Method and system of monitoring, sensor validation and predictive fault analysis

Abstract

The present invention provides an improved method and system for real-time monitoring, validation, optimization and predictive fault analysis in a process control system. The invention monitors process operations by continuously analyzing sensor measurements and providing predictive alarms using models of normal process operation and statistical parameters corresponding to normal process data, and generating secondary residual process models. The invention allows for the creation of a fault analyzer directly from linearly independent models of normal process operation, and provides for automatic generation from such process models of linearly dependent process models. Fuzzy logic is used in various fault situations to compute certainty factors to identify faults and/or validate underlying assumptions. In one aspect, the invention includes a real-time sensor data communications bridge module; a state transition logic module; a sensor validation and predictive fault analysis module; and a statistical process control module; wherein each of the modules operates simultaneously.

1 . A computer-implemented monitoring, validation and analysis system for a process control system having real-time data and process control system alarms, comprising:
 a real-time sensor data communication bridge module for collecting said real-time data;   a sensor validation and predictive fault analysis module for sensor validation and predictive fault analysis; and   a state transition logic module for determining when said sensor validation and predictive fault analysis module should operate;   wherein each of said modules operates simultaneously and interactively.   
   
   
       2 . The system as set forth in  claim 1 , further comprising:
 a statistical process control module for detecting faults independent of said sensor validation and predictive fault analysis module.   
   
   
       3 . The system as set forth in  claim 2  wherein said statistical process control module and said sensor validation and predictive fault analysis module operate concurrently on the same real-time sensor data. 
   
   
       4 . The system as set forth in  claim 2 , further comprising:
 a master module which coordinates the operation of said real-time sensor data communication bridge, said sensor validation and predictive fault analysis module, said statistical process control module and said state transition logic module.   
   
   
       5 . The system as set forth in  claim 1 , further comprising:
 an operator display module.   
   
   
       6 . The system as set forth in  claim 1 , further comprising:
 a database module.   
   
   
       7 . The system as set forth in  claim 1 , further comprising:
 a master module which coordinates the operation of said real-time sensor data communication bridge, said sensor validation and predictive fault analysis module, and said state transition logic module.   
   
   
       8 . The system as set forth in  claim 1  wherein said real-time sensor data communication bridge module interfaces with a distributed control system, a programmable logic controller or a data historian associated with said process control system. 
   
   
       9 . The system as set forth in  claim 1  wherein said sensor validation and predictive fault analysis module comprises a model compiler. 
   
   
       10 . The system as set forth in  claim 1  wherein said sensor validation and predictive fault analysis module comprises a fault analyzer. 
   
   
       11 . The system as set forth in  claim 1  wherein said sensor validation and predictive fault analysis module computes a certainty factor for a possible fault using fuzzy logic. 
   
   
       12 . The system as set forth in  claim 1  wherein said real-time sensor data communication bridge module is adapted to continuously collect real-time data for validation, fault analysis, abnormal condition analysis, monitoring and optimization. 
   
   
       13 . The system as set forth in  claim 1  wherein said sensor validation and predictive fault analysis module is adapted for validation, fault analysis, abnormal condition analysis, monitoring and optimization. 
   
   
       14 . The system as set forth in  claim 1  wherein said sensor validation and predictive fault analysis module operates independent of said process control system alarms.