Rule set for root cause diagnostics

Abstract

A reduced rule set for identifying a root cause of an aberration in an industrial process is generated from a complete rule base. The rule base includes plurality of rules for the industrial process, and each rule comprises a condition of at least one process signal of the industrial process and a fault which corresponds to the condition of at least one process signal. Available process signals are identified. Rules are selectively removed from the rule base to produce the reduced rule set.

Description

BACKGROUND OF THE INVENTION

The present invention relates to industrial process controls and process control loops. More specifically, the invention relates to diagnostics of such loops.

Process control loops are used in process industries to control operation of a process, such as an oil refinery. A transmitter is typically part of the loop and is located in the field to measure and transmit a process variable such as pressure, flow or temperature, for example, to control room equipment. A controller such as a valve controller is also part of the process control loop and controls position of a valve based upon a control signal received over the control loop or generated internally. Other controllers control electric motors or solenoids for example. The control room equipment is also part of the process control loop such that an operator or computer in the control room is capable of monitoring the process based upon process variables received from transmitters in the field and responsively controlling the process by sending control signals to the appropriate control devices. Another process device which may be part of a control loop is a portable communicator which is capable of monitoring and transmitting process signals on the process control loop. Typically, these are used to configure devices which form the loop.

Various techniques have been used to monitor operation of process control loops and to diagnose and identify failures in the loop. However, it would also be desirable to identify the source or “root cause” of a failure, such as by identifying a particular device or component in the system which is the source of an aberration in process operation. This would provide additional information to an operator as to which device in the process needs repair or replacement.

SUMMARY OF THE INVENTION

A reduced rule set for identifying a root cause of an aberration in an industrial process is provided. To generate the reduced rule set, a rule base comprising a plurality of rules for the industrial process is used. Each rule comprises a condition of a plurality of process signals of the industrial process and a fault which corresponds to a condition of the process signals. Available process signals of the industrial process are identified. Rules from the plurality of rules of the rule base are selectively removed to produce the reduced rule set.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified diagram showing a process control loop including a transmitter, controller, hand-held communicator and control room.

FIG. 2 is a schematic diagram of a process control loop model for a liquid level loop.

FIG. 3 is a schematic diagram of a process control loop model for a flow rate control loop.

FIG. 4 is a block diagram of a device for implementing one example of the present invention.

FIG. 5 is a block diagram showing one example hardware implementation of FIG. 4.

FIG. 6 is a simplified block diagram showing steps in accordance with the present invention for generating a reduced rule set.

FIG. 7 is a block diagram showing an automated system for performing the steps of FIG. 6.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention can be used with industrial processes to identify the “root cause” of an aberration which occurs in the process. FIG. 1 is a diagram showing an example of an industrial process control system 2 used to control flow of process fluid system 2 includes process piping 4 which carries a process fluid and two wire process control loop 6 carrying loop current I. A transmitter 8, controller 10, which couples to a final control element in the loop such as an actuator, valve, a pump, motor or solenoid, communicator 12, and control room 14 are all part of process control system 2. If an aberration occurs in the operation of the process, the present invention can be used to identify the cause of the observed aberration.

Loop 6 is shown in one configuration for illustration purposes and any appropriate process control loop may be used such as a 4-20 mA loop, 2, 3 or 4 wire loop, multi-drop loop and a loop operating in accordance with the HART®, Fieldbus or other digital or analog communication protocol. In operation, transmitter 8 senses a process variable such as flow using sensor 16 and transmits the sensed process variable over loop 6. The process variable may be received by controller/valve actuator 10, communicator 12 and/or control room equipment 14. Controller 10 is shown coupled to valve 18 and is capable of controlling the process by adjusting valve 18 thereby changing the flow in pipe 4. Controller 10 receives a control input over loop 6 from, for example, control room 14, transmitter 8 or communicator 12 and responsively adjusts valve 18. In another embodiment, controller 10 internally generates the control signal based upon process signals received over loop 6. Communicator 12 may be the portable communicator shown in FIG. 1 or may be a permanently mounted process unit which monitors the process and performs computations. Process devices include, for example, transmitter 8 (such as a 3095 transmitter available from Rosemount Inc.), controller 10, communicator 12 and control room 14 shown in FIG. 1. Another type of process device is a PC, programmable logic unit (PLC) or other computer coupled to the loop using appropriate I/O circuitry to allow monitoring, managing, and/or transmitting on the loop.

FIG. 2 is a simplified diagram 50 of a graphical model of a process control loop 50 for controlling the level of liquid in a tank 52. As discussed below, such models can be selected and used to diagnose a root cause of an aberration in process operation. A level transmitter 54 measures the level of liquid in tank 52 and provides a primary process variable (PV) to a controller 56. Controller 56 as illustrated is a PID controller, however, it can be any type of controller. Controller 56 also receives a setpoint (SP) which is related to a desired level for the liquid within tank 52. Using a known control algorithms, controller 56 provides a control demand (CD) output to a valve 58. An optional valve position sensor 60 can be used to measure the actual position of the valve stem of valve 58. Other optional components for this particular example model include a pump 62 configured to draw liquid from tank 52, a transmitter 64 configured to measure the inlet flow rate and a transmitter 66 configured to measure the outlet flow rate. As described below, the models and optional components for a model are stored in a memory and can be selected by an operator or other selection technique. In various aspects, the memory can be located or accessible to any device which couples to the process or has access to process signals.

It is preferable to perform the diagnostics of the present invention on the process control system after the operation of the process has settled and is in a steady state mode. This is ensured by observing the mean and standard deviation of process signals. The mean (μ) and standard deviation (σ) of each of the process signals (such as process variables and control signals) are evaluated for a set of N measurements, the mean and standard deviation can be evaluated as follows:

$\begin{array}{cc}\mu =\frac{1}{N}\sum _{i=1}^N{x}_i& \mathrm{EQ}.1\\ \sigma =\sqrt{\frac{1}{N-1}\sum _{i=1}^N{\left(x_i-\mu \right)}^2}& \mathrm{Eq}.2\end{array}$ The number of points, N, depends upon the duration and sampling rates of the signal. In Equations 1 and 2, X_i is the value of a process signal taken at sample number i. Initially, a sampling period of ten minutes can be used with a sampling rate of one sample per second. In one example, the loop is determined to be operating in a steady state mode if the process mean is 100 inH₂O (with 1 inH₂O standard deviation) and the subsequent process means are between 97 inH₂O and 103 inH₂O. One patent which is related to determination of process stability prior to initiating diagnostics in U.S. Pat. No. 6,119,047, issued Sep. 12, 2000, which is incorporated herein by reference in its entirety.

Once steady state operation has been reached, it is also desirable to discard data transients or spikes. One technique to identify such data is by successively comparing the signal mean with the signal standard deviation. The difference in the mean between two successive blocks of data (μ₁ and μ₂) should be less than the standard deviation divided by the square root of N, the number of samples. This can be expressed as:

$\begin{array}{cc}{\mu }_1-\frac{{\sigma }_1}{\sqrt{N}}\le {\mu }_2\le {\mu }_1+\frac{{\sigma }_1}{\sqrt{N}}& \mathrm{EQ}.3\end{array}$ where μ is the mean of the previous block, μ₂ is the mean of the current block, N is the number of points in a block, and σ₁ is the standard deviation of the previous block.

Depending on the process signals which are available for performing diagnostics and used with the model, different root causes can be identified. For example, in the case of the process model shown in FIG. 2, there are three different cases:

TABLE 1
Case	Available Signals	Monitored Faults
1	SP	Level Sensor Drift
	PV	Valve Problem
	CD
2	SP	Level Sensor Drift
	PV	Valve Problem
	CD
	VP
3	SP	Level Sensor Drift
	PV	Valve Problem
	CD	Liquid Leak
	VP
	IF
	OF

During an initial training phase, all of the process signals are collected for a user selectable amount of time, for example, 20 minutes. The mean and standard deviations of the signals are evaluated. This training phase is repeated until the process enters steady state. Once the process is in steady state, trained values (i.e., “nominal values”) for the mean (μ_t) and standard deviation (σ_t) for each of the process signals are stored.

Additionally, prior to identifying a root cause fault, individual process signals can be evaluated to ensure that the process is operating properly. For example, the primary process variable (PV) can be evaluated. In the case of liquid level illustrated in FIG. 2:

TABLE 2
CONDITION            FAULT
PV > 0.95 * PV_RANGE LEVEL HIGH (TANK OVERFLOW)
PV < 0.05 * PV_RANGE LEVEL LOW (TANK DRY)

Where PV_RANGE is the range (maximum and minimum) of the level. This value can be stored in a memory accessible by the process control system when the process control system is configured or can be entered by a user. Similarly, for the control signal (CD), the following faults can be identified:

TABLE 3
CONDITION FAULT
CD < 5%   CONTROL WOUND DOWN
CD > 95%  CONTROL WOUND UP

In the example of Table 3, it is assumed that the control demand is a percentage between 0 and 100. If available, a similar test can be performed on the valve position (VP) process signal.

During a monitoring phase, the various process signals are monitored to determine if they have undergone no change (NC), an upward deviation (U) (the mean signal is above the training mean), or a downward variation (D) (the mean signal is less than a training mean). An NC condition is determined if:

$\begin{array}{cc}{\mu }_t-\frac{{\sigma }_t}{\sqrt{N}}\le \mu \le {\mu }_t+\frac{{\sigma }_t}{\sqrt{N}}& \mathrm{EQ}.4\end{array}$ where μ_t is the mean of the training block, μ is the mean of the current block, N is the number of points in a block, and σ_t is the standard deviation of the training block, μ_t and σ_t are the mean and standard deviation, respectively, of the process signal stored during the training phase. N is the number of samples and μ is the current mean of the process signal.

An upward variation (U) condition is identified if:

$\begin{array}{cc}\mu >{\mu }_t+\frac{{\sigma }_t}{\sqrt{N}}& \mathrm{EQ}.5\end{array}$ where μ_t is the mean of the training block, μ is the mean of the current block, N is the number of points in a block, and σ_t is the standard deviation of the training block.

Finally, a downward variation (D) condition is identified if:

$\begin{array}{cc}\mu <{\mu }_t-\frac{{\sigma }_t}{\sqrt{N}}& \mathrm{Eq}.6\end{array}$ where μ_t is the mean of the training block, μ is the mean of the current block, N is the number of points in a block, and σ_t is the standard deviation of the training block.

Depending upon the number of process signals which are available, a different root cause can be identified as the source of an aberration in the process. For example, if the setpoint, primary variable and control demand process signals are available, a level sensor drift or valve related problem can be identified. An example rule base is given in Table 4:

TABLE 4
        FAULT
SIGNALS Level Sensor Drift or Valve Problem
SP      NC
PV      NC
CD      U or D

If an additional process signal is available, the actual valve position (VP), then the root cause can be more specifically identified as given in Table 5:

	TABLE 5
	FAULT
	SIGNALS	Level Sensor Drift	Valve Problem
	SP	NC	NC
	PV	NC	NC
	CD	U or D	U or D
	VP	U or D	NC

Finally, if the inflow rate (IF) and outflow rate (OF) process signals are available, it is also possible to determine if there is a leak in tank 52 as shown in the rule base of Table 6:

	TABLE 6
	FAULT
		Level Sensor	Valve	Liquid
	SIGNALS	Drift	Problem	Leak
	SP	NC	NC	NC
	PV	NC	NC	NC
	CD	U or D	U or D	D
	VP	U or D	NC	D
	IF	NC	NC	NC
	OF	NC	NC	D

If the changes in the process signals do not match any of the rules set forth in Tables 4, 5 and 6, an unknown fault output can be provided. Further, these rules apply if the process 50 includes pump 62 or operates based upon a pressure differential which is used to drain tank 52.

FIG. 3 is a simplified diagram 100 of a graphical model of a process control loop to control a flow rate. This illustrates another example process control loop. In FIG. 3, a tank 102 (or a pump 103 or other source of a differential pressure) can provide a flow of process fluid. A transmitter 104 senses the flow rate and provides the primary process variable (flow rate) to controller 106. Controller 106 also receives a setpoint (SP) and provides a control demand (CD) signal to valve 108. Valve 108 may optionally report back the actual position of its valve stem (VP). Additional options include a pressure transmitter 110 configured to sense a process pressure (PT) and a redundant flow transmitter 112 configured to sense a redundant flow rate (FT2).

In operation, the mean and standard deviation are determined during a training phase in a manner similar to that described with respect to FIG. 2 and as set forth in Equations 1 and 2, above. However, because a flow rate control typically responds relatively fast, a shorter learning duration can be used, for example two minutes.

Depending upon the number of different process signals which are available, a number of different root causes can be identified as illustrated in Table 7:

TABLE 7
Case	Available Signals	Monitored Faults
1	SP	Flow Sensor
	PV	Drift
	CD	Valve Problem
2	SP	Flow Sensor
	PV	Drift
	CD	Valve Problem
	VP
3	SP	Flow Sensor
	PV	Drift
	CD	Valve Problem
	VP	Liquid Leak
	FT2

Prior to identifying a root cause, basic faults can be checked for. For example, using the rule base in Table 8:

TABLE 8
CONDITION FAULT
PT is D   HEAD LOSS

Further, the condition of the valve can be determined as follows:

TABLE 9
CONDITION FAULT
CD < 5%   CONTROL WOUND DOWN
CD > 95%  CD WOUND UP

Using additional process variables, a “root cause” of an aberration in the process can be identified. When the setpoint, primary process variable and control demand signals are available flow sensor drift or a valve problem can be identified as the root cause of the process aberration as follows:

TABLE 10
        FAULT
SIGNALS Flow Sensor Drift or Valve Problem
SP      NC
PV      NC
CD      U or D

If an additional process signal is available, the actual valve position (VP), then the root cause can be identified as flow sensor drift or a valve problem as follows:

	TABLE 11
	FAULT
	SIGNALS	Flow Sensor Drift	Valve Problem
	SP	NC	NC
	PV	NC	NC
	CD	U or D	U or D
	VP	U or D	NC

Finally, if a redundant transmitter is used to measure a second flow rate variable (FT2), then a leak in the process can also be identified:

	TABLE 12
	FAULT
		Level Sensor	Valve	Liquid
	SIGNALS	Drift	Problem	Leak
	SP	NC	NC	NC
	PV	NC	NC	NC
	CD	U or D	U or D	D
	VP	U or D	NC	D
	FT2	U or D	NC	D
	SIGNALS

FIG. 4 is a block diagram illustrating a process device 100 which implements one example embodiment of the present invention. Process device 100 includes a root cause analysis block 102 which receives a control signal CD through a control signal input 104, a process variable PV through a process variable input 106 and a setpoint SP through a setpoint input 108. Additional process signals (PS₁, PS₂ . . . ) can be received through other inputs such as process signal input 110, 111, etc. depending on the number of additional process signals which are available.

The root cause analysis block 102 is also coupled to a plurality of process configuration models 112. Models 112 can be stored, for example, in a system memory. In the embodiment illustrated, there are a total of X different models which correspond to possible process control configurations. In this example, each model includes a graphical model GM₁ . . . GM_x which provide graphical illustrations of the process. This can be used to provide a graphical user interface to facilitate entry of configuration data by an operator. For example, a graphical model can be similar to the diagrams shown in FIGS. 2 and 3.

Each process model can receive any number of process signals (PS_1A, PS_1B, etc.). In the specific examples shown in FIGS. 2 and 3, there are a minimum of three process signals, the control demand CD, the primary process variable PV and the setpoint SP which are required to identify the root cause of an aberration in the process. In one embodiment, the number of process signals associated with a model is the minimum number of process signals required to perform the root cause analysis, or a greater number of process signals, as desired.

Next, each model can contain any number of optional process signals (OP_1A, OP_1B, . . . ). Each optional process signal corresponds to a process signal (PS₁, PS₂, . . . ) received through inputs 110, 111, etc. In the example of FIG. 2, the valve position VP, inflow rate IF and outflow rate OF are examples of such optional process signals. Some models can be configured which have no additional optional process signals.

Next, each model contains any number of rule bases (RB_1A, RB_1B, . . . ) which are used to determine the root cause based upon the received process signals (the require minimum process signals PS_1A, PS_1B, . . . and any optional process signals OP_1A, OP_1B . . . ). Examples of rule bases are shown in Tables 4, 5, 6, 10, 11 and 12 which were discussed above. Note that the present invention is not limited to the particular use of the rule bases illustrated above to perform the root cause analysis. In one aspect, any analysis technique can be used including neural networks, other rules bases, regressive learning, fuzzy logic, and other known diagnostic techniques or techniques yet to be discovered. With the examples given here, there are a minimum of three process signals which are received, the control demand CD signal, the primary process variable PV signal and the setpoint SP signal. However, other process signals, fewer signals, or different signal combinations can be used to perform the root cause analysis.

Root cause analysis block 102 receives a model selection input 116 which is used to select one of the plurality of models 112. The model selection input can be from an operator or from another source. The model selection input 116 identifies one of the plurality of models 112 for subsequent use by root cause analysis block 102. Additionally, in one example, additional optional process (OP) signals can be selected for use with the selected model. If a graphical user interface is used, the models can include graphical models which can be displayed on a display output 118 and used in configuring the model. For example, the particular process signal can be assigned using the model selection input 116 to one of the process signals (PS_1A, PS_1B . . . ) or optional process signals (OP_1A, OP_1B . . . ) associated with a selected model. This assignment can be illustrated in a graphical form.

Once a model has been selected, the process signals used by the model rule base are assigned to the actual process signals received from the process. The root cause analysis block 102 can perform a root cause analysis using any desired technique such as those set forth above. Based upon the root cause analysis, a root cause output 120 is provided which is an indication of the root cause of an aberration of an event which has occurred in the process.

Pursuant to one embodiment of the invention, FIG. 5 is a simplified block diagram showing one physical implementation of process device 100. In the example of FIG. 5, device 100 couples to a process control loop 132 through input/output 134. Loop 132 can be, for example, the two wire loop shown in. FIG. 1 or other process control loop. Further, the connection does not need to be a direct connection and can simply be a logical connection in which variables from the loop are received through a logical input/output block 134. A microprocessor 136 couples to a memory 138 and a graphical user interface 140. The memory 138 can be used to store variables and programming instructions, as well as models 112 shown in FIG. 4.

The graphical user interface 140 provides an input for receiving the model selection input 116 as well as the display output 118 of FIG. 4 for use during model selection and configuration. Microprocessor 136 can also couple to an optional database 142 which can contain information related to the configuration and operation of the process being monitored. For example, many process control or monitoring systems contain such databases. One example is AMS Suite: Intelligent Device Manager available from Emerson Process Management of Eden Prairie, Minn.

It is appreciated that the root cause process device 100 can be implemented in any process device such as transmitters, controllers, hand-held communicators, or the control room computer shown in FIG. 1. In one embodiment, process device 100 will operate on a computer system or PC located in the control room or other remote location. Process control loop 132 will typically comprise some type of a Fieldbus based loop, or multiple control loops. In such a configuration, process device 100 can poll the desired process signals the various devices coupled to the control loop for the selected model. Although a graphical user interface 140 is shown, the model can be selected using any selection technique and does not need to be selected and configured by a human operator. For example, based upon configuration information stored in another location were provided through other techniques, the appropriate rule base and any model options can be received by device 100. Alternatively, the root cause process device 100 can be implemented in the field and reside in the transmitter for example.

As discussed above, one technique for identifying a root cause of an aberration in the process is by applying rules to process signals of the industrial process. This allows faults to be detected based upon measured process variables. For example, for a process control loop in which a large number of measurements are available, a large number of different types of faults can be detected. Conversely, in a similar process control loop in which fewer measurements are made, some fault conditions may not be recognized. Thus, for each loop, there are both required measurements and optional measurements.

When configuring a rule base to run for a particular process control loop, it is necessary to define which faults are detected and how they depend upon the process variables which are available. If some of the measurements are optional, multiple cases must be defined. For example, for a loop with two optional measurements, there could be up to four different cases which must be defined, because each of the two optional process variables may or may not be available in particular instances. Similarly, with three optional measurements there are up to eight cases which must be defined, and with four optional measurements there are sixteen different cases. Thus, as the number of optional measurements increases, the number of different cases which must be defined increases exponentially.

However, in many instances, each of the different possible cases which can be defined for a particular rule base may not have a significant meaning. In some applications, it may be possible to define less than the full number of possible cases. However, this still requires manually defining multiple cases based upon which measurements are available. This introduces additional human error into the process of defining a rule base. It is also difficult to maintain, and a change in one part of the rule base may require other changes in other parts of the rule base. The complexity of defining a rule base increases greatly for complex loops such as a temperature-to-flow cascade loop. The problems can be even further exacerbated if a user enters customized rules into the rule base.

In one aspect, the present invention provides a method and apparatus for creating a reduced rule set based upon which process variables are available for application to the rule set. This provides a system for automatically determining which faults can be detected when only a subset of the possible measurements are available. Further, if a subset of measurements yield two rules to detect two different faults which have identical conditions (or signatures), this ambiguity is automatically determined and can be shown to an operator during the configuration of the loop.

In order to define a rule base, measurements, process signals, faults and individual rules must be defined. As discussed above, process signals are process variables, control signals, etc. Some process signals are required for a particular rule while others are optional. Faults are the various different faults that can be detected based upon these process signals. Rules define a specific condition (signature) or conditions (signatures) of the process signals which, when met, identify a particular fault or faults in the industrial process. There may be more than one rule corresponding to a fault.

Each rule must specify a value or other characteristic describing the state or condition of one or more process signals. Example states include a process signal being greater than a constant, less than a constant, trending upwards, trending downwards, no change, or irrelevant (i.e., blank) in which any condition for this particular process signal will satisfy the rule.

FIG. 6 is a simplified block diagram 200 showing steps in accordance with the present invention for determining a reduced rule base if only a subset of possible process signals are available. At block 202, a complete rule base is obtained based upon all possible process signals for a particular process.

For each optional process signal that is not available for the particular industrial process, that column is removed from the rule matrix as set forth at 204 in FIG. 6. Any rules or faults which no longer have any non-blank process signals are removed from the matrix at block 206, which produces a reduced rule set. Next at block 208, the remaining rules are examined to identify matching conditions (signatures). Any remaining rules which have identical conditions are combined into a single rule at block 210. If a combined rule has different faults, the faults are combined together to create a new fault if the new combined fault does not already exist. Steps 208-210 are repeated until only unique rules are remaining in the reduced rule matrix.

The following provides an example of the present invention for a level measurement loop in which the level is driven by a pump. In this example, only the process signals Set Point (SP), Process Variable (PV), Control Demand (CD), and In-Flow Rate (IF) are available. At step 202, a complete rule base is obtained:

TABLE 13
Level Loop Driven by Pump
Process Signals
Faults	Rules	SP	PV	CD	VP*	IF*	OF*	PT*
Level High	R1		>HI_LIM
Level Low	R2		<LO_LIM
Control	R3			>95%	>95%
Wound Up
Control	R4			<5%	<5%
Wound
Down
Head Loss	R5							D
Measure-	R6	NC	NC	U	U	NC	NC
ment
Drift	R7	NC	NC	D	D	NC	NC
Valve	R8	NC	NC	U	NC	NC	NC
Problem	R9	NC	NC	D	NC	NC	NC
Liquid Leak	R10	NC	NC	D	D	NC	D
*Denotes an Optional Process Variable

At step 204, any optional process signals which are not available are removed from the rule matrix. For this example, Valve Position (VP), Outflow Rate (bF), and Process Pressure (PT) are not available. This yields a reduced rule set according to table 14:

TABLE 14
VP, OF and PT Removed
Process Signals
Faults	Rules	SP	PV	CD	IF*
Level High	R1		>HI_LIM
Level Low	R2		<LO_LIM
Control Wound Up	R3			>95%
Control Wound Down	R4			<5%
Head Loss	R5
Measurement Drift	R6	NC	NC	U	NC
	R7	NC	NC	D	NC
Valve Problem	R8	NC	NC	U	NC
	R9	NC	NC	D	NC
Liquid Leak	R10	NC	NC	D	NC

Next, at step 206 any rules/faults that have only blank process signals are removed from the matrix. In this example, the fault “Head Loss (HL)” corresponding to rule R₅ has only blank process signals. Therefore, this rule can be removed from the matrix:

TABLE 15
Head Loss fault removed
Process Signals
Faults	Rules	SP	PV	CD	IF*
Level High	R1		>HI_LIM
Level Low	R2		<LO_LIM
Control Wound Up	R3			>95%
Control Wound Down	R4			<5%
Measurement Drift	R6	NC	NC	U	NC
	R7	NC	NC	D	NC
Valve Problem	R8	NC	NC	U	NC
	R9	NC	NC	D	NC
Liquid Leak	R10	NC	NC	D	NC

Next, at step 208, the remaining rules are examined for matching patterns. In this example, rules R6 and R8 have the same pattern and rules R7 and R9 and R10 have the same pattern. At step 210, these identical patterns are combined into a single rule and a new fault is created which is a combination of the faults from the combined rules. In this example, rule R6 is retained and a new fault “measurement drift (MD)/valve problem (VP)” is created. Similarly, rule R7 is retained and a new fault “Measurement Drift/Valve Problem/Liquid Leak” is defined. The final reduced rule base is as follows:

TABLE 16
Final Reduced Rule Base
Process Signals
Faults	Rules	SP	PV	CD	IF*
Level High	R1		>HI_LIM
Level Low	R2		<LO_LIM
Control Wound Up	R3			>95%
Control Wound Down	R4			<5%
Measurement	R6	NC	NC	U	NC
Drift/Valve
Problem
Measurement	R7	NC	NC	D	NC
Drift/Valve
problem/Liquid
Leak

The above example is for a relatively simple process control loop with a correspondingly simple rule base. However, when the method is automated, it can be applied to any rule base, including more complicated rule bases, such as a temperature-to-flow cascade loop.

For example, for a generic rule base, the following nomenclature can be used to represent the process signals, rules and faults:Required Process Signals:={M_R,1, M_R,2, . . . M_R,Nmr}, Where Nmr is the number of Required Process SignalsOptional Process Signals:={M_O,1, M_O,2, . . . M_O,Nmo}, Where Nmo is the number of Optional Process SignalsFaults:={F₁, F₂, . . . F_Nf}, where Nf is the number of Faults.Rules:={R₁, R₂, . . . R_Nr}, where Nr is the number of Rules.V_R,a,b is the condition or state for process signal M_R,b needed to satisfy rule R_a.V_O,a,b is the condition or state for process signal M_O,b needed to satisfy rule R_a.  EQ. 7

With such definition, a complete rule base is as follows:

TABLE 17
Generic RCD Rule Table
Process Signals
Fault	Rule	MR,1	. . .	MR,Nmr	Mo,1	Mo,2	. . .	Mo,Nmo
F1	R1	VR,1,1	. . .	VR,1,Nmr	Vo,1,1	Vo,1,2	. . .	Vo,1,Nmo
	R2	VR,2,1	. . .	VR,2,Nmr	Vo,2,1	Vo,2,2	. . .	Vo,2,Nmo
F2	R3	VR,3,1	. . .	VR,3,Nmr	Vo,3,1	Vo,3,2	. . .	Vo,3,Nmo
	R4	VR,4,1	. . .	VR,4,Nmr	Vo,4,1	Vo,4,2	. . .	Vo,4,Nmo
	R5	VR,5,1	. . .	VR,5,Nmr	Vo,5,1	Vo,5,2	. . .	Vo,5,Nmo
F3	R6	VR,6,1	. . .	VR,6,Nmr	Vo,6,1	Vo,6,2	. . .	Vo,6,Nmo
F4	R7	VR,7,1	. . .	VR,7,Nmr	Vo,7,1	Vo,7,2	. . .	Vo,7,Nmo
. . .	. . .	. . .	. . .	. . .	. . .	. . .	. . .	. . .
FNf	RNr	VR,Nr,1	. . .	VR,Nr,Nmr	Vo,Nr,1	Vo,Nr,2	. . .	Vo,Nr,Nmo

At step 204, all optional process signals that are not available are removed from the table. In a generic configuration, the optional process signals that are not available can be identified as M_ona,1, M_ona,2, . . . . Optional process signals that are available can be identified as M_oa,1, M_oa,2, . . . , M_oa,Nmoa, with Nmoa<=Nmo. The resulting rule table is:

TABLE 18
Generic RCD Rule Table with Unavailable
Process Signals Removed
Process Signals
Fault	Rule	MR,1	. . .	MR,Nmr	Moa,1	Moa,2	. . .	Moa,Nmoa
F1	R1	VR,1,1	. . .	VR,1,Nmr	Voa,1,1	Voa,1,2	. . .	Voa,1,Nmoa
	R2	VR,2,1	. . .	VR,2,Nmr	Voa,2,1	Voa,2,2	. . .	Voa,2,Nmoa
F2	R3	VR,3,1	. . .	VR,3,Nmr	Voa,3,1	Voa,3,2	. . .	Voa,3,Nmoa
	R4	VR,4,1	. . .	VR,4,Nmr	Voa,4,1	Voa,4,2	. . .	Voa,4,Nmoa
	R5	VR,5,1	. . .	VR,5,Nmr	Voa,5,1	Voa,5,2	. . .	Voa,5,Nmoa
F3	R6	VR,6,1	. . .	VR,6,Nmr	Voa,6,1	Voa,6,2	. . .	Voa,6,Nmoa
F4	R7	VR,7,1	. . .	VR,7,Nmr	Voa,7,1	Voa,7,2	. . .	Voa,7,Nmoa
. . .	. . .	. . .	. . .	. . .	. . .	. . .	. . .	. . .
FNf	RNr	VR,Nr,1	. . .	VR,Nr,Nmr	Voa,Nr,1	Voa,Nr,2	. . .	Voa,Nr,Nmoa

At step 206, after the unavailable process signals have been removed, there may be some rules R_n for which all of the measurement conditions V_r,n,i (1<=i<=Nmr) and V_Oa,n,j (1<=j<=Nmoa) are blank. These rules can be removed the rule table. If any faults have had all of their rules removed from the rule table, then these faults should also be removed from the rule table. Assuming for this example that F₃ has been completely removed from the rule table and R₄ and R₅ corresponding to F₂ have been removed from the rule table, the rules R₄, R₅ and R₆ were completely dependent upon the optional measurements that are not available. The resulting rule table is as follows:

TABLE 19
Generic RCD Rule Table with Non-detectable
faults removed
Process Signals
Fault	Rule	MR,1	. . .	MR,Nmr	Moa,1	Moa,2	. . .	Moa,Nmoa
F1	R1	VR,1,1	. . .	VR,1,Nmr	Voa,1,1	Voa,1,2	. . .	Voa,1,Nmoa
	R2	VR,2,1	. . .	VR,2,Nmr	Voa,2,1	Voa,2,2	. . .	Voa,2,Nmoa
F2	R3	VR,3,1	. . .	VR,3,Nmr	Voa,3,1	Voa,3,2	. . .	Voa,3,Nmoa
F4	R7	VR,7,1	. . .	VR,7,Nmr	Voa,7,1	Voa,7,2	. . .	Voa,7,Nmoa
. . .	. . .	. . .	. . .	. . .	. . .	. . .	. . .	. . .
FNf	RNr	VR,Nr,1	. . .	VR,Nr,Nmr	Voa,Nr,1	Voa,Nr,2	. . .	Voa,Nr,Nmoa

Next, at step 208, any rules having identical signatures are identified and combined at step 210. For example, the following pseudo-computer code can be used:

For i=1 to Nr
For j=i+1 to Nr
Rule1 = Ri
Rule 2 = Rj
RulesSame = True
For k=1 to Nmr
If VR,i,k != VR,j,k then RulesSame=False
Next
For k=1 to Nmoa
If Voa,i,k !=Voa,j,k then RulesSame=False
Next
If RulesSame = True then CombineRules (Rule1,Rule2)
Next
Next
Sub CombineRules (Rule1, Rule2)
FaultName = [Rule1 Fault] & [Rule 2 Fault]
If (FaultName Exists) then
Add Rule1 to FaultName
Else
Create New Fault (FaultName)
Add Rule1 to FaultName
EndIf
End Sub

The steps in method of the present invention can be implemented in a computer based system such as that illustrated in FIG. 7. In FIG. 7, computer system 300 includes a processor 302 configured to receive an input 304. The input 304 can be any appropriate input including manual input, electrical inputs such as through a databus, or an input comprising a data received from a memory or other storage device. The input receives a complete rule base 306 along with an identification of optional process signals 308. Processor 302 performs the steps illustrated in FIG. 6 and as discussed above. Based on these steps, a reduced rule set 310 is provided as an output. The reduced rule set 310 can be in any appropriate form including human readable or machine readable form and can be provided on any appropriate output including an output to another computer, a memory, a databus, etc. FIG. 7 also illustrates an optional user interface identified as a graphical user interface 312. Through user interface (GUI) 312, an operator can control operation of processor 302 and receive information from processor 302 related to the application of steps set forth in FIG. 6 and other information. A memory 314 is provided for, for example, storing program instructions in accordance with the steps of the present invention. Memory 314 can be any type of storage medium. In one configuration, memory 314 comprises a permanent memory such as a disk or the like or a temporary memory, including a memory coupled to a databus or network, stores the program instructions to carry out the steps set forth in FIG. 6. These program instructions are provided to processor 302 from memory 314 so that processor 302 implements these steps.

As used herein, process variables are typically the primary variables which are being controlled in a process. As used herein, process variable means any variable which describes the condition of the process such as, for example, pressure, flow, temperature, product level, pH, turbidity, vibration, position, motor current, any other characteristic of the process, etc. Control signal means any signal (other than a process variable) which is used to control the process. For example, control signal means a desired process variable value (i.e. a setpoint) such as a desired temperature, pressure, flow, product level, pH or turbidity, etc., which is adjusted by a controller or used to control the process. Additionally, a control signal means, calibration values, alarms, alarm conditions, the signal which is provided to a control element such as a valve position signal which is provided to a valve actuator, an energy level which is provided to a heating element, a solenoid on/off signal, etc., or any other signal which relates to control of the process. A diagnostic signal as used herein includes information related to operation of devices and elements in the process control loop, but does not include process variables or control signals. For example, diagnostic signals include valve stem position, applied torque or force, actuator pressure, pressure of a pressurized gas used to actuate a valve, electrical voltage, current, power, resistance, capacitance, inductance, device temperature, stiction, friction, full on and off positions, travel, frequency, amplitude, spectrum and spectral components, stiffness, electric or magnetic field strength, duration, intensity, motion, electric motor back emf, motor current, loop related parameters (such as control loop resistance, voltage, or current), or any other parameter which may be detected or measured in the system. Furthermore, process signal means any signal which is related to the process or element in the process such as, for example, a process variable, a control signal or a diagnostic signal. Process devices include any device which forms part of or couples to a process control loop and is used in the control or monitoring of a process.

Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. Although two example processes and example models are. shown in this description, the invention is applicable to other process configurations and models can be generated using known techniques or techniques discovered in the future. Further, other types of rule bases or model configurations can be used with the present invention. The invention can be implemented in a stand-alone device or can be a software module which is added to software used to control or monitor industrial processes. In one aspect, the invention includes the computer instructions and/or storage media used to implement the invention. As used herein, a “process model” is any logical representation of a process and is not limited to the specific examples set forth herein. A “root cause” is the initial cause (or causes) of a variation or aberration in process operation. Other types of process control loops which can be modeled include, but are not limited to, flow control, level control, temperature control, etc., including regulator control and cascade control of gases, liquids, solids or other forms of process material. Specific examples of loops include a flow control loop with valve driven by differential pressure, a level control loop with valve driven by differential pressure, temperature regulatory control to flow regulatory control, level regulatory control to valve pump driven, flow control with valve driven by pump, level regulatory control to valve chiller condenser, level regulatory control to flow regulatory control cascade feed, liquid temperature regulatory control to valve, liquid temperature regulatory control to flow regulatory control, gas flow control with valve driven by differential pressure, gas temperature regulatory control to valve, gas pressure regulatory control to valve, gas pressure regulatory control to flow regulatory control, level regulatory control to flow regulatory control cascade reboiler, liquid pressure regulatory control to valve and level regulatory control to valve reboiler, for example. Various types of process elements which can be controlled include drums and tanks, heat exchangers, towers, steam systems, condensers, boilers, reactors, and heaters, compressors, fuel systems, turbines and flare systems, for example.

Claims

1. A method for generating a reduced rule set for identifying a root cause of an aberration in an industrial process for use in an industrial process field device, comprising: (a) obtaining a rule base comprising a plurality of rules for the industrial process, each rule comprising a condition of at least one process signal of the industrial process and a fault which corresponds to a condition of at least one process signal;(b) identifying which process signals of the industrial process are available to the field device;(c) selectively removing a rule from the plurality of rules of the rule base to produce the reduced rule set, wherein the step of selectively removing a rule is based upon the step of identifying which process signals of the industrial are available; and(d) storing the reduced rule set in a memory of the field device;(e) performing diagnostics in the field device based upon the reduced rule set and the identification process signals.

2. The method of claim 1 including identifying rules within the reduced rule set having identical process signal conditions.

3. The method of claim 2 including combining rules in the reduced rule set which have identical process signal conditions.

4. The method of claim 3 including creating a new fault for a combined rule.

5. The method of claim 1 wherein the process signals comprise process variables.

6. The method of claim 1 including automating steps (a) through (c).

7. The method of claim 6 and including performing (a) through (c) in a computer.

8. The method of claim 3 including repeating the step of combining until only unique rules are left in the reduced rule set.

9. The method of claim 1 wherein the condition of at least one of the process signals comprises the group of conditions consisting of less than a constant, greater than a constant, trending up, trending down, no change and blank.

10. A computer system configured to implement the method of claim 1.

11. An apparatus for determining a reduced rule set for identifying a root cause of an aberration in an industrial process for use in an industrial process field device, comprising; means for obtaining a rule base comprising a plurality of rules for the industrial process, each rule comprising a condition of at least one process signal of the industrial process and a fault which corresponds to a condition of at least one process signal;means for identifying which process signals of the industrial process are available to the field device;means for selectively removing a rule from the plurality of rules of the rule base to produce the reduced rule set, wherein the step of selectively removing a rule is based upon the step of identifying which process signals of the industrial are available; andmeans for storing the reduced rule set in a memory of the field device;means for performing diagnostics in the field device based upon the reduced rule set and the identification process signals.

12. The apparatus of claim 11 including means for identifying rules within the reduced rule set having identical process signal conditions.

13. The apparatus of claim 12 including means for combining rules in the reduced rule set which have identical process signal conditions.

14. The apparatus of claim 13 including means for creating a new fault for a combined rule.

15. The apparatus of claim 11 wherein the process signals comprise process variables.

16. The apparatus of claim 11 wherein the condition of at least one of the process signals comprises the group of conditions consisting of less than a constant, greater than a constant, trending up, trending down, no change and blank.

17. An industrial process diagnostic apparatus for identifying a root cause of an aberration in an industrial process, comprising: a rule base comprising a plurality of rules for the industrial process, each rule comprising a condition of at least one process signal of the industrial process and a fault which corresponds to a condition of at least one process signal;a processor configured to identify which process signals of the industrial process are available and responsively selectively remove a rule from the plurality of rules of the rule base to produce the reduced rule set, based upon the identified process signals.

18. The apparatus of claim 17 wherein the processor is further configured to identify rules within the reduced rule set having identical process signal conditions.

19. The apparatus of claim 18 wherein the process is further configured to combine rules in the reduced rule set which have identical process signal conditions.

20. The apparatus of claim 19 wherein the process is further configured to create a new fault for a combined rule.

21. The apparatus of claim 17 wherein the process signals comprise process variables.

22. The apparatus of claim 17 wherein the condition of at least one of the process signals comprises the group of conditions consisting of less than a constant, greater than a constant, trending up, trending down, no change and blank.