Abstract: Fault diagnostics utilize an embedded tracking digital twin of a valve assembly physical part in a microprocessor system of the valve positioner. The digital twin has simulation model parameters including a fault-related simulation model parameter. The digital twin receives a control signal representing a real control of the at least part of the valve assembly, and generates simulated measurements relating to the simulated control result. The digital twin compare the simulated measurements with real measurements that relate to the real control result, to track an error between the results of simulated operation and the real operation of the valve assembly to adjust the fault-related simulation model parameter in a sense that the error is decreased. The fault-related simulation model parameter relates to a specific physical fault in the physical part of the valve assembly, and it is detectable and identifiable based on the simulation model parameter adjusted value.

Abstract: A controller for controlling a pneumatic or hydraulic actuator of a process device includes a position feedback signal input for receiving a measured position signal representing a position of the actuator or the process device, an actuator pressure output, and a pressure sensor for measuring the actuator pressure. The controller is configured to operate in a measured position feedback mode and a simulated position feedback mode. In the measured position feedback mode the actuator is controlled dependent on a setpoint position and the measured position, and in the simulated position feedback mode the actuator is controller based on the setpoint position and a simulated position of the actuator or the process device. The simulated position is derived from the measured actuator pressure by a simulation model.

Abstract: A controller for controlling a pneumatic or hydraulic actuator of a process device includes a position feedback signal input for receiving a measured position signal representing a position of the actuator or the process device, an actuator pressure output, and a pressure sensor for measuring the actuator pressure. The controller is configured to operate in a measured position feedback mode and a simulated position feedback mode. In the measured position feedback mode the actuator is controlled dependent on a setpoint position and the measured position, and in the simulated position feedback mode the actuator is controller based on the setpoint position and a simulated position of the actuator or the process device. The simulated position is derived from the measured actuator pressure by a simulation model.

Abstract: A pumping energy savings estimator is provided which, based on valve opening data collected for a control valve of a pump-valve system operating in an industrial process, determines an actual maximum (?porg, ˜50% open) of valve operating region of the control valve of the pump-valve system. User can select a new maximum (?pnew, ˜70% open) of valve operating region for the control valve. Then the estimator, based on the determined actual maximum of valve operating region and the selected new maximum of valve operating region, energy saving potential (?psave) in the pump-valve system. The potential energy savings may be put into practice by replacing the original pump with a new smaller pump, or more preferably, replacing or processing the impeller of the original pump, such that the control valve will operate with the selected new optimal maximum opening of valve operating region.

Abstract: A system having a radio frequency identification (RFID) reader and at least one passive RFID sensor tag, the RFID reader sends a radio frequency interrogation signal from to the passive RFID sensor tag having a sensor that provides a sensor value. The RFID reader receives from the passive RFID tag a backscattered radio frequency signal carrying the sensor value. An interrogation rate of the sensor tag, an accuracy of interrogation and/or a power of the radio frequency interrogation signal transmitted to the sensor tag is controlled based on a statistical analysis of the multiple received sensor values, multiple interrogations and/or a signal-to-noise ratio.

Abstract: A plurality of real control inputs and real process measurements provided by a real automation system controlling an industrial process are continuously stored continuously storing in a historian database. At the same time, a plurality of forecast control inputs and process measurements provided by a virtual automation system based on a simulation model are continuously stored in a futurian database. Both the past operation of the industrial process up to present time based on data from the historian database and the forecast future operation of the industrial process from the present time onwards based on data from the futurian database are displayed on the operator screen.

Abstract: A control loop includes a process controller for controlling a field device in a process. A remote measurement transmitter measures a desired process variable and transmits the measured variable as a wireless measurement signal to a wireless interface unit on the controller side. The interface unit passes the received measurement signal, and a trigger signal indicating a reception of a new measurement, to an adaptive estimator. When triggered by a trigger signal from the wireless interface, i.e. when a new measurement value is received, the adaptive estimator outputs the new value measurement value to the process controller. Otherwise, between consecutive trigger signals, the adaptive estimator generates an estimated measurement value that gradually moves towards a setpoint according to a predetermined estimation algorithm or process.

Abstract: A system having a radio frequency identification (RFID) reader and at least one passive RFID sensor tag, the RFID reader sends a radio frequency interrogation signal from to the passive RFID sensor tag having a sensor that provides a sensor value. The RFID reader receives from the passive RFID tag a backscattered radio frequency signal carrying the sensor value. An interrogation rate of the sensor tag, an accuracy of interrogation and/or a power of the radio frequency interrogation signal transmitted to the sensor tag is controlled based on a statistical analysis of the multiple received sensor values, multiple interrogations and/or a signal-to-noise ratio.

Abstract: A pumping energy savings estimator is provided which, based on valve opening data collected for a control valve of a pump-valve system operating in an industrial process, determines an actual maximum (?porg, ˜50% open) of valve operating region of the control valve of the pump-valve system. User can select a new maximum (?pnew, ˜70% open) of valve operating region for the control valve. Then the estimator, based on the determined actual maximum of valve operating region and the selected new maximum of valve operating region, energy saving potential (?psave) in the pump-valve system. The potential energy savings may be put into practice by replacing the original pump with a new smaller pump, or more preferably, replacing or processing the impeller of the original pump, such that the control valve will operate with the selected new optimal maximum opening of valve operating region.

Abstract: In the method and apparatus of the invention, the process point is taken into account when the condition and performance of a control valve are monitored. In the condition monitoring of the valve, process measurements are used in addition to measurements inside the valve in such a manner that the process measurements identify the operating point at which the valve operates, and the measurements inside the valve are observed at these operating points to detect changes and to determine the condition of the valve. According to an aspect of the invention, the variables representing the operating point of an industrial process are considered when changes in the friction load of the valve and/or the load factor of the actuator are observed.

Abstract: A control loop includes a process controller for controlling a field device in a process. A remote measurement transmitter measures a desired process variable and transmits the measured variable as a wireless measurement signal to a wireless interface unit on the controller side. The interface unit passes the received measurement signal, and a trigger signal indicating a reception of a new measurement, to an adaptive estimator. When triggered by a trigger signal from the wireless interface, i.e. when a new measurement value is received, the adaptive estimator outputs the new value measurement value to the process controller. Otherwise, between consecutive trigger signals, the adaptive estimator generates an estimated measurement value that gradually moves towards a setpoint according to a predetermined estimation algorithm or process.

Abstract: An operator tool is provided to assist an operator of a process or machine in decision making. The tool is initiated by the operator selecting a key variable, “Variable of Interest”, at the user interface. The variable of interest usually is an output variable of interest (such as quality, cost, etc.). At least most significant variables related to the selected variable of interest are automatically determined by a statistical method and shown at the user interface. The operator can adjust the related variables shown on the interface. The impact of one variable to another is demonstrated by a prediction method and shown in a numerical and/or graphical form. After being satisfied with the result of the analysis, the operator decides on which is the preferred parameter change in order to overcome the problem in question or achieve the desired improvement, and then implements the corresponding change on the real system.

Abstract: A plurality of real control inputs and real process measurements provided by a real automation system controlling an industrial process are continuously stored continuously storing in a historian database. At the same time, a plurality of forecast control inputs and process measurements provided by a virtual automation system based on a simulation model are continuously stored in a futurian database. Both the past operation of the industrial process up to present time based on data from the historian database and the forecast future operation of the industrial process from the present time onwards based on data from the futurian database are displayed on the operator screen.

Abstract: A tracking simulator models an industrial process simultaneously and in parallel with the industrial process. The simulator receives control inputs provided by an automation system to control the industrial process. Based on these inputs, the simulator with its process model(s) provides simulated process outputs. In order to avoid divergence of the simulation models from the real process, the tracking simulator receives process measurements from the real process and is able to correct, i.e. update, its models based on these real process measurements and the simulator outputs. One or more of the updated or adjusting parameters for the simulation models are generated by PI or PID controller. Additionally, some of the updated parameters can be generated by an NM or SE method. The PI or PID controller can be an automatic controller tuning tool of the automation system. Additionally, some of the updated parameters can be generated by NM.

Abstract: In the method and apparatus of the invention, the process point is taken into account when the condition and performance of a control valve are monitored. In the condition monitoring of the valve, process measurements are used in addition to measurements inside the valve in such a manner that the process measurements identify the operating point at which the valve operates, and the measurements inside the valve are observed at these operating points to detect changes and to determine the condition of the valve. According to an aspect of the invention, the variables representing the operating point of an industrial process are considered when changes in the friction load of the valve and/or the load factor of the actuator are observed.

Abstract: The invention relates to a method and a system for determining hysteresis of a process device in a process environment. The process comprises collecting (50) second-level sample data ys and us from control and measurement signals u and y of a control circuit. Minute mean values y(min) and u(min), which are stored in a database (52), are calculated from these second-level measurement values. The pairs suitable for hysteresis calculation are selected from the minute-level sample pairs um and ym according to a certain procedure. The pairs are also divided into two groups. Unsuitable pairs are rejected (57). Two characteristic curves (54) are calculated from the selected pairs (um, ym) for hysteresis calculation (55). The calculation (55) also includes a routine which evaluates the reliability of the identified hysteresis.

Abstract: The invention relates to a method for measuring and analyzing the performance of a control circuit in an industrial process. Different parameters (indices) illustrating the state of the control circuit are combined in an intelligent manner such that each combination of index (VI, IAE, CTI, OI) values represents a specific example state of the control circuit. The indices and combinations of their values are selected in advance on the basis of expert knowledge and process research. A momentary state of the control circuit is deduced by computing the performance indices on the basis of the measurement data illustrating the control loop operation and by examining which (one) of the predetermined index value combinations best correlate(s) with the corresponding reference combination values. The reference state representing the best correlating combinations is then deduced to be the momentary state of the control circuit.

Abstract: The invention relates to a method and a system for determining hysteresis of a process device in a process environment. The process comprises collecting (50) second-level sample data ys and us from control and measurement signals u and y of a control circuit. Minute mean values y(min) and u(min), which are stored in a database (52), are calculated from these second-level measurement values. The pairs suitable for hysteresis calculation are selected from the minute-level sample pairs um and ym according to a certain procedure. The pairs are also divided into two groups. Unsuitable pairs are rejected (57). Two characteristic curves (54) are calculated from the selected pairs (um, ym) for hysteresis calculation (55). The calculation (55) also includes a routine which evaluates the reliability of the identified hysteresis.

Abstract: The invention relates to a method for measuring and analysing the performance of a control circuit in an industrial process. Different parameters (indices) illustrating the state of the control circuit are combined in an intelligent manner such that each combination of index (VI, IAE, CTI, OI) values represents a specific example state of the control circuit. The indices and combinations of their values are selected in advance on the basis of expert knowledge and process research. A momentary state of the control circuit is deduced by computing the performance indices on the basis of the measurement data illustrating the control loop operation and by examining which (one) of the predetermined index value combinations best correlate(s) with the corresponding reference combination values. The reference state representing the best correlating combinations is then deduced to be the momentary state of the control circuit.