Abstract: A machine-learned method and system for use in operating an industrial plant. A digital twin of the industrial plant is configured to simulate plant operations based on operating variables from a data store. A machine-learned model comprises a stabilizing agent and a disrupting agent. The stabilizing agent modifies the operating variables within the digital twin to perform a stabilizing action for limiting a degree of shutdown and the disrupting agent modifies the operating variables within the digital twin to perform a disruptive action for increasing the degree of shutdown. A composite action reward is configured to reward the machine-learned model for reducing the degree of shutdown from an initial state of the digital twin to a post-action-state of the digital twin.

Abstract: A virtual plant operator system for use in an industrial plant. A data aggregator monitors operating data within the industrial plant and sends the operating data as a current state of the industrial plant to an operator assistant. The operator assistant includes a digital twin of the industrial plant and an artificial intelligence engine. The digital twin of the industrial plant receives the current state and simulates plant operations based on the current state. The artificial intelligence engine has at least one machine-learned model. The machine-learned model processes the simulated plant operations based on the current state to determine a recommendation output. The recommendation output includes stabilizing actions to the plant operations in the industrial plant and/or a predicted degree of shutdown responsive to each of the stabilizing actions.

Abstract: Network of safety PLCs employs multi-PLC verification of a programming application before allowing the application to reprogram any PLC on the safety network. Each PLC on the safety network is equipped with authentication capability that detects attempts to reprogram the PLC and issues an authentication challenge requiring the programming application to process a proof-of-work. The authentication challenge is also sent to other PLCs on the safety network along with the response from the programming application for verification purposes. The other PLCs process the authentication challenge and check the response from the programming application for acceptability. If a majority of the PLCs on the safety network determines the response from the programming application is correct, then the programming application is verified and may proceed with the reprogramming.

Abstract: A method for managing soft errors associated with one or more safety programmable logic controllers (PLCs) is provided. The method includes receiving an expected soft error rate for type(s) of input/output (I/O) modules over time, receiving respective soft error data that was aggregated by the respective safety PLCs based on soft errors detected by I/O modules coupled to the respective safety PLCs. Actual soft error rates are determined per I/O module type based on the received soft error data, and soft error rates are predicted for the safety PLC(s) per I/O module type. The actual and/or predicted soft error rates are compared to the expected soft error rate per I/O module type. The method further includes taking one or more actions in response to a threshold deviation between the actual and/or predicted soft error rates relative to the expected soft error rate for the corresponding I/O module type.

Abstract: A method for managing soft errors associated with one or more safety programmable logic controllers (PLCs) is provided. The method includes receiving an expected soft error rate for type(s) of input/output (I/O) modules over time, receiving respective soft error data that was aggregated by the respective safety PLCs based on soft errors detected by I/O modules coupled to the respective safety PLCs. Actual soft error rates are determined per I/O module type based on the received soft error data, and soft error rates are predicted for the safety PLC(s) per I/O module type. The actual and/or predicted soft error rates are compared to the expected soft error rate per I/O module type. The method further includes taking one or more actions in response to a threshold deviation between the actual and/or predicted soft error rates relative to the expected soft error rate for the corresponding I/O module type.

Abstract: A method is provided for automatically or semi-automatically analyzing process hazards and validating protection mechanisms for an industrial process. The method can involve establishing communication between a simulation tool and a process hazard analysis tool. The simulation tool simulates operation of the process according to a process model. The method can further involve creating, using the process hazard analysis tool, conditions for hazards in the process based on information learned about the industrial process from the simulation tool; for each of the hazards, simulating the hazards using the simulation tool and attempting to prevent the hazards using the process hazard analysis tool by introducing protective mechanism(s) to the process; and evaluating effectiveness of the introduced protective mechanisms for each of the hazards and creating safety requirements for the process based on the evaluated effectiveness.

Abstract: A method is provided for automatically or semi-automatically analyzing process hazards and validating protection mechanisms for an industrial process. The method can involve establishing communication between a simulation tool and a process hazard analysis tool. The simulation tool simulates operation of the process according to a process model. The method can further involve creating, using the process hazard analysis tool, conditions for hazards in the process based on information learned about the industrial process from the simulation tool; for each of the hazards, simulating the hazards using the simulation tool and attempting to prevent the hazards using the process hazard analysis tool by introducing protective mechanism(s) to the process; and evaluating effectiveness of the introduced protective mechanisms for each of the hazards and creating safety requirements for the process based on the evaluated effectiveness.

Abstract: A method is provided for automatically or semi-automatically analyzing process hazards and validating protection mechanisms for an industrial process. The method can involve establishing communication between a simulation tool and a process hazard analysis tool. The simulation tool simulates operation of the process according to a process model. The method can further involve creating, using the process hazard analysis tool, conditions for hazards in the process based on information learned about the industrial process from the simulation tool; for each of the hazards, simulating the hazards using the simulation tool and attempting to prevent the hazards using the process hazard analysis tool by introducing protective mechanism(s) to the process; and evaluating effectiveness of the introduced protective mechanisms for each of the hazards and creating safety requirements for the process based on the evaluated effectiveness.

Abstract: Dual layer interface with a safety instrumented system (SIS) in an industrial plant. A diagnostic status aggregator having an established connection with the SIS collects and stores health and diagnostic status data from the SIS. An interface processing engine communicatively coupled to the diagnostic status aggregator and to a user device receives a new request for information relating to the SIS from the user device. A memory stores processor-executable instructions that, when executed, configure the interface processing engine for parsing the new request to identify one or more specific keywords therein associated with the requested information relating to the SIS, generating a query based on the identified keywords, retrieving, from the diagnostic status aggregator, the status data collected from the SIS responsive to the query, and providing, the status data retrieved from the diagnostic status aggregator to the user device.

Abstract: A method is provided for automatically or semi-automatically analyzing process hazards and validating protection mechanisms for an industrial process. The method can involve establishing communication between a simulation tool and a process hazard analysis tool. The simulation tool simulates operation of the process according to a process model. The method can further involve creating, using the process hazard analysis tool, conditions for hazards in the process based on information learned about the industrial process from the simulation tool; for each of the hazards, simulating the hazards using the simulation tool and attempting to prevent the hazards using the process hazard analysis tool by introducing protective mechanism(s) to the process; and evaluating effectiveness of the introduced protective mechanisms for each of the hazards and creating safety requirements for the process based on the evaluated effectiveness.

Abstract: Network of safety PLCs employs multi-PLC verification of a programming application before allowing the application to reprogram any PLC on the safety network. Each PLC on the safety network is equipped with authentication capability that detects attempts to reprogram the PLC and issues an authentication challenge requiring the programming application to process a proof-of-work. The authentication challenge is also sent to other PLCs on the safety network along with the response from the programming application for verification purposes. The other PLCs process the authentication challenge and check the response from the programming application for acceptability. If a majority of the PLCs on the safety network determines the response from the programming application is correct, then the programming application is verified and may proceed with the reprogramming.

Abstract: A manufacturing execution system (MES) that provides tools for modeling and determining information about physical production lines made up of arrangements of entities. The MES includes configuration tools for modeling the entities in a physical production line. The MES also includes configuration tools for modeling the physical production line. Entity data models and line data models conform to the data structure of respective model templates. Line data models include line definition models and line layout models. Line layout models include an entity link model for each of the entities in the physical production line. The MES includes tools for dynamically determining the bottleneck for the physical production line. Other production metrics are also calculated using the MES.

Abstract: A manufacturing execution system (MES) that provides tools for modeling and determining information about physical production lines made up of arrangements of entities. The MES includes configuration tools for modeling the entities in a physical production line. The MES also includes configuration tools for modeling the physical production line. Entity data models and line data models conform to the data structure of respective model templates. Line data models include line definition models and line layout models. Line layout models include an entity link model for each of the entities in the physical production line. The MES includes tools for dynamically determining the bottleneck for the physical production line. Other production metrics are also calculated using the MES.

Abstract: A manufacturing execution system (MES) that provides tools for modeling and determining information about physical production lines made up of arrangements of entities. The MES includes configuration tools for modeling the entities in a physical production line. The MES also includes configuration tools for modeling the physical production line. Entity data models and line data models conform to the data structure of respective model templates. Line data models include line definition models and line layout models. Line layout models include an entity link model for each of the entities in the physical production line. The MES includes tools for dynamically determining the bottleneck for the physical production line. Other production metrics are also calculated using the MES.

Abstract: A manufacturing execution system (MES) that provides tools for modeling and determining information about physical production lines made up of arrangements of entities. The MES includes configuration tools for modeling the entities in a physical production line. The MES also includes configuration tools for modeling the physical production line. Entity data models and line data models conform to the data structure of respective model templates. Line data models include line definition models and line layout models. Line layout models include an entity link model for each of the entities in the physical production line. The MES includes tools for dynamically determining the bottleneck for the physical production line. Other production metrics are also calculated using the MES.

Abstract: A system and method are described that simplify defining/designing graphical display interfaces for graphically displaying related data elements. The displays provide both depictions of the data elements and the relationships between the data elements in accordance with a pre-defined data element display scheme including both element template (for particular data element types) and relationship view (spatial relationships within a display) definitions. A relationship view displays a set of provided data elements of specified type according to the element template and relationship view definitions.

Abstract: A system and method are described that simplify defining/designing graphical display interfaces for graphically displaying related data elements. The displays provide both depictions of the data elements and the relationships between the data elements in accordance with a pre-defined data element display scheme including both element template (for particular data element types) and relationship view (spatial relationships within a display) definitions. A relationship view displays a set of provided data elements of specified type according to the element template and relationship view definitions.