Apparatus and method for monitoring and maintaining plant equipment

• US 20040133397A1
• Filed: 12/19/2003
• Published: 07/08/2004
• 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 6,934,663 B2
• Time in Patent Office: Days
• US Class Current: 702/185
• 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. As 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 data comprising visual images depicting observable symptoms representative of a plurality of possible failure modes corresponding with the piece of equipment, said visual images usable for visual comparison by the user with observable symptoms of said failure in said piece of equipment;

receiving from the user data based on visual observation of said failure, comprising visual comparison of said visual images with observable symptoms of said failure, including data identifying at least one of said possible failure modes based on said visual comparison; and

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

2. The method as in claim 1, wherein the visual images are digitized photographs.

3. The method as in claim 1, wherein the visual images are schematic drawings.

4. The method as in claim 1, wherein the user performs said visual observation at a first location and the step of analyzing the received data is performed at a second location from which the piece of equipment is not visually observable.

5. 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 as so direct.

6. The method as in claim 5, 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 as so directed is one of (i) an independent step and (ii) included in the step of receiving from the user data identifying at least one failure mode.

7. The method as in claim 1, wherein the step of analyzing the received data comprises the steps of:

matching data representative of a failure mode with data received from the user;

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

selecting data indicative of a root cause of the failure corresponding to the failure mode data as matched to the data received from the user.

8. The method as in claim 1, further comprising the step of:

storing, with reference to said piece of equipment, data regarding said failure.

9. The method as in claim 8, wherein said storing of data includes storing data regarding said data received from the user and said cause of the failure as determined.

10. The method as in claim 1, wherein the data received from the user includes data obtained by visual observation of symptoms observable after the equipment is disassembled.

11. The method as in claim 1, wherein the step of analyzing the received data includes determining a root cause of said failure.

12. The method as in claim 11, wherein the method further comprises the step of:

utilizing the root cause data to determine corrective action.

13. The method as in claim 12, 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.

14. The method as in claim 12, wherein the method further comprises the step of:

providing instructions to a user corresponding to the corrective action.

15. The method as in claim 14, 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.

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

accessing a failure mode 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 observable symptoms with observable symptoms of said failure, including data identifying at least one of said plurality of possible failure modes based on said comparison;

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

selecting data indicative of a root cause of said failure.

17. A method as in claim 16, wherein the step of providing to a user comprises:

providing the user with visual images depicting observable symptoms of a plurality of possible failure modes.

18. The method as in claim 16, 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 as so directed.

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

utilizing the root cause data to determine corrective action.

20. 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 observable symptoms of a plurality of possible failure modes corresponding with the piece of equipment, said data including probability weighting factors associated with possible failure modes;

receiving from the user data based on visual observation of said failure, comprising comparison of said data representative of observable symptoms with observable symptoms of said failure, including data identifying at least one of said possible failure modes based on visual observation; and

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

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

providing the user with visual images depicting observable symptoms of a plurality of possible failure modes.

22. The method as in claim 21, wherein the visual images are digitized photographs.

23. The method as in claim 21, wherein the visual images are schematic drawings.

24. The method as in claim 20, wherein the step of analyzing the received data includes determining a root cause of said failure.

25. The method as in claim 24, wherein the method further comprises the step of:

utilizing the root cause data to determine corrective action.

26. The method as in claim 20, 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 as so directed.

27. The method as in claim 20, wherein the step of analyzing the received data comprises the steps of:

matching data representative of a failure mode with data received from the user;

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

selecting data indicative of a root cause of the failure corresponding to the failure mode data as matched to the data received from the user.

28. The method as in claim 20, wherein the data received from the user includes data obtained by observation of symptoms observable after the equipment is disassembled.

29. The method as in claim 20, further comprising the step of:

storing, with reference to said piece of equipment, data regarding said failure.

30. The method as in claim 29, wherein said storing of data includes storing data regarding said data received from the user and said cause of the failure as determined.

31. 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 observable symptoms of a plurality of possible failure modes corresponding with the piece of equipment;

receiving from the user data based on visual observation of said failure, comprising comparisons of said data representative of observable symptoms with observable symptoms of said failure, including data identifying at least one of said possible failure modes based on said visual observation;

assigning a probability weighting factor to each possible failure mode identified in said data received from the user; and

analyzing the received data with said weighting factors to determine a probable cause of said failure.

32. The method as in claim 31, wherein the step of providing to a user comprises:

providing the user with visual images depicting observable symptoms of a plurality of possible failure modes.

33. The method as in claim 32, wherein the visual images are digitized photographs.

34. The method as in claim 32, wherein the visual images are schematic drawings.

35. The method as in claim 31, wherein the step of analyzing the received data includes determining a root cause of said failure.

36. The method as in claim 35, wherein the method further comprises the step of:

utilizing the root cause data to determine corrective action.

37. The method as in claim 31, 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 as so directed.

38. The method as in claim 31, wherein the step of analyzing the received data comprises the steps of:

matching data representative of a failure mode with data received from the user;

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

selecting data indicative of a root cause of the failure corresponding to the data as matched to the data received from the user.

39. The method as in claim 31, wherein the data received from the user includes data obtained by observation of symptoms observable after the equipment is disassembled.

40. The method as in claim 31, further comprising the step of:

storing, with reference to said piece of equipment, data regarding said failure.

41. The method as in claim 40, wherein said storing of data includes storing data regarding said data received from the user and said cause of the failure is determined.