US 11,656,609 B2
Detecting component degradation in industrial process plants based on loop component responsiveness
Anthony Amaro, Jr., Cedar Park, TX (US); and Mark J. Nixon, Round Rock, TX (US)
Assigned to FISHER-ROSEMOUNT SYSTEMS, INC., Round Rock, TX (US)
Filed by FISHER-ROSEMOUNT SYSTEMS, INC., Round Rock, TX (US)
Filed on Jan. 14, 2021, as Appl. No. 17/148,959.
Prior Publication US 2022/0221844 A1, Jul. 14, 2022
Int. Cl. G05B 19/418 (2006.01); H04L 43/10 (2022.01); G06F 1/10 (2006.01); H04L 43/087 (2022.01)
CPC G05B 19/4185 (2013.01) [G05B 19/4183 (2013.01); G05B 19/4184 (2013.01); G06F 1/10 (2013.01); H04L 43/087 (2013.01); H04L 43/10 (2013.01)] 44 Claims
OG exemplary drawing
 
1. A system for detecting component degradation in an industrial process plant, the system comprising:
a first component and a second component included in a control loop via which an industrial process is controlled by a process control system of the industrial process plant, the process control system including an I/O gateway that is communicatively connected to a plurality of process controllers via respective communications channels, and the plurality of process controllers communicatively disposed between the I/O gateway and respective one or more field devices, and the first component communicatively connected to the second component of the process control system via a diagnostic channel and via a communication channel,
the first component being one of the I/O gateway or a process controller included in the plurality of process controllers,
the second component being the other one of the I/O gateway or the process controller, the second component including a routine executing at the second component and configured to:
process communications and control messages that are received, via the communications channel, at the second component for controlling the industrial process, and
return, via the diagnostic channel to the first component, any heartbeat messages that are received at the second component via the diagnostic channel upon respective receipt at the second component, and
the first component configured to:
transmit, via the communications channel to the second component, the communications and control messages for controlling the industrial process;
sequentially transmit, via the diagnostic channel, a plurality of heartbeat messages to the second component;
receive, via the diagnostic channel, at least a subset of the plurality of heartbeat messages returned to the first component by the second component;
determine an average response time of the second component based on at least one of: a periodicity of a module scheduler execution at the second component, or respective round trip times (RTTs) of the at least the subset of the plurality of heartbeat messages, the respective RTTs determined based on respective times of transmission and reception of the at least the subset of the plurality of heartbeat messages at the first component; and
detect a degradation of the second component when an RTT of a subsequent heartbeat message transmitted by the first component to the second component via the diagnostic channel exceeds a threshold corresponding to the average response time of the second component.