On-line rotating equipment monitoring device

• US 6,839,660 B2
• Filed: 04/22/2002
• Issued: 01/04/2005
• Est. Priority Date: 04/22/2002
• Status: Active Grant

• Current Assignee: Computational Systems Incorporated (Emerson Electric Company)
• Original Assignee: CSI Technology Incorporated (Emerson Electric Company)
• Inventors: Eryurek, Evren, Bouse, Kai, Reeves, Todd
• Primary Examiner(s): Wachsman, Hal
• Assistant Examiner(s): SUAREZ, FELIX E
• Application Number:
  US10/127,868
• Publication Number:
  US 20030200060A1
• Time in Patent Office: 988 Days
• Field of Search: 702/33, 702/57, 702/65, 702/188, 702/189, 702/116, 702/130, 702/141, 702/163, 702/198, 382/105, 386/46, 700/11, 701/36
• US Class Current: 702/188
• CPC Class Codes: G05B 23/0229 knowledge based, e.g. expert systems; genetic algorithms
• CPC Class Codes: G05B 23/0262 Confirmation of fault detection, e.g. extra checks to confirm that a failure has indeed occurred

Abstract

A rotating equipment monitoring device includes a set of sensors, such as temperature, speed, pressure, and vibration sensors, locally connected to a diagnostic unit having a plant communication interface and a processor that implements one or more diagnostic routines. The diagnostic unit collects data from the sensors and performs diagnostics thereon to detect actual or potential problems with the rotating equipment on a continuous or semi-continuous basis. Using the communication interface, the diagnostic unit automatically sends signals indicating detected conditions of the rotating equipment to a maintenance system or a control system via standard or common communication network, such as a HART or Fieldbus network. The diagnostic unit may also be intermittently coupled to an off-line computer, such a one associated with a service provider, who may verify or further define the diagnostics provided by the diagnostic unit.

Claims

1. A rotating equipment monitoring system for use in a process plant having rotational equipment comprising:

a communication network;

a plurality of sensors adapted to be mounted on or near the rotating equipment to measure parameters associated with the rotating equipment during operation of the rotating equipment and to produce data indicative of the measured parameters; and

a diagnostic unit communicatively coupled to receive the data from each of the plurality of sensors, the diagnostic unit including;

a processor;

a memory;

a diagnostic routine stored in the memory and adapted to be executed on the processor to perform diagnostics using the data collected from the plurality of sensors to produce a first condition indication indicating a condition of the rotating equipment; and

a communication interface adapted to be coupled to the communication network to send the first condition indication and the data over the communication network;

a host computer connected to the communication network and receiving at least the first condition indication and responding to the first condition indication to produce commands for controlling the operation of the rotating equipment;

a service provider computer connected to the communication network for receiving the data, for processing the data to determine the condition of the rotating equipment to produce a second condition indication, and for communicating the second condition indication to the host computer; and

the host computer receiving the second condition indication from the communication network and being responsive thereto to selectively produce commands for controlling the operation of the rotating equipment.

2. The system of claim 1 wherein the communication network comprises a control system connected to a local area network connected to a global computer network.

3. The system of claim 1 wherein:

the service provider computer receives the first condition indication and the data, processes the data to determine the condition of the rotating equipment to produce a second condition indication, generates a verify signal to verify the accuracy of the first condition indication based on the second condition indication, and communicates the verification signal and the second condition indication to the communication network, and

the host computer receives the verify signal and the second condition indication from the communication network and is responsive thereto to selectively produce commands for controlling the operation of the rotating equipment.

4. The system of claim 1 wherein the service provider computer receives at least the data and produces a diagnosis including a suggested solution to the condition.

5. The system of claim 1 wherein the service provider computer receives at least the data and produces a diagnosis including a suggested root cause of the condition.

6. The system of claim 1 wherein the communication network comprises a control system connected to a local area network connected to a global computer network, wherein the host computer is connected to the local area network, the diagnostic system is connected to the control system, and the service provider computer is connected to the global computer network.

7. The rotating equipment monitoring device of claim 6, wherein the plurality of sensors includes an accelerometer.

8. The rotating equipment monitoring device of claim 1, wherein the communication interface is a 2-wire communication interface.

9. The rotating equipment monitoring device of claim 8, wherein the communication interface is a Fieldbus interface.

10. The rotating equipment monitoring device of claim 9, wherein the Fieldbus communication interface is one of a FOUNDATION Fieldbus, a Profibus, and a CAN protocol interface.

11. The rotating equipment monitoring device of claim 8, wherein the communication interface is a HART interface.

12. The rotating equipment monitoring device of claim 1, wherein the communication interface is a TCP/IP protocol interface.

13. The rotating equipment monitoring device of claim 1, wherein the communication interface is a 3-wire communication interface.

14. The rotating equipment monitoring device of claim 1, wherein the communication interface is a 4-wire communication interface.

15. The rotating equipment monitoring device of claim 1, wherein the processor includes a digital signal processor and an application processor.

16. The rotating equipment monitoring device of claim 1, wherein the diagnostic routine is adapted to detect a present operating condition of the rotating equipment based on the data from the plurality of sensors.

17. The rotating equipment monitoring device of claim 1, wherein the diagnostic routine is adapted to detect an expected future operating condition of the rotating equipment based on the data from the plurality of sensors.

18. The rotating equipment monitoring device of claim 1, wherein the diagnostic routine is adapted to detect an error condition associated with the rotating equipment.

19. The rotating equipment monitoring device of claim 1, wherein the diagnostic routine includes an expert engine.

20. The rotating equipment monitoring device of claim 19, wherein the expert engine is a rule-based engine.

21. The rotating equipment monitoring device of claim 1, wherein the communication interface automatically sends the first condition indication via the communication network.

22. The rotating equipment monitoring device of claim 1, wherein the diagnostic unit operates substantially continuously during operation of the rotating equipment.

23. The rotating equipment monitoring device of claim 1, wherein the sensors are adapted to be permanently mounted on or near the rotating equipment.

24. The rotating equipment monitoring device of claim 23, wherein the diagnostic unit is adapted to be permanently mounted on or near the rotating equipment.

25. The rotating equipment monitoring device of claim 1, wherein the diagnostic unit includes a local communication interface for connecting a local interface device to perform monitoring or configuration on the rotating equipment monitoring device.

26. A process plant comprising:

a communication network;

a host computer communicatively coupled to the communication network;

a plurality of field devices;

one or more controllers communicatively coupled to the plurality of field devices via the communication network to control the operation of the process plant using the plurality of field devices;

rotating equipment; and

a monitoring device mounted on or near the rotating equipment including;

a plurality of sensors mounted on or near the rotating equipment to measure parameters associated with the rotating equipment during operation of the rotating equipment and to produce data indicative of the measured parameters; and

a diagnostic unit communicatively coupled to receive the data from each of the plurality of sensors, the diagnostic unit including;

a processor;

a memory;

a diagnostic routine stored in the memory and adapted to be executed on the processor to perform diagnostics using the data collected from the plurality of sensors to produce a first condition indication indicating a condition of the rotating equipment; and

a communication interface coupled to the communication network to send the first condition indication over the communication network; and

,

a service provider computer connected to the communication network for receiving the data, for processing the data to determine the condition of the rotating equipment to produce a second condition indication, and for communicating the second condition indication to the communication network; and

the host computer connected to the communication network and receiving the first and second condition indications from the communication network and being responsive thereto to selectively produce commands for controlling the operation of the rotating equipment.

27. The process plant of claim 26, wherein the plurality of sensors includes two or more of a temperature sensor, a pressure sensor, a vibration sensor, and a rotational speed sensor.

28. The process plant of claim 26, wherein the communication interface is a 2-wire communication interface.

29. The process plant of claim 28, wherein the communication interface is a Fieldbus interface.

30. The process plant of claim 28, wherein the communication interface is a HART interface.

31. The process plant of claim 26, wherein the communication interface is a 3-wire communication interface.

32. The process plant of claim 26, wherein the communication interface is a 4-wire communication interface.

33. The process plant of claim 26, wherein the diagnostic routine includes an expert engine.

34. The process plant of claim 26, wherein the communication interface automatically sends the first condition indication via the communication network to the host computer.

35. The process plant of claim 26, wherein the communication interface automatically sends the first condition indication via the communication network to a display application within the host computer to be displayed to plant personnel.

36. The process plant of claim 26, wherein the communication interface automatically sends the first condition indication via the communication network to a maintenance application within the host computer.

37. The process plant of claim 26, wherein the communication interface automatically sends the first condition indication via the communication network to an optimization application within the host computer.

38. The process plant of claim 26, wherein the diagnostic unit operates substantially continuously during operation of the rotating equipment.

39. The process plant of claim 26, wherein the communication interface of the diagnostic unit can be browsed via the communication network.