Fisher-rosemount Systems, Inc

Claudio Fayad

Mark J Nixon

Gary Keith Law

Anthony Amaro, Jr

Robert G Halgren, Iii

Peter Hartmann

John Mark Caldwell

Trevor Duncan Schleiss

Seshatre Natarajan

Sergio Diaz

Aaron Crews

Nina Golder

William McCormick

A distributed control system (DCS) of an industrial process plant includes a data center storing a plant information model that includes a description of physical components, the control framework, and the control network of the plant using a modeling language. A set of exposed APIs provides DCS applications access to the model, and to an optional generic framework of the data center which stores basic structures and functions from which the DCS may automatically generate other structures and functions to populate the model and to automatically create various applications and routines utilized during run-time operations of the DCS and plant. Upon initialization, the DCS may automatically sense the I/O types of its interface ports, detect communicatively connected physical components within the plant, and automatically populate the plant information model accordingly. The DCS may optionally automatically generate related control routines and/or I/O data delivery mechanisms, HMI routines, and the like.

Industrial process control system as a data center of an industrial process plant

A software defined (SD) process control system (SDCS) implements controller and other process control-related business logic as logical abstractions (e.g., application layer services executing in containers, VMs, etc.) decoupled from hardware and software computing platform resources. An SD networking layer of the SDCS utilizes process control-specific operating system support services to manage the usage of the computing platform resources and the creation, deletion, modifications, and networking of application layer services with devices disposed in the field environment and with other services, responsive to the requirements and needs of the business logic and dynamically changing conditions of SDCS hardware and/or software assets during run-time of the process plant (such as performance, faults, addition/deletion of hardware and/or software assets, etc.). Thus, dynamic (re-)allocation of hardware/software resources is primarily, if not entirely, and continually governed in real-time by present requirements and needs of application layer services as well as dynamically changing SDCS conditions.

Software defined process control system and methods for industrial process plants

To provide a trusted, secure, and immutable record of transactions within a process plant, techniques are described for utilizing a distributed ledger in process control systems. The distributed ledger may be maintained by nodes which receive transactions broadcasted from field devices, controllers, operator workstations, or other devices operating within the process plant. The transactions may include process plant data, such as process parameter data, product parameter data, configuration data, user interaction data, maintenance data, commissioning data, plant network data, and product tracking data. The distributed ledgers may also be utilized to execute smart contracts to allow machines such as field devices to transact by themselves without human intervention. In this manner, recorded process parameter values and product parameter values may be retrieved to verify the quality of products. Moreover, regulatory data may be recorded in response to triggering events so that regulatory agencies can review the data.

Distributed ledgers in process control systems

A hyperconverged industrial process control architecture is disclosed for controlling an industrial process within a physical process environment using a software-defined distributed control system (DCS) environment. The software-defined DCS environment may be implemented by virtualizing the hardware components of a DCS architecture on a server group to enable both software-defined process controllers and back-end DCS applications to run within the server group. This software-defined DCS network architecture reduces the hardware requirements of the process control system and reduces configuration complexity by implementing control components and higher-level components within a common environment within the server group.

Industrial control system hyperconverged architecture

A process control input/output (I/O) device provides traditional I/O support with direct physical layers or interfaces associated with traditional process control communication protocols while at the same time supporting an advanced physical layer or other IP based physical layer and the communication protocols that run on top of them. In addition, the new I/O device is able to nest protocols inside of other protocols for use when protocols, such as safety protocols, require additional handshaking, confirmations, etc. Still further, the new I/O device includes hardware configurable capabilities that enable easy configuration of a process control system that uses multiple different physical layers, including those used by traditional process control protocols such as HART and FOUNDATION Fieldbus protocols, and more advanced physical layers, including those that are used by IP-based, Ethernet based, packet based and other types of advanced communication protocols.

Integration of multiple communication physical layers and protocols in a process control input/output device

An edge gateway system securely delivers and exposes data generated by and/or related to a process plant for consumption by external systems, and includes a field-facing component that sends, to an edge-facing component of the system, a collection of data types defined based on configurations of the process plant and represented using a syntax that is native to the one or more external systems. The field-facing component streams process plant-related content data indicated by one or more interest lists to the edge-facing component, where the streamed data is expressed using the collection of data types. Each interest list may include multiple types of data (e.g., control, I/O, diagnostic, device, historical, etc.) that collectively represent a particular named entity of the plant. Accordingly, the streamed data is securely delivered and exposed, via the edge-facing component, to the external systems.

Edge gateway system with data typing for secured process plant data delivery

An edge gateway system securely delivers and exposes data generated by and/or related to a process plant for consumption by external systems, and includes an edge-facing component that receives process plant-related data from a process plant via a field-facing component of the system. The received data may comport with an exposable data type system utilizing a syntax known to the external systems. The edge-facing component stores the received data in a data lake, and mines the data lake to thereby discover relationships between stored data points. Indications of the received data and the discovered interrelationships are stored in a contextualized process plant knowledge repository, such as a graph database, that is accessible to the external systems and other systems and applications via one or more access mechanisms, which may include utilities, services, servers, and/or applications. Some of the access mechanisms allow external applications to be installed at the edge-facing component.

Edge gateway system with contextualized process plant knowledge repository

Drones (e.g., unmanned aerial vehicles, or 'UAVs') equipped with cameras and sensors may be configured to travel throughout the field environment of a process plant to monitor process plant conditions. Onboard computing devices associated with the drones control the movement of the drones through the field environment of the process plant. The onboard computing devices interface with the cameras and other sensors and communicate with user interface devices, controllers, servers and/or databases via a network. The onboard computing devices may receive drone commands from user interface devices and/or servers, or may access drone commands stored in one or more databases. The onboard computing devices may transmit data captured by the cameras and/or other sensors to UI devices, controllers, servers, etc. Accordingly, the user interface devices may display data (including live video feeds) captured by the drone cameras and/or drone sensors to an operator in a human machine interface application.

Drone-enabled operator rounds

An edge gateway system securely delivers and exposes data generated by and/or related to a process plant for consumption by external systems, and includes a field-facing component that stores interest lists indicating the particular data that is allowed to be exposed by the field-facing component. Each interest list is defined (e.g., manually and/or automatically) in accordance with an exposable data type system extracted from (in some cases, multiple different) configurations of the process plant, and may include multiple types of data (e.g., control, I/O, diagnostic, device, historical, etc.) that collectively represent a particular named entity of the plant. The field-facing component obtains the process plant-related data indicated by the interest lists, and provides the obtained field content data to an edge-facing component of the edge gateway system for exposure to external systems, for example, by streaming and/or publishing the obtained data to the edge-facing component.

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Austin, TX, United States of America

Claudio Fayad