Local device and process diagnostics in a process control network having distributed control functions

Claim 2

A field device for use in a process control system including a plurality of field devices mutually coupled by a two-wire, digital, powered bus, the bus supplying a field device control signal to the field device, the field device comprising: a pneumatically operated fluid control valve having an actuator connected to a pneumatic pressure line, wherein said actuator is adapted to cause the fluid control valve to move to a position ranging from an open position to a closed position; a position sensor coupled to the fluid control valve that senses the position of the fluid control valve; a pressure sensor coupled to the pneumatic pressure line that senses a pneumatic pressure within the pneumatic pressure line; an electrical to pneumatic transducer coupled to the actuator by the pneumatic pressure line adapted to control the pneumatic pressure in the pneumatic pressure line as a function of an electrical signal; an electronic controller communicatively coupled directly to the electrical to pneumatic transducer, the pressure sensor, and the position sensor other than through the bus, the electronic controller including a control logic that determines the electrical signal based on feedback signals indicative of a pressure sensed by the pressure sensor and a position sensed by the position sensor and based on the field device control signal; and a digital interface coupled to the two-wire, digital, powered bus and coupled to the electronic controller, the digital interface including: a power circuit adapted to be coupled to the bus that supplies power derived from the powered bus to the electronic controller and the electrical to pneumatic transducer, and a two-way communication circuit adapted to receive a field device control signal from the bus and to transmit signals indicative of a status of the field device to the bus.

Claim 3

A field device according to claim 1, further including a pneumatic relay coupled on the pneumatic pressure line between the electrical to pneumatic transducer and the valve and the pressure sensor is coupled to the pneumatic pressure line between the electrical to pneumatic transducer and the pneumatic relay.

Claim 4

A field device according to claim 2, including a further pressure sensor coupled to the pneumatic pressure line between the pneumatic relay and the valve.

Claim 5

A field device according to claim 1, further including a pneumatic relay coupled on the pneumatic pressure line between the electrical to pneumatic transducer and the valve and the pressure sensor is coupled to the pneumatic pressure line between the pneumatic relay and the valve.

Claim 6

A field device according to claim 1, wherein the pneumatic pressure line includes a pressure supply line that is coupled to an input of the electrical to pneumatic transducer and the pressure sensor is coupled to the pneumatic pressure supply line to measure the pressure supplied to the input of the electrical to pneumatic transducer.

Claim 7

A field device according to claim 1, further comprising: a second control logic for execution in the electronic controller for executing and controlling a diagnostic valve test protocol in response to a diagnostic test request received from the bus and for generating valve diagnostic data corresponding to variations in pressure measured by the pressure sensor and variations in valve position measured by the position sensor, and a storage coupled to the electronic controller for storing the valve diagnostic data.

Claim 8

A field device according to claim 6, further comprising: a third control logic for execution in the electronic controller for digitally transmitting valve diagnostic data to the bus.

Claim 9

A field device according to claim 7, wherein the field device executes the diagnostic test protocol independently of operations of other field devices on the bus.

Claim 10

A field device according to claim 1, wherein the digital interface communicates via the two-wire, digital, powered bus using a Fieldbus standard communication protocol.

Claim 11

A process control system comprising: a control console for generating commands and receiving data; a two-wire, digital, powered bus coupled to the control console; and a plurality of field devices mutually coupled by the two-wire, digital, powered bus, the bus supplying commands including a field device control signal to the field devices, one of the field devices including: a pneumatically operated fluid control valve having an actuator coupled to a pneumatic pressure line to cause the fluid control valve to move to a position ranging from an open position to a closed position; a position sensor coupled to the fluid control valve for sensing the position of the fluid control valve; a pressure sensor coupled to the pneumatic pressure line for sensing the pneumatic pressure within the pressure line; an electrical to pneumatic transducer coupled to the valve by the pneumatic pressure line for controlling the pneumatic pressure in the pneumatic pressure line as a function of an electrical signal; an electronic controller communicatively coupled directly to the electrical to pneumatic transducer, the pressure sensor, and the position sensor other than through the bus, the electronic controller including a control logic that determines the electrical signal based on feedback signals indicative of a pressure sensed by the pressure sensor and a position sensed by the position sensor and based on the field device control signal; and a digital interface coupled to the two-wire, digital, powered bus and coupled to the electronic controller, the digital interface including: a circuit for supplying power derived from the powered bus to the field device including the electronic controller and the electrical to pneumatic transducer, and a two-way communication circuit for receiving signals including the field device control signal from the bus and transmitting signals indicative of a status of the field device to the bus.

Claim 12

A process control system comprising: a control console for generating commands and receiving data; a two-wire, digital, powered bus coupled to the control console; and a plurality of field devices mutually coupled by the two-wire, digital, powered bus, the bus supplying commands including a field device control signal to the field devices, one of the field devices including: a pneumatically operated fluid control valve having an actuator coupled to a pneumatic pressure line to cause the fluid control valve to move to a position ranging from an open position to a closed position; a position sensor coupled to the fluid control valve for sensing the position of the fluid control valve; a pressure sensor coupled to the pneumatic pressure line for sensing the pneumatic pressure within the pressure line; an electrical to pneumatic transducer coupled to the valve by the pneumatic pressure line for controlling the pneumatic pressure in the pneumatic pressure line as a function of an electrical signal; an electronic controller communicatively coupled directly to the electrical to pneumatic transducer, the pressure sensor, and the position sensor other than through the bus, the electronic controller including a control logic that determines the electrical signal based on feedback signals indicative of a pressure sensed by the pressure sensor and a position sensed by the position sensor and based on the field device control signal; and a digital interface coupled to the two-wire, digital, powered bus and coupled to the electronic controller, the digital interface including: a circuit for supplying power derived from the powered bus to the field device including the electronic controller and the electrical to pneumatic transducer, and a two-way communication circuit for receiving signals including the field device control signal from the bus and transmitting signals indicative of a status of the field device to the bus.

Claim 13

A process control system according to claim 10, further including a pneumatic relay coupled on the pneumatic pressure line between the electrical to pneumatic transducer and the valve and the pressure sensor is coupled to the pneumatic pressure line between the electrical to pneumatic transducer and the pneumatic relay.

Claim 14

A process control system according to claim 10, further including a pneumatic relay coupled on the pneumatic pressure line between the electrical to pneumatic transducer and the valve and the pressure sensor is coupled to the pneumatic pressure line between the pneumatic relay and the valve.

Claim 15

A process control system according to claim 10, wherein the pneumatic pressure line includes a pressure supply line that is coupled to an input of the electrical to pneumatic transducer and the pressure sensor is coupled to the pressure supply line to measure the pressure supplied to the input of the electrical to pneumatic transducer.

Claim 16

A process control system according to claim 10, further comprising: a second control logic for execution in the electronic controller for executing and controlling a diagnostic valve test protocol in response to a diagnostic test request received from the bus and for generating valve diagnostic data corresponding to variations in pressure measured by the pressure sensor and variations in valve position measured by the position sensor; and a storage coupled to the electronic controller for storing the valve diagnostic data.

Claim 17

A process control system according to claim 14, further comprising: a third control logic for execution in the electronic controller for digitally transmitting valve diagnostic data to the bus.

Claim 18

A process control system according to claim 15, wherein the field device executes the diagnostic test protocol independently of operations of other field devices on the bus.

Claim 19

A process control system according to claim 10 wherein: the control console includes an operating logic for generating and transmitting a plurality of diagnostic test commands for a plurality of field devices; and the plurality of field devices each includes further operating logic for executing the diagnostic test commands independently of operations of other field devices on the bus so that the operations are executed in parallel.