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iaiops-process

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Read process instrumentation across HART-IP, OPC-UA, and Modbus with built-in diagnostics for downtime, data quality, and OEE.

What it does

Connects to chemical, pharma, food & beverage, and oil & gas plants via HART-IP (transmitters, valve positioners, loop current on UDP/TCP 5094), OPC-UA (DCS and gateway read), and Modbus-TCP/RTU (skids, analyzers, serial RTU). Includes process-specific tools: PID control loop health triage (oscillation, steady-state offset, output saturation) and heat exchanger fouling detection via thermal efficiency calculation. Exposes a cross-protocol diagnostic brain covering downtime root cause analysis, data quality scoring (staleness, flatline, bad quality), OEE computation, baseline change detection, alarm bad-actor identification, and historian coverage. All protocol tools are read-only by design;…

When to use it

  • Diagnosing a HART transmitter loop fault or burst-mode communication issue
  • Pulling PV/SV/TV/QV data from a DCS via OPC-UA for OEE or anomaly analysis
  • Reading analyzer or skid registers over Modbus-TCP/RTU and mapping them to named tags
  • Running downtime root cause or data quality scorecard across mixed HART/OPC-UA/Modbus assets

The skill document

iaiops-process — 流程工业 edition（HART + Modbus + OPC-UA + 脑）

启动：IAIOPS_MCP=process / iaiops-mcp-process（= opcua + modbus + hart + 脑）。 现场有 UNS/Sparkplug 时用 IAIOPS_MCP=process,sparkplug（sparkplug 工具清单见 iaiops-factory skill）。HART 需 extra：pip install iaiops[hart]。

工具

HART-IP（只读；过程仪表 — 变送器、阀门定位器，经网关）

transport 为 udp（默认）或 tcp，端口 5094。

  • hart_device_identity — 通用设备身份（command 0）
  • hart_primary_variable — 主变量 PV（command 1）：值 + 单位码
  • hart_dynamic_variables — 动态变量 PV/SV/TV/QV + 回路电流（command 3）
  • hart_burst_sample — 主动采样 burst 发布的变量；hart_burst_listen — 被动监听非请求 burst publish（待核实 per 网关）

OPC-UA（只读；DCS/网关旁路读取）

  • opcua_server_info / opcua_browse / opcua_read_node / opcua_read_many
  • opcua_subscribe_sample opcua_read_alarms opcua_alarm_events(A&C 带时间戳) opcua_read_history(HDA)
  • opcua_diagnose_connection — 连接失败归因（证书/策略/认证/网络/配置）
  • opcua_discover_tags — 自动发现 + 语义资产建模
  • opcua_health_summary — tag vs 阈值分类；opcua_anomaly_scan — 有界统计异常扫描

Modbus-TCP / Modbus-RTU（只读；撬装/分析仪/RTU 从站）

  • modbus_read_holding modbus_read_input modbus_read_coils modbus_read_discrete
  • modbus_detect_byte_order — 字节/字序自动探测
  • modbus_list_templates / modbus_apply_template — 厂商寄存器模板 → 命名 tag
  • modbus_health_summary — 寄存器 vs 阈值分类

流程专属（edition 工具;仅随 process edition 加载,不进全局脑）

  • control_loop_health — PID 回路诊断:从一段 PV/SP/OP 采样检出振荡(PV 反复穿越 SP)、 稳态偏差(PV 长期偏离 SP)、输出饱和(OP 压在 0/100%)。给 verdict(saturated>oscillating> offset>ok)。非整定器,只分诊哪些回路要看。纯分析,每项引用数值。
  • heat_exchanger_fouling — 换热器结垢检测:按四路温度算热侧温度效能 ε=(hot_in−hot_out)/ (hot_in−cold_in),前后半窗对比;效能低于阈值或下降超阈即 fouling(结垢征兆,先于强制清洗)。 纯分析,喂 OPC-UA/Modbus/HART 温度点,verdict 引用效能数值。

跨协议脑（永远随 server 暴露）

  • 诊断：diagnose_dataflow downtime_root_cause downtime_root_cause_live downtime_triage learn_cause_weights rca_corpus_from_maintenance historian_health alarm_bad_actors tag_health subscription_health heartbeat_health alarm_flood_analysis alarm_cascade alarm_rationalization_worksheet
  • 数据质量：data_quality_scorecard data_quality_fleet_rollup（流程工业重点： staleness / flatline / bad-quality —— 仪表坏数据绝不静默插值喂 AI）
  • 分析：oee_compute downtime_events oee_multidim monitor_changes health_summary (deprecated) anomaly_scan (deprecated)
  • 资产：asset_inventory cross_protocol_asset_model adopt_alias_map diff_alias_map
  • 基线：baseline_learn baseline_check baseline_record_change baseline_status （change-log 基线：拒学薄历史、只报持续越带、每次告警必引基线样本 —— 非黑盒异常检测）
  • 合规/信创：compliance_mapping compliance_frameworks compliance_dengbao_levels compliance_report compliance_evidence_bundle historian_push export_data historian_query historian_coverage stream_publish stream_publish_event rca_narrate fleet_status fleet_incidents pdm_forecast historian_push export_data
  • 程序解读：plc_program_outline plc_program_xref plc_program_section plc_program_visibility（解读导出的 ST/AWL/L5X 程序,只读文件,强制引用行号）
  • 元：protocols_supported

Workflows

  1. Doctor-first：protocols_supported → iaiops doctor → HART 先 hart_device_identity 证明网关链路，OPC-UA 先 opcua_diagnose_connection。
  2. Read-first：仪表读 PV（hart_primary_variable）→ 动态变量 → burst； 回路异常/告警风暴用 alarm_bad_actors（ISA-18.2），"没数据"用 diagnose_dataflow。
  3. MOC 写：本 edition 三个协议的工具全部只读（无写表面）。若叠加 sparkplug， mqtt_publish 为 [WRITE][HIGH][MOC]：默认 dry_run=True + 改前状态 undo + iaiops approve 具名审批双确认。未经授权绝不写生产控制系统。

支持版本矩阵（内部 HLD §8，设计文档不随本仓发布；待核实 不得当既成事实）

协议库(pin)规范/版本覆盖传输自测
HART-IPhart-protocol>=2023.6,<2025（extra）HART-IP（经网关）过程仪表：变送器/阀门定位器UDP/TCP 5094⚠️ codec CI 自测；真机网关 待核实
OPC-UAasyncua>=2.0,<3OPC UA 1.0x（DA+HA+AC 子集）任意合规 Server / DCS 网关opc.tcp✅ mock+HDA
Modbus-TCPpymodbus>=3.5,<4App 1.1b3；FC 1/2/3/4/5/6/15/16任意 TCP 从站TCP/502✅
Modbus-RTUpymodbus>=3.5,<4 + pyserial>=3.5Modbus serial (RTU)串口从站RS-485/serial✅ socat PTY verified 2026-07-02；物理 RS-485 待核实

Questions people ask

What transport layers does HART-IP use?
HART-IP operates on UDP or TCP port 5094 through a gateway. The skill provides device identity (command 0), primary variable (command 1), dynamic variables PV/SV/TV/QV with loop current (command 3), and burst sample/listen tools.
Are writes allowed to the DCS or field instruments?
No. All HART-IP, OPC-UA, and Modbus tools in this edition are strictly read-only. If Sparkplug/MQTT is enabled, mqtt_publish is gated behind MOC approval with dry_run=True and undo capability.
How does data quality handling differ from standard monitoring?
The data quality scorecard flags staleness, flatline, and bad-quality tags — ensuring corrupted or missing instrument data is not silently interpolated before feeding AI or analytics.

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