# US 7,162,385 B2 · Control system simulation, testing, and operator training

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- Number: US 7,162,385 B2
- Document ID: US7162385B2
- Status: Granted
- Kind: B2
- Application number: 10/952,085
- Filed: 2004-09-27
- Published: 2005-10-06
- Granted: 2007-01-09
- Earliest claimed: 2000-01-24
- Assignees: Fluor Corporation
- Inventors: Paul G. Scharold; D. Dwight Brayton; Christopher S. Ghormley; Shane R. Addleman
- Web page: https://patentgrep.com/patent/US7162385B2

## CPC

- G06F 11/261: {by simulating additional hardware, e.g. fault simulation}
- G05B 19/05: Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G09B 25/02: of industrial processes; of machinery
- G05B 2219/13174: Pc, computer connected to plc to simulate machine
- G05B 2219/24058: Remote testing, monitoring independent from normal control by pc
- G05B 2219/24061: Simulator, generates input signals, shows output signals of logic
- G06F: ELECTRIC DIGITAL DATA PROCESSING (computer systems based on specific computational models G06N)
- G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G)
- G09B: EDUCATIONAL OR DEMONSTRATION APPLIANCES; APPLIANCES FOR TEACHING, OR COMMUNICATING WITH, THE BLIND, DEAF OR MUTE; MODELS; PLANETARIA; GLOBES; MAPS; DIAGRAMS (devices for psychotechnics or for testing reaction times A61B5/16; games, sports, amusements A63; projectors, projector screens G03B)

## Abstract

A requirements database and test generator generates tests for functional and field testing and generates requirements documentation, user manuals, operational procedures, instrument data sheets, instrument indices, instrument loop diagrams, validation reports, and test reports, including exception and passing reports. A portable process control simulator system which provides control system users with scenarios that mirror field operation as defined.

## Claims

### Claim 1

A method for training an operator to operate a plant control system comprising:
simulating an HMI portion of the plant control system;
simulating the control portion of the plant control system;
simulating the plant sensors and actuators;
coupling and using the simulated HMI, simulated control system, and simulated sensor and actuators together such that operator interaction with the simulated HMI results in the HMI being updated as if the operator was interacting with the HMI portion of a live control system;
wherein the steps of simulating and using are performed on a computer that is uncoupled from the plant control system; and
causing the operator to interact with the simulated HMI.

### Claim 2 (depends on 1)

The method of claim 1 wherein the HMI portion of the plant control system comprises a computer display screen, and simulating the HMI portion of the plant control system includes obtaining images of the display screen during operation of the HMI, and utilizing the obtained images in simulating the HMI portion of the plant control system.

### Claim 3 (depends on 2)

The method of claim 2 wherein the simulated HMI, simulated control system, and simulated plant are each software based and stored on a removable storage medium.

### Claim 4 (depends on 3)

The method of claim 3 wherein the storage medium is a CDROM or DVD disk.

### Claim 5 (depends on 4)

The method of claim 4 wherein the step of simulating the plant is accomplished via a hardware simulator.

### Claim 6

A method of testing a control system and training an operator comprising:
providing an operator to be trained;
coupling a test and training system to a plant control system; wherein the plant control system controls a plurality of actuators in a plant;
causing the test and training system to output a report that indicates both the quality of the operator's performance and the quality of the control system's performance during the period when the operator was interacting with the control system.