METHODS AND SYSTEMS FOR DATA COLLECTION IN CHEMICAL OR PHARMACEUTICAL PROCESS WITH FUTURE STATUS PREDICTION AND LOAD BALANCING

Abstract

Methods and systems for data collection in chemical or pharmaceutical processes with future status prediction and load balancing are disclosed. A monitoring system for data collection can include a data acquisition circuit to interpret a plurality of detection values, each of the plurality of detection values corresponding to input received from an input sensor operatively coupled to a component or a subprocess of the chemical or pharmaceutical process, a data analysis circuit to analyze a subset of the plurality of detection values to determine a future status of a component or subprocess process, wherein the future status includes at least one of: a future state, a future condition, or a future stage, and an analysis response circuit to perform an action in response to the determination of the future status, wherein the action includes rebalancing a process load.

Claims

1. A monitoring system for data collection in a chemical or pharmaceutical process, the system comprising: a data acquisition circuit structured to interpret a plurality of detection values, each of the plurality of detection values corresponding to input received from a detection package, the detection package comprising at least one of a plurality of input sensors, wherein each of the plurality of input sensors is operatively coupled to at least one of a plurality of components or a subprocess of the chemical or pharmaceutical process; a data analysis circuit structured to analyze a subset of the plurality of detection values to determine a future status of at least one of the plurality of components or the subprocess of the chemical or pharmaceutical process, wherein the future status of the at least one of the plurality of components or the subprocess comprises at least one of: a future state of the at least one of the plurality of components, a future condition of the at least one of the plurality of components, or a future stage of the subprocess; and an analysis response circuit structured to perform an action in response to the determination of the future status, wherein the action comprises rebalancing a process load.

2. The monitoring system of claim 1, wherein rebalancing the process load further comprises rebalancing the process load between at least some of the plurality of components to achieve at least one of: extending a life of one of the plurality of components and facilitating maintenance on one of the plurality of components.

3. The monitoring system of claim 1, wherein the action further comprises facilitating maintenance on at least one of the plurality of components.

4. The monitoring system of claim 3, wherein facilitating maintenance comprises facilitating maintenance to achieve at least one of: extending a maintenance interval of one of the plurality of components; synchronizing a first maintenance interval of a first one of the plurality of components with a second maintenance interval of a second one of the plurality of components; differentiating a first maintenance interval of a first one of the plurality of components from a second maintenance interval of a second one of the plurality of components; and aligning a maintenance interval of one of the plurality of components with an external reference time.

5. The monitoring system of claim 4, wherein the external reference time includes at least one of: a planned shutdown time for the subprocess of the chemical or pharmaceutical process, a time that is past an expected completion time of the subprocess of the chemical or pharmaceutical process, and a scheduled maintenance time for the one of the plurality of components.

6. The monitoring system of claim 1, wherein the future status is a future state of the at least one component, and the future state of the at least one component is based on a time parameter.

7. The monitoring system of claim 1, wherein the future status is a future state of the at least one component, and the future state of the at least one component is based on a state of the subprocess.

8. The monitoring system of claim 1, wherein the future status is a future state of the at least one component, and the future state of the at least one component is based on a predetermined predicted value.

9. A monitoring system for data collection in a chemical or pharmaceutical process, the system comprising: a data collector communicatively coupled to a plurality of input channels, wherein the data collector collects data from the plurality of input channels based on a selected data collection routine, wherein each input channel is connected to a monitoring point from which data is collected, wherein the collected data provides a plurality of detection values including detection values for a component of a plurality of components associated with a subprocess of the chemical or pharmaceutical process; a data storage structured to store a plurality of collector routes and collected data that corresponds to the plurality of input channels, wherein the plurality of collector routes each comprises a different data collection routine; a data acquisition and analysis circuit structured to interpret the plurality of detection values from the collected data and structured to determine a future status of the component or the subprocess of the chemical or pharmaceutical process, wherein the future status of the component or the subprocess comprises at least one of: a future state of the component, a future condition of the component, or a future stage of the subprocess; and an analysis response circuit structured to perform an action in response to the determination of the future status, wherein the action comprises rebalancing loads of the plurality of components associated with the subprocess.

10. The monitoring system of claim 9, wherein rebalancing the loads of the plurality of components associated with the subprocess further comprises rebalancing to achieve at least one of: extending a life of at least one of the plurality of components and facilitating maintenance on at least one of the plurality of components.

11. The monitoring system of claim 9, wherein the action further comprises facilitating maintenance on at least one of the plurality of components.

12. The monitoring system of claim 11, wherein facilitating maintenance comprises facilitating maintenance to achieve at least one of: extending a maintenance interval of one of the plurality of components; synchronizing a first maintenance interval of a first one of the plurality of components with a second maintenance interval of a second one of the plurality of components; differentiating a first maintenance interval of a first one of the plurality of components from a second maintenance interval of a second one of the plurality of components; and aligning a maintenance interval of one of the plurality of components with an external reference time.

13. The monitoring system of claim 12, wherein the external reference time includes at least one of: a planned shutdown time for the subprocess of the chemical or pharmaceutical process, a time that is past an expected completion time of the subprocess, and a scheduled maintenance time for one of the plurality of components.

14. The monitoring system of claim 9, wherein the future status is a future state of the component, and the future state of the component is based on a time parameter.

15. The monitoring system of claim 9, wherein the future status is a future state of the component, and the future state of the component is based on a state of the subprocess.

16. The monitoring system of claim 9, wherein the future status is a future state of the component, and the future state of the component is based on a predetermined predicted value.

17. A computer-implemented method for data collection in a chemical or pharmaceutical process, the method comprising: collecting data from a plurality of input channels communicatively coupled to a data collector based on a data collection routine, wherein each input channel is connected to a monitoring point from which data is collected, wherein the collected data provides a plurality of detection values including detection values for at least one of a plurality of components or a subprocess of the chemical or pharmaceutical process; analyzing the plurality of detection values from the collected data to determine a future status of at least one of the plurality of components or the subprocess of the chemical or pharmaceutical process, wherein the future status of the at least one of the plurality of components or the subprocess comprises at least one of: a future state of the at least one of the plurality of components, a future condition of the at least one of the plurality of components, and a future stage of the subprocess; and performing an action in response to the determination of the future status, wherein the action comprises rebalancing process loads.

18. The method of claim 17, wherein the performing an action further comprises rebalancing the process loads between at least some of the plurality of components to achieve at least one of: extending a life of one of the plurality of components and facilitating maintenance on one of the plurality of components.

19. The method of claim 18, wherein the facilitating maintenance comprises extending a maintenance interval of one of the plurality of components.

20. The method of claim 18, wherein the facilitating maintenance comprises synchronizing a first maintenance interval of a first one of the plurality of components with a second maintenance interval of a second one of the plurality of components.

21. The method of claim 18, wherein the facilitating maintenance comprises differentiating a first maintenance interval of a first one of the plurality of components from a second maintenance interval of a second one of the plurality of components.

22. The method of claim 18, wherein the facilitating maintenance comprises aligning a maintenance interval of one of the plurality of components with an external reference time.

23. The method of claim 17, wherein the future status is a future state of the at least one component, and the future state of the at least one component is based on at least one of a time parameter, a state of the subprocess, or a predetermined predicted value.