Self-validated measurement systems
View Patent ↗Sensor data may be received from multiple sensors configured to sense properties of a process control system. The sensor data may include sensed values and uncertainty data corresponding to the sensed values. A new measurement associated with the process control system and corresponding uncertainty data for the new measurement may be determined based on the sensed values and uncertainty data received from the multiple sensors.
1. A method of determining operating conditions of an industrial process control system, the method comprising:
receiving first sensor data generated by multiple sensors associated with a first subsystem included in an industrial process control system, the first sensor data including, from each of the multiple sensors associated with the first subsystem, a sensed value and uncertainty data associated with the sensed value;
determining a first subsystem measurement based on the received first sensor data;
determining first uncertainty data associated with the first subsystem measurement based on the received first sensor data;
receiving second sensor data generated by multiple sensors associated with a second subsystem included in the industrial process control system, the second subsystem being different from the first subsystem and the second sensor data including, from each of the multiple sensors associated with the second subsystem, a sensed value and uncertainty data associated with the sensed value;
determining a second subsystem measurement based on the received second sensor data;
determining second uncertainty data associated with the second subsystem measurement based on the received second sensor data;
accessing the first subsystem measurement, the first uncertainty data associated with the first subsystem measurement, the second subsystem measurement, and the second uncertainty data associated with the second subsystem measurement; and
determining, using one or more processing devices, operating conditions of the industrial process control system based on the accessed first subsystem measurement, the accessed first uncertainty data associated with the first subsystem measurement, the accessed second subsystem measurement, and the accessed second uncertainty data associated with the second subsystem measurement,
wherein determining, using one or more processing devices, operating conditions of the industrial process control system based on the accessed first subsystem measurement, the accessed first uncertainty data associated with the first subsystem measurement, the accessed second subsystem measurement, and the accessed second uncertainty data associated with the second subsystem measurement comprises detecting, using one or more processing devices, discrepancies between the accessed first subsystem measurement and the accessed second subsystem measurement.
2. The method of claim 1 wherein determining operating conditions of the industrial process control system based on the accessed first subsystem measurement, the accessed first uncertainty data associated with the first subsystem measurement, the accessed second subsystem measurement, and the accessed second uncertainty data associated with the second subsystem measurement comprises determining an availability measurement for the industrial process control system.
3. The method of claim 1 wherein determining operating conditions of the industrial process control system based on the accessed first subsystem measurement, the accessed first uncertainty data associated with the first subsystem measurement, the accessed second subsystem measurement, and the accessed second uncertainty data associated with the second subsystem measurement comprises determining a measurement value for the industrial process control system and corresponding uncertainty data for the measurement value for the industrial process control system, the uncertainty data for the measurement reflecting propagated uncertainty data associated with the multiple sensors associated with the first subsystem and the multiple sensors associated with the second subsystem.
4. The method of claim 1 wherein determining the first subsystem measurement based on the received first sensor data comprises:
accessing model-based data representing a process performed by the first subsystem;
accessing historical information associated with the process performed by the first subsystem; and
determining the first subsystem measurement based on the model-based data and the historical information.
5. The method of claim 4 wherein determining the first subsystem measurement based on the model-based data and the historical information comprises:
determining that at least one of the multiple sensors associated with the first subsystem is malfunctioning; and
estimating a value for the at least one malfunctioning sensor based on the model-based data and the historical information; and
determining the first subsystem measurement based on the estimated value for the at least one malfunctioning sensor.
6. An industrial process control system comprising:
a first subsystem configured to perform a first portion of an industrial process, the first subsystem including multiple sensors;
a second subsystem configured to perform a second portion of the industrial process, the second subsystem including multiple sensors, the second subsystem being different from the first subsystem, and the second portion of the industrial process being different than the first portion of the industrial process; and
one or more processing devices configured to perform operations comprising:
receiving first sensor data generated by the multiple sensors associated with the first subsystem included in the industrial process control system, the first sensor data including, from each of the multiple sensors associated with the first subsystem, a sensed value and uncertainty data associated with the sensed value;
determining a first subsystem measurement based on the received first sensor data;
determining first uncertainty data associated with the first subsystem measurement based on the received first sensor data;
receiving second sensor data generated by the multiple sensors associated with the second subsystem included in the industrial process control system, the second sensor data including, from each of the multiple sensors associated with the second subsystem, a sensed value and uncertainty data associated with the sensed value;
determining a second subsystem measurement based on the received second sensor data;
determining second uncertainty data associated with the second subsystem measurement based on the received second sensor data;
accessing the first subsystem measurement, the first uncertainty data associated with the first subsystem measurement, the second subsystem measurement, and the second uncertainty data associated with the second subsystem measurement; and
determining operating conditions of the industrial process control system based on the accessed first subsystem measurement, the accessed first uncertainty data associated with the first subsystem measurement, the accessed second subsystem measurement, and the accessed second uncertainty data associated with the second subsystem measurement,
wherein determining operating conditions of the industrial process control system based on the accessed first subsystem measurement, the accessed first uncertainty data associated with the first subsystem measurement, the accessed second subsystem measurement, and the accessed second uncertainty data associated with the second subsystem measurement comprises detecting discrepancies between the accessed first subsystem measurement and the accessed second subsystem measurement.
7. A method of determining measurement values, the method comprising:
receiving, from a first sensor, a first sensed value corresponding to a first property of an industrial process;
receiving, from the first sensor, first uncertainty data associated with the first sensed value;
receiving, from a second sensor, a second sensed value corresponding to a second property of the industrial process, the second property of the industrial process being different than the first property of the industrial process;
receiving, from the second sensor, second uncertainty data associated with the second sensed value;
determining, for the industrial process and using one or more processing devices, a measurement and corresponding uncertainty data for the measurement based on the first sensed value, the first uncertainty data, the second sensed value, and the second uncertainty data, the measurement corresponding to a property of the industrial process that is different than at least one of the first property of the industrial process and the second property of the industrial process; and
controlling operation of the industrial process based on the determined measurement and corresponding uncertainty data,
wherein controlling operation of the industrial process based on the determined measurement and corresponding uncertainty data comprises, in the event of a fault condition, maintaining availability of the industrial process by reducing a required accuracy for a current operating range or reducing the current operating range.
8. The method of claim 7 wherein determining, for the industrial process, the measurement and corresponding uncertainty data for the measurement comprises determining, for the industrial process, a measurement that corresponds to a property of the industrial process that is different than both the first property of the industrial process and the second property of the industrial process.
9. The method of claim 7 wherein determining, for the industrial process, the measurement and corresponding uncertainty data for the measurement based on the first sensed value, the first uncertainty data, the second sensed value, and the second uncertainty data comprises:
accessing model-based data representing the industrial process for which the measurement is being determined; and
computing the measurement and uncertainty data based on the accessed model-based data representing the industrial process for which the measurement is being determined.
10. The method of claim 9 wherein:
computing the measurement and uncertainty data based on the accessed model-based data representing the industrial process for which the measurement is being determined comprises computing the measurement by applying the first sensed value and second sensed value to a theoretical model representing the industrial process.
11. The method of claim 7 further comprising:
determining, based on the second sensed value and the second uncertainty data, that the second sensor is malfunctioning, wherein
determining, for the industrial process, the measurement and corresponding uncertainty data for the measurement based on the first sensed value, the first uncertainty data, the second sensed value, and the second uncertainty data comprises:
accessing model-based data representing the industrial process for which the measurement is being determined,
determining an estimated value for the second property based on the accessed model-based data;
determining uncertainty data associated with the estimated value for the second property based on the accessed model-based data; and
determining, for the industrial process, the measurement and corresponding uncertainty data for the measurement based on the estimated value for the second property and the uncertainty data associated with the estimated value for the second property.
12. The method of claim 7 wherein determining, for the industrial process, the measurement and corresponding uncertainty data for the measurement based on the first sensed value, the first uncertainty data, the second sensed value, and the second uncertainty data comprises:
accessing historical information associated with the industrial process for which the measurement is being determined; and
determining, for the industrial process, the measurement and corresponding uncertainty data for the measurement based on the accessed historical information.
13. The method of claim 12 wherein accessing historical information associated with the industrial process for which the measurement is being determined comprises accessing data including past values sensed by the first sensor and the second sensor during operation of the industrial process.
14. The method of claim 12 further comprising:
determining, based on the second sensed value and the second uncertainty data, that the second sensor is malfunctioning, wherein
determining, for the industrial process, the measurement and corresponding uncertainty data for the measurement based on the accessed historical information comprises:
determining an estimated value for the second property based on the accessed historical information;
determining uncertainty data associated with the estimated value for the second property; and
determining, for the industrial process, the measurement and corresponding uncertainty data for the measurement based on the estimated value for the second property and the uncertainty data associated with the estimated value for the second property.
15. The method of claim 7 wherein:
receiving, from the first sensor, first uncertainty data associated with the first sensed value comprises receiving data indicating an accuracy statistic associated with the first sensed value;
receiving, from the second sensor, second uncertainty data associated with the second sensed value comprises receiving data indicating an accuracy statistic associated with the second sensed value; and
determining, for the industrial process, a measurement and corresponding uncertainty data for the measurement based on the first sensed value, the first uncertainty data, the second sensed value, and the second uncertainty data comprises determining a measurement and corresponding accuracy statistic for the measurement.
16. The method of claim 7 wherein:
receiving, from the first sensor, first uncertainty data associated with the first sensed value comprises receiving data indicating an operating status of the first sensor;
receiving, from the second sensor, second uncertainty data associated with the second sensed value comprises receiving data indicating an operating status of the second sensor; and
determining, for the industrial process, a measurement and corresponding uncertainty data for the measurement based on the first sensed value, the first uncertainty data, the second sensed value, and the second uncertainty data comprises determining a measurement and corresponding data indicating an operating status of the resulting measurement of the industrial process.
17. The method of claim 16 wherein:
receiving data indicating an operating status of the first sensor comprises receiving data indicating whether the first sensor is operating correctly, is partially operating correctly, or is not operating correctly;
receiving data indicating an operating status of the second sensor comprises receiving data indicating whether the second sensor is operating correctly, is partially operating correctly, or is not operating correctly;
determining a measurement and corresponding data indicating an operating status of the industrial process comprises determining whether the resulting measurement of the industrial process is operating correctly, is partially operating correctly, or is not operating correctly based on the data indicating whether the first sensor is operating correctly, is partially operating correctly, or is not operating correctly and the data indicating whether the second sensor is operating correctly, is partially operating correctly, or is not operating correctly.
18. The method of claim 7 further comprising:
accessing model-based data representing the industrial process;
accessing historical information associated with the industrial process; and
validating the first sensed value and the second sensed value based on the accessed model-based data and the accessed historical information.
19. The method of claim 7 wherein:
receiving, from the first sensor, the first sensed value corresponding to the first property of the industrial process comprises receiving, from one of a temperature sensor, a pressure sensor, a level sensor, or a flow meter, a sensed value corresponding to one of a temperature, a pressure, a level, or a totalized flow quantity of liquid in a custody transfer process; and
receiving, from the second sensor, the second sensed value corresponding to the second property of the industrial process comprises receiving, from one of a temperature sensor, a pressure sensor, a level sensor, or a flow meter, a sensed value corresponding to one of a temperature, a pressure, a level, or a totalized flow quantity of liquid in the custody transfer process.
20. A method of determining measurement values, the method comprising:
receiving, from a first sensor, a first sensed value corresponding to a first property of an industrial process;
receiving, from the first sensor, first data indicating an accuracy statistic associated with the first sensed value;
receiving, from a second sensor, a second sensed value corresponding to a second property of the industrial process, the second property of the industrial process being different than the first property of the industrial process;
receiving, from the second sensor, second data indicating an accuracy statistic associated with the second sensed value; and
determining, for the industrial process and using one or more processing devices, a measurement and corresponding accuracy statistic for the measurement based on the first sensed value, the first data, the second sensed value, and the second data, the measurement corresponding to a property of the industrial process that is different than at least one of the first property of the industrial process and the second property of the industrial process,
wherein the first sensed value corresponding to the first property of the industrial process is related to the second sensed value corresponding to the second property of the industrial process; and
wherein determining a measurement and corresponding accuracy statistic for the measurement comprises determining an accuracy statistic for the measurement indicating that the measurement is more accurate than the first sensed value and the second sensed value.
21. A method of determining measurement values, the method comprising:
receiving, from a first sensor, a first sensed value corresponding to a first property of an industrial process;
receiving, from the first sensor, first data indicating an accuracy statistic associated with the first sensed value;
receiving, from a second sensor, a second sensed value corresponding to a second property of the industrial process, the second property of the industrial process being different than the first property of the industrial process;
receiving, from the second sensor, second data indicating an accuracy statistic associated with the second sensed value; and
determining, for the industrial process and using one or more processing devices, a measurement and corresponding accuracy statistic for the measurement based on the first sensed value, the first data, the second sensed value, and the second data, the measurement corresponding to a property of the industrial process that is different than at least one of the first property of the industrial process and the second property of the industrial process,
wherein determining a measurement and corresponding accuracy statistic for the measurement comprises:
accessing model-based data representing the industrial process for which the measurement is being determined;
adjusting the accuracy statistic associated with the first sensed value based on the model-based data;
adjusting the accuracy statistic associated with the second sensed value based on the model-based data;
determining an accuracy statistic for the measurement based on the adjusted accuracy statistic associated with the first sensed value and the adjusted accuracy statistic associated with the second sensed value.
22. The method of claim 21 wherein adjusting the accuracy statistic associated with the first sensed value based on the model-based data comprises:
determining a value for at least one property that influences the accuracy of the first sensor; and
adjusting the accuracy statistic associated with the first sensed value based on the value for at least one property that influences the accuracy of the first sensor and the model-based data.
23. A system for determining measurement values, the system comprising:
a first sensor configured to sense a first property of an industrial process;
a second sensor configured to sense a second property of the industrial process, the second property of the industrial process being different than the first property of the industrial process; and
one or more processing devices configured to perform operations comprising:
receiving, from a first sensor, a first sensed value corresponding to a first property of an industrial process;
receiving, from the first sensor, first uncertainty data associated with the first sensed value;
receiving, from a second sensor, a second sensed value corresponding to a second property of the industrial process, the second property of the industrial process being different than the first property of the industrial process;
receiving, from the second sensor, second uncertainty data associated with the second sensed value;
determining, for the industrial process, a measurement and corresponding uncertainty data for the measurement based on the first sensed value, the first uncertainty data, the second sensed value, and the second uncertainty data, the measurement corresponding to a property of the industrial process that is different than at least one of the first property of the industrial process and the second property of the industrial process; and
controlling operation of the industrial process based on the determined measurement and corresponding uncertainty data,
wherein controlling operation of the industrial process based on the determined measurement and corresponding uncertainty data comprises, in the event of a fault condition, maintaining availability of the industrial process by reducing a required accuracy for a current operating range or reducing the current operating range.
24. A system for determining measurement values, the system comprising:
a first sensor configured to sense a first property of an industrial process;
a second sensor configured to sense a second property of the industrial process, the second property of the industrial process being different than the first property of the industrial process; and
one or more processing devices configured to perform operations comprising:
receiving, from a first sensor, a first sensed value corresponding to a first property of an industrial process;
receiving, from the first sensor, first data indicating an accuracy statistic associated with the first sensed value;
receiving, from a second sensor, a second sensed value corresponding to a second property of the industrial process, the second property of the industrial process being different than the first property of the industrial process;
receiving, from the second sensor, second data indicating an accuracy statistic associated with the second sensed value; and
determining, for the industrial process, a measurement and corresponding accuracy statistic for the measurement based on the first sensed value, the first data, the second sensed value, and the second data, the measurement corresponding to a property of the industrial process that is different than at least one of the first property of the industrial process and the second property of the industrial process,
wherein the first sensed value corresponding to the first property of the industrial process is related to the second sensed value corresponding to the second property of the industrial process; and
wherein determining a measurement and corresponding accuracy statistic for the measurement comprises determining an accuracy statistic for the measurement indicating that the measurement is more accurate than the first sensed value and the second sensed value.
25. A system for determining measurement values, the system comprising:
a first sensor configured to sense a first property of an industrial process;
a second sensor configured to sense a second property of the industrial process, the second property of the industrial process being different than the first property of the industrial process; and
one or more processing devices configured to perform operations comprising:
receiving, from a first sensor, a first sensed value corresponding to a first property of an industrial process;
receiving, from the first sensor, first data indicating an accuracy statistic associated with the first sensed value;
receiving, from a second sensor, a second sensed value corresponding to a second property of the industrial process, the second property of the industrial process being different than the first property of the industrial process;
receiving, from the second sensor, second data indicating an accuracy statistic associated with the second sensed value; and
determining, for the industrial process, a measurement and corresponding accuracy statistic for the measurement based on the first sensed value, the first data, the second sensed value, and the second data, the measurement corresponding to a property of the industrial process that is different than at least one of the first property of the industrial process and the second property of the industrial process,
wherein determining a measurement and corresponding accuracy statistic for the measurement comprises:
accessing model-based data representing the industrial process for which the measurement is being determined;
adjusting the accuracy statistic associated with the first sensed value based on the model-based data;
adjusting the accuracy statistic associated with the second sensed value based on the model-based data;
determining an accuracy statistic for the measurement based on the adjusted accuracy statistic associated with the first sensed value and the adjusted accuracy statistic associated with the second sensed value.
26. The system of claim 25 wherein adjusting the accuracy statistic associated with the first sensed value based on the model-based data comprises:
determining a value for at least one property that influences the accuracy of the first sensor; and
adjusting the accuracy statistic associated with the first sensed value based on the value for at least one property that influences the accuracy of the first sensor and the model-based data.