Apparatus and method for monitoring and maintaining plant equipment

• US 20030004656A1
• Filed: 07/26/2002
• Published: 01/02/2003
• Est. Priority Date: 02/22/1999
• Status: Active Grant

• Current Assignee: Carl C. Bjornson
• Original Assignee: Carl C. Bjornson
• Inventors: Bjornson, Carl C.
• Granted Patent: US 6,728,660 B2
• Time in Patent Office: Days
• US Class Current: 702/34
• CPC Class Codes: G05B 23/0278 Qualitative, e.g. if-then rules; Fuzzy logic; Lookup tables; Symptomatic search; FMEA
• CPC Class Codes: G05B 23/0283 Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: Y10T 137/0452 Detecting or repairing leak

Abstract

A computer system implements a process for gathering, synthesizing, and analyzing data relating to a pump and/or seal or other rotating equipment failure. Data indicating the current state of the equipment is gathered and verified prior to a failure occurring so that accurate information is available. After a failure or problem occurs, data about the problem or failure are methodically gathered to aid in the determination of the root cause of the failure. In particular, visual images of failure modes are provided to the user to ensure that proper and accurate data are obtained. A user also is directed to gather other data about the failure and the system. After data relating to the problem or failure has been gathered, the data are synthesized and an analysis is performed to determine the root cause of the failure or problem. These various methods and apparatus allow a non-specialist to properly identify and diagnose a failure or problem associated with a mechanical seal and pump. After the analysis has determined the root cause of the problem or failure in the system, the system suggests corrective actions and plans for implementing a corrective action. Installation instructions, training and safety information can be provided to the user to ensure proper execution of the selected corrective action. A plant reliability manager also may monitor the progress and verify that installation, maintenance and failure correction are performed correctly. The plant reliability manager also may track problems or failures by each individual or department to determine if additional training is needed.

Claims

1. A method for analyzing a failure in a piece of equipment, the method comprising the steps of:

providing to a user, for comparison with symptoms of said failure, data representative of a plurality of possible failure modes corresponding with the piece of equipment;

receiving from the user data based on observation of symptoms of said failure, including data identifying at least one of said possible failure modes based on said observation; and

analyzing the received data to determine a cause of said failure.

2. The method as in claim 1, wherein the step of providing to a user comprises:

providing the user with visual images of failure modes.

3. The method as in claim 2, wherein the visual images are digitized photographs.

4. The method as in claim 2, wherein the visual images are schematic drawings.

5. The method as in claim 1, wherein the step of analyzing the received data includes determining a root cause of said failure and the method further comprises the step of:

updating stored data characterizing the piece of equipment with data indicative of the root cause.

6. The method as in claim 1, wherein prior to the step of analyzing the received data the method further comprises the steps of:

directing the user to obtain data from the piece of equipment by visual observation thereof; and

receiving from the user data obtained from the piece of equipment by said visual observation.

7. The method as in claim 6, wherein:

the step of directing the user to obtain data is one of (i) an independent step and (ii) included in the step of providing to a user; and

the step of receiving from the user data obtained from the piece of equipment is one of (i) an independent step and (ii) included in the step of receiving from the user data representative of at least one failure mode.

8. The method as in claim 6, wherein the step of analyzing the received data comprises the steps of:

matching data representative of the failure mode with the user provided data obtained from the piece of equipment;

forming an association between the matched data and data indicative of the root cause of the failure; and

selecting data indicative of a root cause of the failure corresponding to the association of the failure mode and the data obtained from the piece of equipment.

9. The method as in claim 6, wherein the step of directing the user to obtain the data from the piece of equipment includes obtaining the data during a period when the equipment is operating.

10. The method as in claim 6, wherein the step of directing the user to obtain the data from the piece of equipment includes obtaining the data during a period when the equipment is not operating.

11. The method as in claim 6, wherein the step of directing the user to obtain the data from the piece of equipment includes obtaining the data during a period when the equipment is not operating and prior to the disassembling of the piece of equipment.

12. The method as in claim 6, wherein the step of having the user obtain the data from the piece of equipment includes obtaining the data after the equipment is disassembled.

13. The method as in claim 1, wherein the method further comprises the step of:

utilizing the root cause data to determine corrective action.

14. The method as in claim 13, wherein the method further comprises the step of:

updating stored data characterizing the piece of equipment with data indicative of the root cause and corrective action.

15. The method as in claim 13, wherein the step of utilizing the root cause data comprises selecting a corrective action corresponding to the data indicative of the root cause.

16. The method as in claim 13, wherein the method further comprises the step of:

providing instructions to a user corresponding to the corrective action.

17. The method as in claim 16, wherein the step of providing instructions corresponding to the corrective action includes providing a user with a computer displayed engineering drawing of the corrective action.

18. The method as in claim 1, wherein the method further comprises the step of:

providing an approval of the corrective action by another user.

20. A method as in claim 19, wherein the step of providing to a user comprises:

providing the user with visual images of failure modes.

21. The method as in claim 19, wherein prior to the step of accessing said database the method comprises:

directing the user to obtain data from the piece of equipment by visual observation thereof; and

receiving from the user data obtained from the piece of equipment by said visual observation.

22. The method as in claim 21, wherein the step of accessing said database comprises:

matching data received from the user with failure mode data accessible in said database; and

selecting data indicative of a root cause of said failure.

23. The method as in claim 22, wherein the method further comprises the step of:

utilizing the root cause data to determine corrective action.

25. Apparatus as in claim 24, wherein the database (106) comprises visual images representative of failure modes.

26. Apparatus as in claim 25, wherein the visual images are digitized photographs.

27. Apparatus as in claim 25, wherein the first and second data are based on observation of symptoms of the failure by a user able to directly observe the piece of equipment.

28. Apparatus as in claim 24, wherein the system failure analyzer is arranged to cross reference the first and second data for purposes of data validation.

29. Apparatus as in claim 24, further comprising a design deficiency module (503) coupled to the equipment database and the system failure analyzer and arranged to provide to the system failure analyzer data indicative of an incompatibility between the piece of equipment and the first or second data for use by the system failure analyzer in providing output comprising data indicative of the root cause.

30. Apparatus as in claim 24, further comprising:

an information analyzer (250) arranged to receive output data from the system failure analyzer and to provide output data comprising correction action data regarding correction of the failure.

31. Apparatus as in claim 30, wherein the equipment database (224) comprises data indicative of operating conditions of the piece of equipment and at least one of the system failure analyzer and the information analyzer is arranged to access such data indicative of operating conditions in the providing of output data.

32. An apparatus as in claim 30, wherein the information analyzer is arranged to provide output data comprising an action plan corresponding to the corrective action data.

33. An apparatus as in claim 32, wherein the information analyzer is arranged to provide output data comprising follow-up planning corresponding to the action plan.

34. An apparatus as in claim 30, wherein the information analyzer is arranged to provide output data comprising installation instructions compatible with the corrective action data.

35. An apparatus as in claim 30, wherein the information analyzer is arranged to provide output data comprising data related to the failure to be provided to a consultant.

36. An apparatus as in claim 30, wherein the information analyzer is arranged to provide output data to the equipment database to update data regarding characteristics of the piece of equipment based on the output data provided by the information analyzer.

37. An apparatus as in claim 30, wherein the information analyzer is arranged to provide output data comprising training information to execute corrective action.

38. Apparatus as in claim 30, further comprising:

a process fluid database comprising data indicative of a characteristic of a process fluid used with the piece of equipment; and

a process fluid analyzer (512) coupled to the process fluid database and at least one of the system failure analyzer and the information analyzer, and arranged to provide output data comprising data indicative of a possible incompatibility of the piece of equipment and a process fluid.

39. Apparatus as in claim 30, further comprising:

a mechanical seal verifier (514) arranged to receive data indicative of a characteristic of the piece of equipment and data indicative of a characteristic of a mechanical seal used with that equipment, the mechanical seal verifier coupled to at least one of the system failure analyzer and the information analyzer, and arranged to provide output data indicative of a possible incompatibility of the piece of equipment and the mechanical seal.

40. Apparatus as in claim 39, wherein the mechanical seal verifier is coupled to the equipment database (224) and said database comprises data indicative of characteristics of at least one mechanical seal usable with the piece of equipment.

41. Apparatus as in claim 30, further comprising:

an input-output module (502) coupled to the equipment database and arranged to receive input data including new equipment data and provide data representative of input data to the equipment database for inclusion therein.

42. Apparatus as in claim 30, further comprising:

a plant performance database comprising data indicative of a characteristic of maintenance data of the piece of equipment; and

a plant performance module (122) coupled to the plant performance database and at least one of the system failure analyzer and the information analyzer, and arranged to receive data indicative of a failure of the piece of equipment and provide output data comprising plant reliability data to the plant performance database for inclusion therein.

43. Apparatus as in claim 42, wherein the plant performance module is arranged to provide output data comprising life cycle cost data.

44. Apparatus as in claim 42, wherein the plant performance module is arranged to provide output data comprising mean time between failure data.

46. Apparatus as in claim 45, wherein the system failure analyzer is arranged to cross reference the first and second data for purposes of data validation.

47. Apparatus as in claim 45, further comprising a design deficiency module (503) coupled to the system failure analyzer and arranged to provide to the system failure analyzer data indicative of an incompatibility between the piece of equipment and the first or second data for use by the system failure analyzer in providing output comprising data indicative of the root cause.

48. Apparatus as in claim 45, further comprising:

a process fluid database comprising data indicative of a characteristic of a process fluid used with the piece of equipment; and

a process fluid analyzer (512) coupled to the process fluid database and the system failure analyzer, and arranged to provide output data comprising data indicative of a possible incompatibility of the piece of equipment and a process fluid.

49. Apparatus as in claim 45, further comprising:

a mechanical seal verifier (514) arranged to receive data indicative of a characteristic of the piece of equipment and data indicative of a characteristic of a mechanical seal used with that equipment, the mechanical seal verifier coupled to the system failure analyzer and arranged to provide output data indicative of a possible incompatibility of the piece of equipment and the mechanical seal.

50. Apparatus as in claim 49, further comprising:

an equipment database (224) coupled to the mechanical seal verifier and comprising data indicative of characteristics of at least one mechanical seal usable with the piece of equipment.

51. Apparatus as in claim 50, further comprising:

an input-output module (502) coupled to the equipment database and arranged to receive input data including new equipment data and provide data representative of input data to the equipment database for inclusion therein.

52. Apparatus as in claim 45, further comprising:

a plant performance database comprising data indicative of a characteristic of maintenance data of the piece of equipment; and

a plant performance module (122) coupled to the plant performance database and the system failure analyzer and arranged to receive data indicative of a failure of the piece of equipment and provide output data comprising plant reliability data to the plant performance database for inclusion therein.

53. Apparatus as in claim 52, wherein the plant performance module is arranged to provide output data comprising life cycle cost data.

54. Apparatus as in claim 52, wherein the plant performance module is arranged to provide output data comprising mean time between failure data.

19. A method for analyzing a failure in a piece of equipment, the method comprising the steps of:

accessing a database comprising failure mode data accessible to provide data representative of possible failure modes of said piece of equipment;

providing to a user, for comparison with symptoms of said failure, data representative of a plurality of possible failure modes of said piece of equipment;

receiving from the user data based on observation of symptoms of said failure, including data identifying at least one of said plurality of possible failure modes based on said observation;

accessing said database, with use of data received in the step of receiving from the user, to determine a cause of said failure.

24. An apparatus, for analyzing a failure in a piece of failed equipment, comprising:

a failure mode database (106) comprising data on equipment failure modes accessible to provide failure mode data representative of a plurality of possible failure modes of said failed equipment for comparison by a user to symptoms of said failure;

an equipment database (224) comprising data on characteristics of equipment, to provide at least one of access to stored data on said failed equipment prior to said failure and storage of data relating to said failure; and

a system failure analyzer (900) coupled to the failure mode and equipment databases and responsive to

(i) first data representative of a failure mode as selected by the user based on observation of the failed equipment in comparison to failure mode data provided to the user from the failure mode database, and

(ii) second data received from the user based on observation of the failed equipment and identifying at least one symptom of said failure,

the system failure analyzer arranged to process the first data and second data to provide output data representative of a cause of said failure.

45. An apparatus, for analyzing a failure in a piece of failed equipment, comprising:

a failure mode database (106) comprising data on equipment failure modes accessible to provide failure mode data representative of a plurality of possible failure modes of said failed equipment for comparison by a user to symptoms of said failure; and

a system failure analyzer (900) coupled to the failure mode database and responsive to

(i) first data representative of at least one failure mode as selected by the user based on observation of the failed equipment in comparison to failure mode data provided to the user from the failure mode database, and

(ii) second data received from the user based on observation of the failed equipment and relating to at least one symptom of said failure,

the system failure analyzer arranged to process the first and second data to provide output data representative of a cause of said failure.

55. A plant performance method, utilizing data corresponding to a piece of equipment, the method comprising the steps of:

storing equipment data indicative of at least one characteristic of a piece of equipment;

storing operating data representative of at least one of the installation, operation and maintenance of the piece of equipment;

storing action data representative of at least one of any failure, modification or corrective action on the piece of equipment;

accessing and analyzing at least a portion of the stored equipment, operating and action data for plant performance purposes comprising one or more of failure analysis, corrective action, reliability analysis, design analysis, and replacement proposal generation relating to the piece of equipment; and

providing output data based on said analysis.

56. A plant performance method as in claim 55, further comprising, before the accessing and analyzing step:

storing data representative of a plurality of failure modes potentially affecting the piece of equipment.

57. A plant performance method as in claim 56, wherein the data representative of failure modes includes visual images of failure modes.

58. A plant performance method as in claim 55, further comprising:

storing data indicative of a responsible party undertaking corrective action following a failure in the piece of equipment;

storing data indicative of subsequent failures of the piece of equipment;

storing maintenance data for the piece of equipment; and

accessing and analyzing at least a portion of the stored data for plant performance purposes comprising tracking the reliability of the responsible party in undertaking corrective action.

59. A plant performance method as in claim 58, wherein the step of storing maintenance data includes storing at least one of mean time between failure data, life cycle cost data and downtime data relating to the piece of equipment.

60. A plant performance method as in claim 55, wherein the step of storing maintenance data includes storing at least one of mean time between failure data, life cycle cost data and downtime data relating to the piece of equipment.

61. A plant performance method as in claim 55, further comprising:

accessing at least a portion of the stored equipment, operating and action data to provide data comprising replacement part data indicative of at least one replacement part required for corrective action to resolve a failure of the piece of equipment.

62. A plant performance method as in claim 61, further comprising:

providing a template for replacement part data;

placing replacement part data into the template; and

preparing a replacement part report for transmission.

63. A plant performance method as in claim 61, wherein the replacement part data comprises engineering data corresponding to at least one of the piece of equipment, a sub-assembly used therewith, and a component thereof.

64. A plant performance method as in claim 55, further comprising:

receiving a request for information regarding the piece of equipment;

accessing at least a portion of the stored equipment, operating and action data to retrieve information for the piece of equipment; and

sending retrieved information in response to the request.

65. A plant performance method as in claim 55, further comprising:

storing data representative of at least one of specifications and computer numerically controlled machining instructions corresponding to at least one of the piece of equipment, a sub-assembly used therewith, and a component thereof, with at least said data indicative of a characteristic of the piece of equipment;

receiving information on a request for quote on an item comprising at least one of the piece of equipment, a sub-assembly used therewith, and a component therewith;

accessing at least a portion of the stored equipment, operating and action data to retrieve information for preparation of a quote on said item; and

preparing a quote on said item using the retrieved information.

66. A plant performance method as in claim 65, wherein the request for quote is a request for at least one of a corrective action, a failure analysis, a specification, and machining instructions for said item.

67. A plant performance method as in claim 65, further comprising, before the step of receiving information, the step of:

providing a standard form template specifying information to be included in the request.

68. A plant performance method as in claim 55, further comprising:

receiving data indicative of a failure or problem affecting the piece of equipment;

accessing the stored data to retrieve information relevant to the failure or problem; and

providing output data comprising information relevant to the failure or problem affecting the piece of equipment.

69. A plant performance method as in claim 68, wherein the step of providing output data comprises:

providing visual images of failure modes.

70. A plant performance method as in claim 69, wherein the visual images are digitized photographs.