Abstract: A technique for controlling a process using non-periodically received process variable measurements enables more robust controller responses to setpoint changes. The control technique implements iterations of a control routine to generate a control signal using a reset or rate contribution component that produces an expected process response to the control signal. When a new measurement of the process variable is unavailable to the controller, the reset or rate contribution component that was generated in response to the receipt of the previous process variable is maintained when generating the control signal. However, the reset contribution component is iteratively recalculated during each controller execution cycle so that the output of the reset contribution component incorporates expected process changes that occur as a result of a setpoint change.

Abstract: In order to reduce or eliminate aliasing in a process control network, filtering of a measurement signal may be set based on the module execution rate in a process control system. A Nyquist frequency for the module may be determined based on the module execution rate where the Nyquist frequency may be twice the execution rate. Filtering after an analog to digital convertor may be set based on the module execution rate. In the analog to digital convertor, digital filtering after the converter may be set based on the module execution rate and the frequency content of the analog signal may be attenuated by a filter at and above the Nyquist frequency for the module execution rate.

Abstract: A method of routing data in a mesh communication network including a plurality of network devices and operating in a process control environment, including assigning one of a plurality of priority levels associated with the communication network to a data packet, sending the data packet from a source network device included in the plurality of network devices to a destination network device included in the plurality of network devices, and routing the data packet to a destination network device via at least one intermediate network device included in the plurality of network devices. The act of routing includes comparing, at each intermediate network device, the priority level of the data packet to a priority mask of the intermediate network device, and modifying at least one of scheduling or routing of the data packet if the priority level of the data packet is not associated with the priority mask of the intermediate network device.

Abstract: A process modeling technique uses a single statistical model developed from historical data for a typical process and uses this model to perform quality prediction or fault detection for various different process states of a process. The modeling technique determines means (and possibly standard deviations) of process parameters for each of a set of product grades, throughputs, etc., compares on-line process parameter measurements to these means and uses these comparisons in a single process model to perform quality prediction or fault detection across the various states of the process. In this manner, a single process model can be used to perform quality prediction or fault detection while the process is operating in any of the defined process stages or states.

Abstract: A method of scheduling communications in a multi-node wireless mesh network which has a first network device and a second network device includes defining a communication timeslot of a predetermined duration, defining a first superframe having a repeating superframe cycle including a first number of the communication timeslots, defining a second superframe having a repeating superframe cycle including a second number of the communication timeslots, aligning the first superframe with the second superframe, so that one of the timeslots of the first superframe begins simultaneously with one of the timeslots of the second superframe, and associating the first and the second superframes with a network schedule, so that the first network device and the second network device transmit data according to the network schedule.

Abstract: A method of adaptively scheduling communications in a wireless mesh network including a plurality of network nodes includes generating a network routing scheme based on a topology of the wireless mesh network, generating a communication schedule for the wireless mesh network, and automatically updating the communication schedule in response to detecting a change in a transmission requirement of at least one of the plurality of network nodes. The act of generating a communication schedule includes defining a communication timeslot of a predefined duration and defining a plurality of superframes as repeating cycles of a certain number of consecutively scheduled communication timeslots.

Abstract: A method of routing a data packet between a first node and a second node on a communication network includes defining a first graph through the first node and the second node and zero or more intermediate nodes, associating several nodes which belong to the communication network with the first graph, associating a first unique graph identifier with the first graph and providing at least partial definitions of the first graph and the first unique identifier to at least some of the nodes associated with the first graph. The method then sends data packet with the graph identifier from the first node, and directs the data packet to the second node via the zero or more intermediate nodes using the graph identifier. This method may include forwarding the packet to a neighbor node of an intermediate node if the intermediate node and the neighbor node are nodes associated with the first graph and if the intermediate node and the neighbor node are connected by at least one direct communication connection.

Abstract: Methods and systems for integrating external and/or enterprise data into a process control system are disclosed. A user interface may be provided to enable browsing and selection of a data item from an external and/or enterprise data source. The selected data item may be associated with a process control entity. At run time, independent of a configuration of the process control entity, an external data integration server or instance of an external data integration service at a process control computing device may periodically communicate with the data source to obtain an updated current value and updated current status for the selected data item for use by the process control entity. The external data integration server and/or external data integration service may consolidate access of external/enterprise data across process control entities, optimize communications with various data sources, and maintain a status of communication with each various data source.

Abstract: Example methods, apparatuses and systems to correlate candidate factors to a predicted fault in a process control system are disclosed. Techniques may include obtaining a value associated with a particular factor corresponding to a process, and predicting a fault based on the value. A set of candidate factors corresponding to the predicted fault may be determined, and a correlation between the predicted fault and at least one factor from the set may be displayed. Different sections of the display may respectively correspond to the predicted fault and to the at least one factor, and the correlation may be indicated by time aligning the different sections. Modifications to one displayed section may result in automatic modification of other sections to maintain the correlation. A user may select one or more candidate factors to be displayed, and may indicate a particular point of a particular section to obtain additional details.

Abstract: A method useful for providing a user interface for a process plant includes displaying graphical depictions of process plant elements of the process plant via the user interface. Information is generated for a plurality of content layers of a process graphic display of the process plant elements by processing data regarding operation of the process plant. Content to be displayed via the user interface is determined from the generated information by determining which content layer of the plurality of content layer is to be displayed. In some embodiments, the determination may be made based on a user profile characteristic. The generated information may therefore support multiple views of the process plant via the user interface for a plurality of different types of users of the user interface, and may involve processing data regarding actual and simulated operation of the process plant.

Abstract: A process is modeled by resolving the process into a plurality of process stages, including at least a first process stage and a second process stage, and developing a plurality of models, each model corresponding to a respective one of the plurality of process stages, wherein the model corresponding to each process stage is developed using data from one or more runs of that process stage and output quality data relating to the one or more runs of that process stage and wherein the model corresponding to each process stage is adapted to produce an output quality prediction associated with that process stage, and wherein the output quality prediction produced by the model of a first one of the process stages is used to develop the model of a second one of the process stages.

Abstract: A batch modeling and analysis system uses a simple and computationally inexpensive technique to align data collected from an on-going, currently running or on-line batch process with a batch model formed for the batch process so as to enable the reliable determination of the current operational state of the on-line batch process with respect to the batch model. This data alignment technique enables further statistical processing techniques, such as projection to latent sources (PLS) and principle component analysis (PCA) techniques, to be applied to the on-line batch data to perform analyses on the quality of the currently running batch. These analyses, in turn, provide useful information to a user, such as a batch operator, that enables the user to determine the quality of the batch at the present time, based on the batch model, and the likelihood that the desired batch output quality metrics will be reached at the end of the batch run.

Abstract: In a batch process control system employing storage tanks without mixers, properties of the storage tank pump out feedstock may be modeled to more accurately control the quality of a process. This model may not require the measurement of input or pump out flow or assume perfect blending. Rather, the developed model may assume that feedstock input into a storage tank may remain layered with some mixing due to continuous convection, turbulence during loading, or other factors. The model may include a projection of the properties describing a storage tank layer of input material into the model. For each new load of storage tank input feedstock, model zones may be shifted and the zone from which the feedstock is drawn may be updated with the properties from the new load.

Abstract: A system and method for controlling a process includes simulating the process and producing a simulated output of the process, developing a set of target values based on measured inputs from the process and based on the simulated output from the process simulator, and producing multiple control outputs configured to control the process based on the set of target values during each operational cycle of the process control system. The simulated outputs include one or more predicted future values up to the steady state of the process.

Abstract: A method in a computer system for developing a process control strategy includes providing a module template having a first plurality of components and being associated with a control operation, receiving a selection of one or more of the first plurality of components of the module template, generating an instance of a module based on the module template, including instantiating only the selected one or more of the first plurality of components, and associating the generated instance of the module with the process control strategy.

Abstract: Methods and systems for integrating external and/or enterprise data into a process control system are disclosed. A user interface may be provided to enable browsing and selection of a data item from an external and/or enterprise data source. The selected data item may be associated with a process control entity. At run time, independent of a configuration of the process control entity, an external data integration server or instance of an external data integration service at a process control computing device may periodically communicate with the data source to obtain an updated current value and updated current status for the selected data item for use by the process control entity. The external data integration server and/or external data integration service may consolidate access of external/enterprise data across process control entities, optimize communications with various data sources, and maintain a status of communication with each various data source.

Abstract: A first principles model may be used to simulate a batch process, and the first principles model may be used to configure a multiple-input/multiple-output control routine for controlling the batch process. The first principles model may generate estimates of batch parameters that cannot, or are not, measured during operation of the actual batch process. An example of such a parameter may be a rate of change of a component (e.g., a production rate, a cell growth rate, etc.) of the batch process. The first principles model and the configured multiple-input/multiple-output control routine may be used to facilitate control of the batch process.

Abstract: A system and method for creating and incorporating a function block within a process control system enables a user of the process control system to generate a function block by combining a plurality of files selected from a group of files provided by the manufacturer of the process control system to form a source code file associated with the function block. The user can modify the function block source code file to include a procedure, routine or algorithm that is not provided by the manufacturer and can send the modified source code file to the manufacturer for validation. If the function block source code file is validated, a security measure such as a digital signature is provided to the user that enables the user to incorporate the function block within the process control system.

Abstract: An appendable system includes a plurality of appendable devices that are adapted to interoperate with each other and/or a workstation via a communication network to monitor and/or control a process. Each of the appendable devices can communicate with one or more sensors and/or control outputs and includes a housing that facilitates mounting of the appendable device to a surface.

Abstract: A system and method for creating and incorporating a function block within a process control system enables a user of the process control system to generate a function block by combining a plurality of files selected from a group of files provided by the manufacturer of the process control system to form a source code file associated with the function block. The user can modify the function block source code file to include a procedure, routine or algorithm that is not provided by the manufacturer and can send the modified source code file to the manufacturer for validation. If the function block source code file is validated, a security measure such as a digital signature is provided to the user that enables the user to incorporate the function block within the process control system.