Apparatus and method for monitoring and maintaining plant equipment

• US 20050222813A1
• Filed: 05/26/2005
• Published: 10/06/2005
• 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 7,308,331 B2
• Time in Patent Office: Days
• US Class Current: 702/183
• 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 failure and other data relating to a pump, seal or other equipment. Data indicating the current state of the equipment may be gathered and verified prior to a failure occurring so that accurate information is available. After a failure or problem occurs, data about the system and the problem or failure can be methodically gathered to aid in the determination of the root cause of the failure. The data may be synthesized and an analysis performed to determine the cause or causes of the failure or problem. The system may suggest corrective actions and plans for implementing 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 plant performance method, to provide data regarding corrective action relating to a failure of a piece of equipment, the method comprising the steps of:

storing first data indicative of at least one characteristic of said piece of equipment;

providing second data representative of an actual failure relating to said piece of equipment;

accessing at least a portion of said first data, with use of said second data; and

providing third data indicative of corrective action relating to said actual failure of said piece of equipment.

2. A plant performance method as in claim 1, wherein the step of storing first data comprises:

storing first data including data relating to corrective action regarding at least one failure of said piece of equipment.

3. A plant performance method as in claim 1, wherein the step of providing third data comprises:

providing third data comprising engineering data relating to said piece of equipment.

4. A plant performance method as in claim 1, wherein the step of providing third data comprises:

providing third data comprising replacement part data regarding at least one replacement part.

5. A plant performance method as in claim 1, wherein the step of providing third data comprises:

providing third data comprising data usable to order at least one replacement part.

6. A plant performance method as in claim 1, wherein the step of providing third data comprises:

providing third data comprising data usable to generate a proposal for at least one replacement part.

7. A plant performance method as in claim 1, wherein the step of providing third data comprises:

providing third data comprising data usable to generate a request for quote regarding procurement of at least one replacement part.

8. A plant performance method as in claim 1, wherein said piece of equipment is one of a mechanical seal, a piece of rotating equipment and a bearing.

9. A plant performance method, to detect a design deficiency regarding a piece of equipment, the method comprising the steps of:

storing first data indicative of at least one characteristic of said piece of equipment;

providing second data representative of an operational deficiency relating to said piece of equipment;

accessing at least a portion of said first data, with use of said second data; and

providing third data indicative of a design deficiency relating to operation of said piece of equipment.

10. A plant performance method as in claim 9, wherein the step of storing first data comprises:

storing first data including data relating to the design of said piece of equipment.

11. A plant performance method as in claim 9, further comprising the step of:

outputting said third data indicative of a design deficiency.

12. A plant performance method as in claim 9, further comprising the step of:

storing said third data indicative of a design deficiency to enable accessing thereof with said first data.

13. A plant performance method as in claim 9, wherein said data indicative of a design deficiency includes data indicative of at least one deficiency of a system related to operation of said piece of equipment.

14. A plant performance method, to prepare a request for quote regarding a piece of equipment, the method comprising the steps of:

storing first data indicative of at least one characteristic of said piece of equipment;

receiving information regarding preparation of a request for quote relating to said piece of equipment;

accessing at least a portion of said first data, with use of said information;

providing second data usable to prepare a request for quote; and

preparing a request for quote with use of said second data.

15. A plant performance method as in claim 14, wherein the step of preparing a request for quote comprises:

preparing a request for quote for corrective action relating to a failure of said piece of equipment.

16. A plant performance method as in claim 14, wherein the step of preparing a request for quote comprises:

preparing a request for quote for failure analysis regarding a failure of said piece of equipment.

17. A plant performance method as in claim 14, wherein the step of preparing a request for quote comprises:

preparing a request for quote for a specification relating to said piece of equipment or a component thereof.

18. A plant performance method as in claim 14, wherein the step of preparing a request for quote comprises:

preparing a request for quote for machining data usable with computer numerically controlled equipment for manufacturing said piece of equipment or a component thereof.

19. A plant performance method as in claim 14, wherein the step of preparing a request for quote comprises:

preparing a request for quote relating to one of said piece of equipment, a component thereof and a system in which said piece of equipment is used.

20. A plant performance method, to provide information regarding plant reliability, the method comprising the steps of:

storing first data regarding plant reliability, including data relating to a piece of equipment used in said plant;

receiving information relating to a request for information regarding plant reliability;

accessing said first data, with use of said information; and

providing information regarding reliability of operation of said plant.

21. A plant performance method as in claim 20, wherein the step of receiving information regarding a request comprises:

receiving information relating to a request for information regarding reliability of said piece of equipment.

22. A plant performance method as in claim 20, wherein the step of storing first data comprises:

storing first data relating to a failure of a piece of equipment used in said plant.

23. A plant performance method as in claim 20, additionally comprising the step of:

using said information regarding reliability of operations to output such information.

24. A plant performance method, to provide data regarding an operational failure affecting plant performance, the method comprising the steps of:

determining a party responsible for implementing corrective action regarding said operational failure;

storing first data regarding action by said party to provide corrective action in subsequent occurrences of said operational problem; and

storing second data comprising maintenance data indicative of the causes of subsequent occurrences of said operational failure.

25. A plant performance method as in claim 24, wherein the step of storing second data comprises:

storing second data indicative of the performance of said party in implementing said corrective action.

26. A plant performance method as in claim 24, wherein the step of storing second data comprises:

storing second data relating to mean time between failure regarding said subsequent occurrences.

27. A plant performance method as in claim 24, wherein the step of storing second data comprises:

storing second data usable in determining life cycle costs of a piece of equipment involved in a subsequent occurrence.

28. A plant performance method as in claim 24, wherein the step of storing second data comprises:

storing second data usable in determining downtime of a piece of equipment involved in a subsequent occurrence.

29. A plant performance method as in claim 24, wherein said subsequent occurrences involve a failure of a piece of equipment.