WO2024079621A1 - Procédé pour créer et afficher une harmonie de logique de commande d'un système de sécurité et de commande de processus industriel - Google Patents

Procédé pour créer et afficher une harmonie de logique de commande d'un système de sécurité et de commande de processus industriel Download PDF

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Publication number
WO2024079621A1
WO2024079621A1 PCT/IB2023/060161 IB2023060161W WO2024079621A1 WO 2024079621 A1 WO2024079621 A1 WO 2024079621A1 IB 2023060161 W IB2023060161 W IB 2023060161W WO 2024079621 A1 WO2024079621 A1 WO 2024079621A1
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WIPO (PCT)
Prior art keywords
control
interlocks
interlock
unique
function
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PCT/IB2023/060161
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English (en)
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WO2024079621A9 (fr
Inventor
Daniele SORRESSA
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Key Solution Srl
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Publication of WO2024079621A1 publication Critical patent/WO2024079621A1/fr
Publication of WO2024079621A9 publication Critical patent/WO2024079621A9/fr

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Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • G05B19/4188—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by CIM planning or realisation
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B9/00—Safety arrangements
    • G05B9/02—Safety arrangements electric
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31469—Graphical display of process as function of detected alarm signals

Definitions

  • the present invention relates to the field of industrial control systems, and has been developed with particular regard to a process for creating and displaying a control logic hierarchy of an industrial process control and safety system.
  • Industrial control is the practical application of automatic control theory applied to the field of industrial processes.
  • control actions performed by a control process and system can be of various types, and closely linked to the type of industrial plant involved.
  • the degree of risk of the production process is to be understood as a combination of the (low, moderate, high) likelihood of potential accidental events and the level of potential consequences (minor, serious, extensive, catastrophic).
  • Process control systems such as those used in the above-mentioned plants, comprise control instrumentation consisting of a set of instruments for measuring, adjusting, and controlling the industrial process.
  • control instrumentation may comprise:
  • the measuring devices comprise an instrument installed on the plant, such as a sensor, capable of measuring a value of a parameter to be monitored.
  • the measuring device is in physical contact with a portion of the plant and measures the instantaneous value of a concerned quantity, e.g. temperature, pressure, flow, level, etc.
  • the signal measured by the sensor is transmitted to a process controller.
  • the final adjustment members usually comprise a device capable of performing a physical function (such as opening or closing a valve, increasing or decreasing a temperature, making a measurement, detecting a condition, etc.), so that one or more processes being carried out within the plant or process system can be controlled.
  • a physical function such as opening or closing a valve, increasing or decreasing a temperature, making a measurement, detecting a condition, etc.
  • Process controllers usually consist of electronic boards capable of receiving signals indicative of the process measurements made by one or more value measuring devices, and of sending control signals, via communication lines or links, to the final adjustment members based on the information received, so as to control the operation of at least a part of the plant or process system.
  • Each electronic board of a process controller, and, in some cases, of one or more of the measuring devices and final adjustment members, has stored therein, and is capable of executing, a respective process control application. For example, upon receipt of a predetermined instantaneous value from a value measuring device, the circuit board sends a predetermined control signal to a predetermined final adjustment member.
  • Each process controller can also send to and receive data from other process controllers connected to one or more different value measuring devices and/or final adjustment member.
  • a plurality of I/O devices are arranged between a process controller and one or more value measuring devices and one or more final adjustment members to enable communications, e.g. by converting electrical signals to digital values and vice versa. Communication can take place via analogue, digital or combined analogue/digital buses or via a wireless communication link or network.
  • Interlocks are functional blocks interconnected to each other, and represented as objects in a programming protocol. Each interlock carries out one or more functions within the control scheme according to a predetermined logic. Each interlock receives as input one or more pieces of information, also called causes, from one of the components of the control instrumentation, or from other interlocks within the control scheme. Each interlock outputs information or instructions, also called effects, according to the set logic, to other functional blocks within the control scheme, or to one of the components of the control instrumentation.
  • the control system is configured in such a way that the interlocks execute a predetermined logic which is set during the configuration step. For example, an interlock may be configured to automatically close a valve if a sensor, arranged upstream of the valve, detects an incorrect parameter.
  • the information from the control instrumentation is generally provided, via a communication network, to one or more hardware devices available to an operator, such as workstations, personal computers or, in general, computer devices, located in control rooms or in other locations away from the plant environment.
  • hardware devices available to an operator, such as workstations, personal computers or, in general, computer devices, located in control rooms or in other locations away from the plant environment.
  • Typical functions of an industrial process control process may be, for example, the modification of the operation of one or more control modules within process controllers or value measuring devices and final adjustment members, the display of the current process status, or the display of alarms generated by the control instrumentation.
  • control systems comprise one or more applications, stored in a non-transitory machine-readable storage medium, and executed by different devices, such as one or more workstations or computing devices.
  • a configuration application allows a user to create or modify interlocks and upload interlocks to one or more process controllers via a communication network.
  • Control systems also comprise display applications, which can be executed on one or more operator-accessible workstations. These applications receive data from the control applications via the communication network and display the data so that the operator can monitor the process.
  • a plant or process system typically includes equipment and other components, and, consequently, a set of instruments for measuring, adjusting, and controlling the industrial process, and, consequently, a plurality of interlocks, which operate in a highly interdependent manner.
  • the general object of the present invention is to solve these problems by providing a process for creating and displaying a control logic hierarchy of an industrial process control system, without modifying the already existing control logic or any other element of the control instrumentation.
  • Another object of the present invention is to solve these problems by creating a control logic starting from control instrumentation, and optionally validate or modify an already existing control logic.
  • Another object of the present invention is to provide a control system for an industrial process that is capable of making the management of the control logic and control instrumentation more efficient.
  • the Applicant has devised according to the invention, a process for creating and displaying a control logic hierarchy of an industrial process control and safety system, wherein the control and safety system comprises a control instrumentation in turn comprising a plurality of process controllers connected respectively to one or more value measuring devices, to one or more final adjustment members, and to one or more workstations via a communication network, and wherein each process controller implements one or more respective functions according to one or more interlocks of the control and safety process, one or more display and configuration applications implemented in operator workstations, wherein the process comprises the steps of:
  • FIG. 1 represents a schematic block diagram of a control system according to the present invention
  • FIG. 2 represents a first portion of a display of a hierarchy of a control logic obtained by means of the process of the present invention
  • Figure 3 represents a second portion of a display of the hierarchy of a control logic in Figure 2;
  • Figure 4 represents a third portion of a display of the hierarchy of a control logic in Figure 2.
  • a process control and safety system 1 includes one or more process controllers that receive signals indicative of process measurements, made by value measuring devices, of a parameter to be monitored.
  • the process controllers process these signals to implement a control routine and generate control signals sent to final adjustment members to control the operation of a process in the plant.
  • the signals are transmitted over wired and/or wireless process control communication networks or links.
  • the value measuring devices and/or final adjustment members communicate with the process controllers using I/O devices.
  • the process controllers, value measuring devices, final adjustment members and I/O devices can be connected to each other via wired or wireless data transmission systems.
  • Fig. 1 being a schematic representation, comprises a limited number of elements and mutual connections, but in a process control system 1 according to the present invention any number and combinations of the aforesaid elements may be present.
  • Fig. 1 shows a first process controller 10 that is connected to a plurality of value measuring devices 20 via input/output (I/O) cards 22 and a data transmission cable.
  • the process controller 10 includes a processor 24, a memory 26, and one or more process control functions, as will become clearer from the following description.
  • the process controller 10 is also connected to a plurality of final adjustment members 30 via a process control communication network 40 and a wireless gateway 42.
  • the network 40 may include one or more wired and/or wireless communication links, wherein communication, i.e. data transmission, may take place via input/output (I/O) cards 22, and may be achieved using any suitable communication protocol such as, for example, an Ethernet protocol.
  • I/O input/output
  • the process controller is also connected via a wired connection to a final adjustment member 30, and via a wireless connection also to a value measuring device 20.
  • the process controller 10 may operate to implement a process using one or more of the value measuring devices 20 and one or more of the final adjustment members 30.
  • the processor of the process controller 10 implements one or more functions according to one or more control modules, or interlocks, of the control process, which can be stored in the memory of the process controller 10.
  • the processor is configured to communicate with the value measuring devices 20 and final adjustment members 30, and with other nodes that are connected in communication to the controller 10.
  • routines and interlocks within the process control system 10 may take any form, including software and hardware. Routines and interlocks may be implemented in any desired software format, such as using object-oriented programming, ladder logic, sequential functional diagrams, function block diagrams or using any other software programming language or design algorithm.
  • the memory on which some or all control modules may be stored can be any suitable type of memory, such as random access memories (RAM) and/or read-only memories (ROM).
  • the control modules may be encoded, for example, in one or more EPROMs, EEPROMs, applicationspecific integrated circuits (ASICs) or any other hardware or firmware element.
  • the process control system 1 implements control logic using what is commonly referred to as interlocks, wherein each interlock is an object or another part (e.g. a subroutine) of a general control routine and operates in combination with other interlocks to implement process control circuits within the process control system 1 .
  • the interlocks typically execute:
  • an input function also called a cause, associated with a value measuring device, such as a sensor or other process parameter measuring device;
  • control function such as the one associated with a control routine executing a PID control, or fuzzy logic, etc.
  • an output function also called an effect, which controls the operation of some devices, such as a valve or motor, to perform some physical function within the process control system 1 .
  • the input function may be an output function of another control system interlock
  • the output function may be an input function of another control system interlock
  • Interlocks may be stored and executed by a process controller 10, usually when interlocks are used or associated with standard devices or certain types of smart devices, or they may be stored and implemented by value measuring devices 20 and/or final adjustment members 30.
  • the process control system 1 also comprises one or more operator-accessible workstations 50, which are connected to the communication network 40. Through the workstations 50, the operators can monitor the runtime operations of the process plant 1 , as well as execute any diagnostic, corrective, maintenance actions and/or other types of actions that may be required. At least some of the workstations 50 may be located in various protected areas within or near the plant. The workstations 50 may be wired or wireless computing devices.
  • the process control system 1 also comprises one or more databases 60 containing a list of the interlocks in the control system and the configurations of each interlock.
  • the database 60 may be either of the paper type or electronic type (as shown in the embodiment in Figure 1 ), and comprises one analogue or digital sheet or card for each interlock. Within each sheet or card the input functions (causes), output functions (effects) and control functions inherent to a predestined interlock are indicated.
  • the process of creating a control logic hierarchy of an industrial process control system comprises a first step wherein each interlock of the control and safety system is identified and a unique identifier is associated with each interlock.
  • the unique identifier may be a data element already defined within the database 60, or it may be associated from scratch.
  • the process comprises a second step wherein the input functions, control functions and output functions of each identified interlock are acquired.
  • the input functions, control functions and output functions of each identified interlock are acquired.
  • each identified interlock is pre-configured, e.g. already contained within the database 60, and are therefore not determined or configured by an operator at this step.
  • the first and second steps could include a digital acquisition, e.g., but not limited to, by means of an OCR method, of each interlock, and the respective input functions, control functions and output functions.
  • the causes, or input functions, of the interlocks may be output functions of the control instrumentation, or settings configured by an operator, or intermediate logic placed between the control instrumentation and the interlocks.
  • Identical causes, or input functions, that exist on different interlocks are usually referred to as “references”.
  • the process comprises a third step wherein a unique action identifier is associated to each input function and output function acquired of each identified interlock.
  • the process comprises a fourth step wherein each input function and each output function is also associated with a unique function identifier, wherein the unique function identifier of an input function is different from the unique function identifier of an output function.
  • the process comprises a fifth step wherein a logical connection between the interlocks is created by associating two unique action identifiers that are equal but with function identifiers differing from each other.
  • the process comprises a sixth step wherein a logical hierarchy between the associated interlocks is automatically generated by one or more workstations based on the logical connections between the previously created interlocks.
  • the process comprises a seventh step wherein an anomaly is identified in one of the process controllers 10 and/or in one or more of the value measuring devices 20, and/or in one or more of the final adjustment members 30.
  • An anomaly is defined as any event or piece of data that is different or deviates from a predetermined event or data stored within the control system. For example, based on a predetermined temperature range measured by a predetermined value measuring device 20, corresponding to an input function of an interlock, the control function of that interlock provides an error, anomaly or even lockout signal if the temperature value measured by the value measuring device 20 does not fall within the aforesaid predetermined range.
  • the process comprises an eighth step wherein a display of all the interlocks of the process controllers 10 and/or one or more value measuring devices 20, and/or one or more final adjustment members 30, affected by the aforesaid anomaly on the basis of the generated logical hierarchy are generated, via a workstation.
  • the process comprises a ninth step wherein a display of a bypass and/or interlock function of the process controllers 10 and/or one or more value measuring devices 20, and/or one or more final adjustment members 30 that can be activated by an operator is generated by means of a workstation. Activation of the bypass and/or interruption function generates a signal from the workstation which is sent via the communication network 40 input/output (I/O) cards 22 to the process controller alone 10 and/or to one or more value measuring devices 20 and/or to one or more final adjustment members 30.
  • the process of creating a hierarchy of a control logic of an industrial process control system may comprise some steps as an alternative to the first steps of the previous embodiment.
  • the process may in fact comprise an initial step wherein each component of the control instrumentation is identified and associated with a unique identifier.
  • the process may then comprise a second step wherein the input functions and the output functions of each identified component of the control instrumentation are acquired, and a step wherein each input function is associated also with a unique function identifier and wherein each output function is associated also with a unique function identifier.
  • the process may comprise a third subsequent step wherein two or more interlocks are defined by associating a unique output identifier of a control instrumentation component with an equal unique input function identifier of an interlock, and associating a unique input identifier of a control instrumentation component with an equal unique output function identifier of said interlock.
  • the process may comprise a fourth step wherein a unique action identifier is associated with each acquired input function and output function of each identified interlock.
  • a unique action identifier is associated with each acquired input function and output function of each identified interlock.
  • the process may comprise a further step wherein a logical connection is created between two or more interlocks is created by associating two unique action identifiers that are the same but with function identifiers differing from each other.
  • the process may comprise a subsequent step wherein a logical hierarchy between the associated interlocks is automatically generated by one or more workstations based on the logical connections between the previously created interlocks.
  • the process may comprise a further step wherein an anomaly is identified in one of the process controllers 10, and/or in one or more of the value measuring devices 20, and/or in one or more of the final adjustment members 30.
  • the process may comprise a subsequent step wherein a display of all the interlocks of the process controllers 10 and/or one or more value measuring devices 20, and/or one or more final adjustment members 30, affected by the aforesaid anomaly is generated, via a workstation, based on the generated logical hierarchy.
  • the process may comprise a further step wherein a display of a bypass and/or interlock function of the process controllers 10 and/or one or more value measuring devices 20, and/or one or more final adjustment members 30 that can be activated by an operator is generated, by means of a workstation.
  • This embodiment therefore allows a new control logic to be created from the control instrumentation, rather than relying on control logic already existing in the control system.
  • the new control logic may be used to validate or modify an already existing control logic.
  • certain components such as analogue input components, may be present in several positions of the plant, and each of them may be connected to or comprise a transmitter. It is possible that the transmitters are all the equal to each other even if the function performed by the analogue component is different.
  • Such transmitters also called “typical” transmitters, may all be associated, at a preliminary step in the process of the present invention, with a unique identifier, so that this association operation does not have to be repeated each time.
  • the process control system 1 may comprise one or more display and configuration applications 70.
  • the display application may be executed on one or more computer devices to allow an operator to view process interlocks.
  • the display application and the associated user interfaces collectively form a display system to create/configure control and/or display modules.
  • the user interfaces for the display system 70 may be implemented at the operator workstations 50, and used by operators during real-time (or “runtime”) operations of the process plant. In other embodiments, the user interfaces for the display system 70 may be installed on different workstations, on remote workstations or on portable electronic devices.
  • the display application or applications 70 provide various objects that the operator can view and control in order to control the process control system 1 (e.g., interlocks, displays of value measuring devices, final adjustment members, etc.) as discussed above.
  • interlock 100 One of these object types or classes may be an interlock 100.
  • Each instance of the display object of interlock 100 may represent a relationship between two interlocks 100, 100', or between an interlock 100 and a specific component of the control instrumentation (value measuring devices 20, process controllers 10, final adjustment members 30).
  • connection arrows also called “connectors”.
  • the hierarchy created simultaneously highlights both the component affected by the anomaly and the interlock 100 connected thereto, but also, and most importantly, all other interlocks, and any components of the control instrumentation, that are affected by that anomaly. This allows the operator to:
  • control systems also comprise a configuration system to configure the process controllers and send new configurations to the process controllers via the communication network 40.
  • One or more of these configurations can allow the process controller receiving it to automatically switch off or deactivate the control instrumentation components when affected by a detected anomaly.
  • the process of generating a hierarchy may acquire additional properties, such as hardware information of the control system.
  • properties may comprise data specifying the timing and/or order of automatic shutdown, but also timing of data transmission between one process controller and another, especially when two interacting process controllers on the same interlock are located on different process units.
  • Hardware information is understood to be, for example, information on which electronic boards of each process controller 10 a predetermined interlock logic is implemented, and also in which rack this electronic board is located and with which CPU, belonging to the workstation, it is connected.
  • the weight value of a signal can, for example, be assigned with reference to the process controllers involved in the same interlock. If an interlock comprises 3 causes, or input functions, an effect, or output signal, and a control function, the total weight of that interlock is 5. If four out of five of those functions are allocated to a first process controller 10 and the fifth function to a second process controller, it is advisable to re-configure the two process controllers so that one of them allocates all the five functions. According to a further embodiment of the present invention, it is possible to carry out maintenance operations on the control and safety system.
  • an operator is able to determine whether the exclusion of certain control functions, i.e. signals from certain components of the control instrumentation, would lead to a plant shutdown or a dangerous safety situation if, for maintenance reasons, an electronic board of a process controller 10, which also manages that signal, were replaced.
  • the function of activating and/or deactivating an interlock generates a signal from the workstation which is sent via the communication network 40 and input/output (I/O) cards 22 to the process controller 10 on which the logic of the interlock to be activated or deactivated is implemented.
  • I/O input/output

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  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
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  • Programmable Controllers (AREA)
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Abstract

La présente invention concerne un procédé pour créer et afficher une hiérarchie de logique de commande d'un système de sécurité et de commande de processus industriel, qui comprend les étapes suivantes consistant à : identifier chaque composant d'instrumentation de commande (10, 20, 30) et associer à chaque composant d'instrumentation de commande (10, 20, 30) un identifiant unique; définir au moins deux verrouillages en associant un identifiant de sortie unique d'un composant d'instrumentation de commande (10, 20, 30) à un identifiant de fonction d'entrée unique égal d'un verrouillage, et en associant un identifiant d'entrée unique d'un composant d'instrumentation de commande (10, 20, 30) à un identifiant de fonction de sortie unique égal de ce verrouillage; générer une hiérarchie logique entre les verrouillages associés sur la base des connexions logiques entre les verrouillages précédemment créés.
PCT/IB2023/060161 2022-10-13 2023-10-10 Procédé pour créer et afficher une harmonie de logique de commande d'un système de sécurité et de commande de processus industriel WO2024079621A1 (fr)

Applications Claiming Priority (2)

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IT102022000021147A IT202200021147A1 (it) 2022-10-13 2022-10-13 Procedimento di creazione e visualizzazione di una gerarchia di una logica di controllo di un sistema di controllo e sicurezza di un processo industriale
IT102022000021147 2022-10-13

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WO2024079621A9 WO2024079621A9 (fr) 2024-08-22

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170017211A1 (en) * 2015-07-14 2017-01-19 Yokogawa Engineering Asia Pte. Ltd. Systems and methods for optimizing control systems for a process environment
US20190004505A1 (en) * 2017-06-28 2019-01-03 Fisher-Rosemount Systems, Inc. Interlock chain visualization

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170017211A1 (en) * 2015-07-14 2017-01-19 Yokogawa Engineering Asia Pte. Ltd. Systems and methods for optimizing control systems for a process environment
US20190004505A1 (en) * 2017-06-28 2019-01-03 Fisher-Rosemount Systems, Inc. Interlock chain visualization

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WO2024079621A9 (fr) 2024-08-22

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