, 7-3, 7-4 are arranged to control a process component 5-A, 5-B, 5-C, 5-D according to a respective setpoint value which can be set by means of the industrial control system 1. A process variable is to be construed as a measurable quantity, such as pressure, temperature or voltage, associated with a process component.

The exemplified industrial control system 1 of Fig. 1 further comprises a communications network N, a data communications unit 11 connectable to the communications network N and which provides an interface between the industrial process 3 and an operator supervising the industrial process 3, a display device 15 and an input unit 13. The communications unit 11 comprises a processor 10, and a memory 12.

The communications network N may be a wireless system, or a combination of a wired and wireless system. The communications network N is arranged to enable data communication between the control units 7-1, 7-2, 7-3, 7-4 and the data communications unit 11.

The data communications unit 11 is connectable to the input unit 13. The input unit 13 can for example be a keyboard, mouse or a touch screen. The input unit 13 is arranged to receive input commands from a user of the industrial control system 1, e.g. a process operator.

Fig. 2 is a schematic diagram of a mobile terminal 17 arranged for wireless communication, for example with the communications network N. The mobile terminal 17 is arranged to be used for maintenance operations of process components of an industrial process.

The mobile terminal 17 comprises a camera 19 for capturing process component images of process components of the industrial process. The camera 19 can capture the image of a process component, wherein the process component image can be sent to the communications unit 11 via the communications network N. The mobile terminal 17 may also have a display for displaying process component data received from the industrial control system 1. The mobile terminal 17 may be a dedicated mobile terminal especially manufactured for the purpose of use in an industrial process. Alternatively, the mobile terminal may for example be a smart phone or a tablet computer. Methods of facilitating the maintenance of process components in an industrial process will now be described in more detail with reference to Figs 3a-b and Fig. 4.

As shown in Fig. 3a, a maintenance engineer 21 carrying a mobile terminal 17 may approach a process component, for example process component 5-A. The process component 5-A is provided with a visual identifier 23. The maintenance engineer 21 uses the mobile terminal 17 to capture an image of the process component 5-A. Preferably, the process component image is taken such that also the visual identifier 23 is included in the process component image. Thus, the captured process component image comprises the process component image and identification data of the captured process component, the identification data being included in the visual identifier in the process component image.

According to one variation of the method, the process component image is processed by the mobile terminal such that the

identification data is extracted from the visual identifier in the process component image, wherein the process component image and the extracted identification data are automatically sent by the mobile terminal 17 to the industrial control system 1. Alternatively, the process component image may be automatically sent, when captured, to the industrial control system 1, without processing of the visual identifier in the process component image. Even thought the process component image has not been processed so as to extract the identification data from the visual identifier, the identification data is embedded in the depicted visual identifier and thus in the process component image.

Referring now to Fig. 4, in a step SI the process component image and identification data pertaining to the visual identifier 23 in the process component image are received by the industrial control system 1, for example by the communications unit 11.

According to one variation of the method, for example if the process component image has not been processed in the mobile terminal 17, the process component image is processed by the processor 10 of the communications unit 11 to thereby obtain the identification data of the process component from the process component image. The identification data is thus extracted from the visual identifier in the process component image. The process component image may comprise identification data of several process components of the industrial process. This can for example be the case if several process components and their respective visual identifiers are depicted in the process component image. In a step S2, the processor 10 compares the identification data received from the mobile terminal with the identification data of process components included in process graphics representing the industrial process stored in the memory 12.

In a step S3, the process component image is by means of the processor 10 associated with a process component of the process graphics that matches the identification data associated with the process component image. If several process components are depicted in the process component image, each with unique identification data, the step S3 of associating, according to one variation of the method, comprises associating the process component image with each process component of the process graphics that matches the identification data of the process component image.

According to one embodiment, it is indicated in the process graphics that the step S3 of associating has been carried out. The indication can for example be made by visual indication in the form of highlighting of the process component in the process graphics which has been associated with the process component image.

In a step S4, the process component image is displayed on the display device 15 together with the process component of the process graphic in the process graphics. Fig. 3b depicts a front view of the display device 15 displaying a portion of process graphics G. A representation 5'-A of process component 5-A is shown in the process graphics G. Moreover, the process component image 5"- A of the process component 5'-A in the process graphics G is shown on the display device 15. An operator can thereby study the process component image 5"-A while being certain that the displayed process component image 5"-A is a depiction of the actual process component 5-A which is to be subject to maintenance work by a maintenance engineer.

According to one embodiment, a user selection of that process component in the process graphics which is associated with the process component image is received in a step S3-1 by the processor 10 from the input unit 13 prior to the step S4 of displaying the process component image, wherein the step S4 of displaying is carried out in response to receiving the user selection. Thus, an operator may select a process component in the process graphics, wherein the therewith associated process component image is displayed on the display device 15. Thus, the process component image 5"-A will only be displayed upon user request.

According to one embodiment, the processor 10 may send process component data relating to that process component which is depicted in the process component image to the mobile terminal. Hereto, the mobile terminal 17 may be arranged to receive and display the process component data. A maintenance engineer may thereby be able view the process component data which relates to the process component and which is to be subject to maintenance work.

The inventive concept has mainly been described above with reference to a few examples. However, as is readily appreciated by a person skilled in the art, other embodiments than the ones disclosed above are equally possible within the scope of the inventive concept, as defined by the appended claims.

Claims

1. A method for facilitating the maintenance of a process

component (5-A, 5-B, 5-C, 5-D) of an industrial process (3), wherein the method comprises: Receiving (SI), from a mobile terminal (17), a process

component image (5"-A) of a process component (5-A) and identification data of the process component (5-A), comparing (S2) the identification data with identification data of process components (5-A, 5-B, 5-C, 5-D) included in process graphics (G) representing the industrial process (3), associating (S3) the process component image (5"-A) with a process component (5'-A) of the process graphics (G) that matches the identification data associated with the process component image (5"-A), and displaying (S-4) the process component image (5"-A) together with the process component (5'-A) of the process graphic in the process graphics (G).

2. The method as claimed in claim 1, comprising, prior to

displaying the process component image, receiving (S3-1) a user selection of the process component (5'-A) in the process graphics (G) associated with the process component image (5"-A).

3. The method as claimed in claim 1 or 2, comprising indicating in the process graphics (G) that the step of associating has been carried out.

4. The method as claimed in any of the preceding claims, wherein the identification data of the process component is embedded into the process component image.

5. The method as claimed in claim 4, comprising processing the process component image to thereby obtain the identification data of the process component.

6. The method as claimed in any of the preceding claims, comprising sending process component data relating to that process component which is depicted in the process component image to the mobile terminal (17).

7. The method as claimed in any of the preceding claims, wherein the process component image comprises identification data of several process components (5-A, 5-B, 5-C, 5-D) of the industrial process (3).

8. The method as claimed in claim 7, wherein the step of associating (S3) comprises associating the process component image with each process component of the process graphics that matches the identification data of the process component image.

9. A computer program product comprising computer-executable components for causing a device to perform the steps recited in any one of claims 1-8 when the computer-executable components are run on a processor included in the device.

10. An industrial control system (1) for facilitating the

maintenance of a process component (5-A, 5-B, 5-C, 5-D) of an industrial process (3), wherein the industrial control system (1) comprises: a memory (12) arranged to store identification data of process components (5'-A) included in process graphics (G) representing the industrial process (3), a processor (10) arranged to receive, from a mobile terminal (17), a process component image (5"-A) of a process component (5-A) and identification data of the process component (5-A), wherein the processor is arranged to compare identification data received from the mobile terminal (17) with the identification data stored in the memory (12), and wherein the processor (10) is arranged to associate the process component image (5"-A) with a process component (5'-A) of the process graphics (G) that matches the identification data associated with the process component image (5"-A), and a display device (15) arranged to display the process component image (5"-A) together with its associated process component (5'-A) of the process graphic in the process graphics (G).

11. The industrial control system (1) as claimed in claim 10, wherein the display device (15) is arranged to indicate in the process graphics (G) that a process component image (5"-A) has been associated with a process component (5'-A) in the memory (12).

12. The industrial control system (1) as claimed in claim 10 or 11, wherein the identification data of the process component (5-A) is embedded into the process component image (5"-A).

13. The industrial control system (1) as claimed in any of claims 10-12, wherein the processor (10) is arranged to send process component data relating to that process component which is depicted in the process component image to the mobile terminal (17).

14. The industrial control system (1) as claimed in any of claims 10-13, wherein the process component image comprises identification data of several process components (5-A, 5-B, 5-C, 5-D) of the industrial process.

15. The industrial control system (1) as claimed in claim 14, wherein the processor is arranged to associate the process component image with each process component of the process graphics that matches the identification data of the process component image.