ONLINE CONDITION-BASED MONITORING FOR TANK FARMS

• US 20100299105A1
• Filed: 05/11/2010
• Published: 11/25/2010
• Est. Priority Date: 05/20/2009
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Vass, Jiri, Stluka, Petr, Sai, Bin
• Granted Patent: US 8,249,829 B2
• Time in Patent Office: Days
• US Class Current: 702/184
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/32234 Maintenance planning
• CPC Class Codes: G05B 23/0254 based on a quantitative model, e.g. mathematical relationships between inputs and outputs; functions: observer, Kalman filter, residual calculation, Neural Networks
• 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: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A method for online condition-based monitoring (CBM) of a tank farm including a plurality of storage tanks includes providing a tank model including a diagnostic and/or predictive tank model based on calculated tank metrics that is derived from historical data including tank operation data. The calculated tank metrics include tank operational metrics based on the tank operational data for the storage tanks and tank condition metrics based on tank inspection or maintenance data for the storage tanks. The tank model provides relationships between the tank condition metrics and the tank operational metrics. Results are generated using the tank model including at least one failure indicia for at least a first of the storage tanks using the calculated tank metrics and current measured data for the first tank as inputs to the tank model. The failure indicia is processed for scheduling at least one maintenance task for the first tank.

Claims

1. A method for online condition-based monitoring (CBM) of at least one tank farm including a plurality of storage tanks, comprising:

providing a tank model comprising at least one of a diagnostic tank model and a predictive tank model based on calculated tank metrics archived in a data store that is derived from collected historical data including tank operational data, said calculated tank metrics including tank operational metrics based on said tank operational data for said plurality of storage tanks and tank condition metrics based on tank inspection data or tank maintenance data for said plurality of storage tanks, said tank model providing relationships between said tank condition metrics and said tank operational metrics;

generating results using said tank model including at least one failure indicia for at least a first of said plurality of storage tanks using said calculated tank metrics archived in said data store and current data for said first tank as inputs to said tank model, and

processing said failure indicia for scheduling at least one maintenance task for said first tank.

2. The method of claim 1, wherein said failure indicia includes at least one of an abnormal tank condition, an estimate of fault extent, a likelihood of one or more specific failures, long-term sensor degradation including drift or bias, and an estimate of a time-to-failure as a function of stress.

3. The method of claim 1, wherein said processing further comprises processing of said results to generate a summarization of an estimated condition of respective ones of said plurality of storage tanks, and clustering respective ones of said plurality of storage tanks into priority groups according to said estimated conditions.

4. The method of claim 1, wherein said collected historical data comprises said tank operational data, said tank inspection data, said tank maintenance data, tank background information, and environment condition data including at least one of humidity, temperature and wind.

5. The method of claim 1, wherein said tank operational data is automatically collected by a plurality of sensors or gauges at each of said plurality of storage tanks, and said tank inspection data, and said tank maintenance data are manually collected.

6. The method of claim 5, wherein said plurality of sensors or gauges are selected from a temperature sensor, a level gauge, a flow meter, a pressure transmitter, a water level sensor, an acoustic sensor, a corrosion monitoring sensor, an infrared sensor, a gas chromatograph, a fiber-optic sensor, and a liquid-sensing probe.

7. The method of claim 1, wherein said collected historical data is transferred to said data store using a secure network.

8. The method of claim 1, further comprising:

automatically conveying an electronic notification to a specified user of said online CBM, wherein said electronic notification comprises said maintenance task and includes a feedback mechanism, wherein said feedback mechanism allows at least one of a verification selection, a reschedule selection, and a rejection selection, and

receiving from said specified user feedback data via said feedback mechanism.

9. The method of claim 8, wherein said tank model is updatable, and wherein said feedback data is utilized by said online CBM to modify a subsequent generation of said tank model.

10. The method of claim 1, wherein said tank model comprises both said diagnostic tank model and said predictive tank model.

11. The method of claim 1, wherein said tank farm processes oil or gas products.

12. The method of claim 1, wherein said plurality of storage tanks comprise above the ground storage tanks (ASTs).

13. The method of claim 1, wherein said plurality of storage tanks comprise underground storage tanks (USTs).

20. The system of claim 11, wherein said tank farm processes oil or gas products.

14. A system for the online condition-based monitoring (CBM) of a tank farm comprising a plurality of storage tanks, comprising:

a plurality of sensors or gauges at each of said plurality of storage tanks;

a data store for storing archived tank data; and

an online CBM system for said tank farm, comprising;

a tank model comprising at least one of a diagnostic tank model and a predictive tank model based on calculated tank metrics archived in said data store that is derived from collected historical data including data including tank operational data obtained in part from said plurality of sensors or gauges, said calculated tank metrics including tank operational metrics based on said tank operational data for said plurality of storage tanks and tank condition metrics based on tank inspection or maintenance data for said plurality of storage tanks, said tank model providing relationships between said tank condition metrics and said tank operational metrics;

wherein said tank model generates results including at least one failure indicia for at least a first of said plurality of storage tanks using said calculated tank metrics archived in said data store and current data for said first tank as inputs to said tank model, and

a data processor for processing said failure indicia for scheduling at least one maintenance task for said first tank.

15. The system of claim 14, wherein said failure indicia includes at least one of an abnormal tank condition, an estimate of fault extent, a likelihood of one or more specific sensor failures and/or abnormal tank condition, long-term sensor degradation including drift or bias, and an estimate of a time-to-failure as a function of stress.

16. The system of claim 14, wherein said data processor processes said results to generate a summarization of an estimated condition of respective ones of said plurality of storage tanks, and clusters respective ones of said plurality of storage tanks into priority groups according to said estimated conditions.

17. The system of claim 14, wherein said collected historical data comprises said tank operational data, said tank inspection data, said tank maintenance data, tank background information, and environment condition data including at least one of humidity, temperature and wind.

18. The system of claim 14, wherein said plurality of sensors or gauges are selected from a temperature sensor, a level gauge, a flow meter, a pressure transmitter, a water level sensor, an acoustic sensor, a corrosion monitoring sensor, an infrared sensor, a gas chromatograph, a fiber-optic sensor, and a liquid-sensing probe.

19. The system of claim 14, wherein said tank model comprises both said diagnostic tank model and said predictive tank model.