Plant process management system with normalized asset health

• US 10,248,114 B2
• Filed: 08/03/2016
• Issued: 04/02/2019
• Est. Priority Date: 10/11/2015
• Status: Active Grant

• Current Assignee: Computational Systems Incorporated (Emerson Electric Company)
• Original Assignee: Computational Systems Incorporated (Emerson Electric Company)
• Inventors: Hilemon, Christopher G., Hayzen, Anthony J., Slemp, Mark
• Primary Examiner(s): Connolly, Mark A
• Application Number:
  US15/227,070
• Publication Number:
  US 20170102695A1
• Time in Patent Office: 972 Days
• CPC Class Codes: G05B 2219/24015 Monitoring
• CPC Class Codes: G05B 23/021 adopting a different treatment of each operating region or a different mode of the monitored system, e.g. transient modes; different operating configurations of monitored system
• CPC Class Codes: G05B 23/0264 Control of logging system, e.g. decision on which data to store; time-stamping measurements
• CPC Class Codes: G06F 16/24578 using ranking

Abstract

A process plant management system with asset health normalization and aggregation. Aspects of the system include asset monitoring components that sense operating parameters and determine the condition of assets using a number of disparate asset condition assessment methodologies based on those parameters. The system calculates normalized component health scores from the reported asset condition information and evaluates the normalized component health scores to produce an overall asset health score for each asset. The system maintains a hierarchical representation that organizes assets using physical and logical relationships. The system generates virtual health scores for parent objects in the hierarchy from the health scores of the children of each parent object.

Claims

1. An apparatus for evaluating health for a plurality of assets in a plant process management system, the apparatus comprising:

a. an asset manager implemented as software running on a processor, and organizing the plurality of assets into a hierarchical arrangement of parent objects and child objects;

b. a plurality of asset monitoring components, each asset monitoring component comprising a sensor operatively connected to one of the assets, each asset monitoring component determining a condition value for the asset based on a parameter measured using the sensor,

c. a health normalization module implemented as software running on a processor, and calculating parametric health scores based on the asset condition values determined by the asset monitoring components, the parametric health scores normalized to a selected range of values, and

d. a user interface allowing selection of a parent object from the hierarchy,

e. wherein the asset manager;

i. computes a normalized asset health score for each child object underlying the parent object that is monitored by one of the asset monitoring components based on the normalized parametric health scores received from the connected asset monitoring component,

ii. computes a virtual health score as the normalized asset health score for each child object underlying the parent object from the normalized asset health score of each child object underlying the unmonitored parent object;

iii. computes a virtual health score for the selected parent object from the normalized asset health score of each child object depending from the selected parent object; and

iv. displays a visualization of the virtual health score for the parent object via the user interface.

2. The apparatus of claim 1:

a. wherein the plurality of asset monitoring components comprises;

b. a first asset monitoring component comprising a sensor operatively connected to a first asset and used to measure a condition value of the first asset, the first asset condition value measured on a first scale; and

c. a second asset monitoring component comprising a sensor operatively connected to a second asset and used to measure a condition value of the second asset, the second asset condition value measured on a second scale; and

d. wherein the health normalization module calculates a first normalized parametric health score for the first asset based on the first asset condition value and a second normalized parametric health score for the first asset based on the second asset condition value.

3. The apparatus of claim 1 wherein the plurality of asset monitoring components includes a first asset monitoring component comprising:

a. at least one sensor operatively connected to a first asset in a first measurement location, each sensor measuring a condition value for the first measurement location; and

b. at least one sensor operatively connected to the first asset in a second measurement location, each sensor measure a condition value for the second measurement location.

4. The apparatus of claim 3 wherein the health normalization module calculates normalized parametric health scores corresponding to the measured condition values, the health normalization module calculating a first measurement location health score from the normalized parametric health scores corresponding to the measured condition values for the first measurement location and a second measurement location health score from the normalized parametric health scores corresponding to the measured condition values for the second measurement location.

5. The apparatus of claim 3 wherein the health normalization module calculates an overall asset health score from the normalized parametric health scores corresponding to the measured condition values for the first and second measurement locations.

6. The apparatus of claim 5 wherein the overall asset health score is one of the lowest measured condition value for the first and second measurement locations and the average of the measured condition values for the first and second measurement locations.

7. The apparatus of claim 5 wherein the overall asset health score is the lowest measured condition value for the first and second measurement locations reduced by the average of the remaining measured condition values for the first and second measurement locations.

8. A method of evaluating health for a plurality of assets in a plant process management system having a plurality of asset monitoring components, each asset monitoring component operatively connected to one of the assets, sensing a parameter associated with the asset, and determining a native health value for the asset based on the sensed parameter, the method comprising the acts of:

a. receiving native health values from the plurality of asset monitoring components;

b. computing parametric health scores based on the native health values, the parametric health scores being normalized to a selected range;

c. computing a measurement location health score for each measurement location of a selected asset from the parametric health scores associated with sensors of an asset monitoring component that are located in the same measurement location of the selected asset;

d. computing an asset health score for the selected asset based on a group of measurement location health scores for the selected asset associated with the same asset monitoring component; and

e. adopting the asset health score as an overall asset health score for the asset when the selected asset is monitored by a single asset monitoring component.

9. The method of claim 8 wherein the act of computing a measurement location health score further comprises the act of computing the measurement location health score for a selected measurement location of the asset by one of calculating the average or the median of the parametric health scores associated with the selected measurement location or selecting as the lowest parametric health score associated with the selected measurement location.

10. The method of claim 8 wherein the act of computing a measurement location health score further comprises the act of computing the measurement location health score for a selected measurement location by reducing the lowest parametric health score associated with the selected measurement location by one of the average and the median of a normalized severity value corresponding with the other parametric health scores associated with the selected measurement location.

11. The method of claim 8 wherein the act of computing an asset health score for the selected asset based on the group of measurement location health scores for the selected asset associated with the same asset monitoring component further comprises the act of reducing the lowest measurement location health score in the group by a weighted average of the remaining measurement location health scores in the group.

12. The method of claim 8 wherein the act of computing an asset health score for the selected asset based on the group of measurement location health scores for the selected asset associated with the same asset monitoring component further comprises the acts of:

a. associating a weight with each asset monitoring component contributing to a measurement location health score;

b. applying the weight associated with the asset monitoring component that produced the measurement location health score to the difference between the maximum value of the selected range and each measurement location health score for a selected asset to produce a set of weight factors associated with the selected asset;

c. dividing an average of the weight factors by an average of the weights associated with the selected asset; and

d. subtracting the quotient from the maximum value of the selected range to produce the asset health score.

13. The method of claim 8 wherein the act of computing an asset health score for the selected asset based on the group of measurement location health scores for the selected asset associated with the same asset monitoring component further comprises the acts of:

a. associating a weight with each parameter contributing to a measurement location health score;

b. applying the weight associated with the parameter on which the measurement location health score is based to the difference between the maximum value of the selected range and each measurement location health score in the group to produce a set of weight factors;

c. subtracting each weight factor from the maximum value of the selected range to produce a set of adjusted measurement location health scores for the selected asset; and

d. selecting the minimum adjusted measurement location health score as the overall asset health score.

14. The method of claim 8 further comprising the act of organizing the plurality of assets into a hierarchical arrangement of child objects and parent objects.

15. The method of claim 14 further comprising the act of generating a virtual health score for a selected parent object by calculating an average of the asset health scores for each child object of the selected parent object or selecting the minimum asset health score from the asset health scores for the child objects of the selected parent object.

16. The method of claim 14 further comprising the acts of:

a. associating a weight with each asset;

b. applying the associated weight to the difference between the maximum value of the consistent scale and the overall asset health score of each child asset of a selected parent asset to produce a set of weight factors;

c. dividing an average of the weight factors by an average of the weights; and

d. subtracting the quotient from the maximum value of the consistent scale to produce a virtual health score for the selected parent asset.

17. The method of claim 8 further comprising the act of generating a virtual health score for a selected parent object from the overall asset health scores for each child object of the selected parent object.

18. The method of claim 17 wherein the act of combining the overall asset health scores for each child asset of a selected parent object to produce a comprehensive health score for the selected parent object further comprises the act of calculating the comprehensive health score as one of an average of the overall asset health scores for the each child asset of the selected parent object or the minimum overall asset health score out of the overall asset health scores for the child assets of the selected parent object.