System and method for monitoring rotating and reciprocating machinery

• US 8,958,995 B2
• Filed: 02/21/2012
• Issued: 02/17/2015
• Est. Priority Date: 04/02/2009
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Kar, Chinmaya, Sunderam, Meenakshi
• Primary Examiner(s): Raymond, Edward
• Application Number:
  US13/401,769
• Publication Number:
  US 20130218484A1
• Time in Patent Office: 1,092 Days
• Field of Search: 702/36, 702/130, 702182-185
• US Class Current: 702/36
• CPC Class Codes: G01K 13/08 in rotary movement
• CPC Class Codes: G01M 15/05 by combined monitoring of two or more different engine parameters
• CPC Class Codes: G01M 15/12 by monitoring vibrations
• CPC Class Codes: G05B 23/0232 based on qualitative trend analysis, e.g. system evolution
• CPC Class Codes: G05B 23/0243 model based detection method, e.g. first-principles knowledge model
• 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

Abstract

A system includes multiple sensors configured to measure one or more characteristics of a rotating o reciprocating systems. The system also includes a monitoring system configured to monitor a health of the rotating system. The monitoring system includes an input interface configured to receive multiple input signals from the sensors. The monitoring system also includes a processing unit configured to identify a fault in the rotating system using the input signals. The monitoring system further includes an output interface configured to provide an indicator identifying the fault. The processing unit is configured to identify the fault by (i) generating a pressure-volume diagram from a fusion of the input signals and comparing the pressure-volume diagram to a previous diagram to determine changes in the diagrams and/or (ii) normalizing the input signals and using the normalized input signals to identify a defect and calculate a confidence level of the defect.

Claims

1. An apparatus comprising:

an input interface configured to receive multiple input signals, each input signal associated with a respective stage of a rotating or reciprocating system;

a processing unit configured to identify a fault in the rotating or reciprocating system using the input signals, wherein the processing unit is configured to identify the fault by;

generating a first pressure-volume diagram associated with a first stage of the rotating or reciprocating system and a second pressure-volume diagram associated with a second stage of the rotating or reciprocating system from a fusion of the input signals; and

comparing the first and second pressure-volume diagrams to determine whether a problem exists in at least one of the stages;

an output interface configured to provide an indicator identifying the fault.

2. The apparatus of claim 1, wherein the input signals comprise at least one of:

a signal associated with a temperature measurement;

a signal associated with a pressure measurement;

a signal associated with a speed measurement;

a signal associated with a vibration measurement; and

a signal associated with a performance measurement comprising at least one of;

a discharge pressure, a suction pressure, and a suction temperature.

3. The apparatus of claim 1, wherein the input interface is configured to be coupled to at least one of:

a dynamic pressure sensor configured to provide a valve pressure; and

a temperature sensor configured to provide a valve cover temperature.

4. The apparatus of claim 3, wherein the processing unit is configured to:

fuse a first input signal from the dynamic pressure sensor and a second input signal from the temperature sensor;

detect a problem at the valve; and

based on the detected problem, determine whether the valve should be replaced.

5. The apparatus of claim 1, wherein the processing unit is configured to compare a pressure-volume diagram associated with a first stage of the rotating or reciprocating system and a pressure-volume diagram associated with a second stage of the rotating or reciprocating system to determine whether a problem exists in the first stage.

6. The apparatus of claim 1, wherein the processing unit is configured to determine if the fault is at least one of:

a process-related issue;

a valve failure;

a pressure packing failure;

a piston ring failure; and

a defect in a pump system.

7. The apparatus of claim 1, wherein the indicator identifying the fault comprises at least one of:

one or more of the pressure-volume diagrams;

a suction valve condition indicator;

a discharge valve condition indicator;

a pressure rings indicator;

a pressure packing indicator; and

a process issues indicator.

8. An apparatus comprising:

an input interface configured to receive multiple input signals, each input signal associated with a respective stage of reciprocating system;

a processing unit configured to identify a fault in the rotating or reciprocating system using the input signals, wherein the processing unit is configured to identify the fault by normalizing the input signals and using the normalized input signals to identify a defect and calculate a confidence level of the defect; and

an output interface configured to provide an indicator identifying the fault;

wherein the processing unit is configured to normalize the input signals using at least one of;

a root mean square (RMS) value and a Kurtosis value.

9. An apparatus comprising:

an input interface configured to receive multiple input signals, each input signal associated with a respective stage of a rotating or reciprocating system;

a processing unit configured to identify a fault in the rotating or reciprocating system using the input signals, wherein the processing unit is configured to identify the fault by generating a pressure-volume diagram from a fusion of the input signals and comparing the pressure-volume diagram to another diagram to determine changes in the diagrams; and

an output interface configured to provide an indicator identifying the fault;

wherein the processing unit is configured to generate the fusion by performing at least one of;

a fuzzy fusion;

a Dempster-Shafer fusion; and

a Bayesian fusion.

10. A system comprising:

multiple sensors configured to measure one or more characteristics of a rotating or reciprocating system; and

a monitoring system configured to monitor a health of the rotating or reciprocating system, the monitoring system comprising;

an input interface configured to receive multiple input signals from the sensors;

a processing unit configured to identify a fault in the rotating or reciprocating system using the input signals, wherein the processing unit is configured to identify the fault by;

generating a first pressure-volume diagram associated with a first stage of the rotating or reciprocating system and a second pressure-volume diagram associated with a second stage of the rotating or reciprocating system from a fusion of the input signals; and

comparing the first and second pressure-volume diagrams to determine whether a problem exists in at least one of the stages; and

an output interface configured to provide an indicator identifying the fault.

11. The system of claim 10, wherein the input signals comprise at least one of:

a signal associated with a temperature measurement;

a signal associated with a pressure measurement;

a signal associated with a speed measurement;

a signal associated with a vibration measurement; and

a signal associated with a performance measurement comprising at least one of;

a discharge pressure, a suction pressure, and a suction temperature.

12. The system of claim 10, wherein the sensors comprise at least one of:

a dynamic pressure sensor configured to provide a valve pressure; and

a temperature sensor configured to provide a valve cover temperature.

13. The system of claim 12, wherein the processing unit is configured to:

fuse a first input signal from the dynamic pressure sensor and a second input signal from the temperature sensor;

detect a problem at the valve; and

based on the detected problem, determine whether the valve should be replaced.

14. The system of claim 10, wherein the processing unit is configured to compare a pressure-volume diagram associated with a first stage of the rotating or reciprocating system and a pressure-volume diagram associated with a second stage of the rotating or reciprocating system to determine whether a problem exists in the first stage.

15. The system of claim 10, wherein the processing unit is configured to determine if the fault is at least one of:

a process-related issue;

a valve failure;

a pressure packing failure;

a piston ring failure; and

a defect in a pump system.

16. The system of claim 10, wherein the indicator identifying the fault comprises at least one of:

one or more of the pressure-volume diagrams;

a suction valve condition indicator;

a discharge valve condition indicator;

a pressure rings indicator;

a pressure packing indicator; and

a process issues indicator.

17. A system comprising:

multiple sensors configured to measure one or more characteristics of a rotating or reciprocating system; and

a monitoring system configured to monitor a health of the rotating or reciprocating system, the monitoring system comprising;

an input interface configured to receive multiple input signals from the sensors;

a processing sing unit configured to identify a fault in the rotating or reciprocating system using the input signals, wherein the processing unit is configured to identify the fault by generating a pressure-volume diagram from a fusion of the input signals and comparing the pressure-volume diagram to another diagram to determine changes in the diagrams; and

an output interface configured to provide an indicator identifying the fault;

wherein the processing unit is configured to generate the fusion by performing at least one of;

a fuzzy fusion;

a Dempster-Shafer fusion; and

a Bayesian fusion.

18. A method comprising:

receiving multiple input signals, each input signal associated with a respective stage of a rotating or reciprocating system;

identifying a fault in the rotating or reciprocating system using the input signals, wherein the fault is identified by;

generating first a pressure-volume diagram associated with a first stage of the rotating or reciprocating system and a second pressure-volume diagram associated with a second stage of the rotating or reciprocating system from a fusion of the input signals; and

comparing the first and second pressure-volume diagrams to determine whether a problem exists in at least one of the stages; and

providing an indicator identifying the fault.

19. The method of claim 18, wherein:

receiving the input signals comprises receiving a valve pressure from a dynamic pressure sensor and a valve cover temperature from a temperature sensor; and

identifying the fault comprises;

fusing a first input signal from the dynamic pressure sensor and a second input signal from the temperature sensor;

detecting a problem at the valve; and

based on the detected problem, determining whether the valve should be replaced.

20. A non-transitory computer readable medium embodying a computer program, the computer program comprising computer readable program code for:

receiving multiple input signals, each input signal associated with a respective stage of a rotating or reciprocating system;

identifying a fault in the rotating or reciprocating system using the input signals, wherein the fault is identified by;

generating first a pressure-volume diagram associated with a first stage of the rotating or reciprocating system and a second pressure-volume diagram associated with a second stage of the rotating or reciprocating system from a fusion of the input signals; and

comparing the first and second pressure-volume diagrams to determine whether a problem exists in at least one of the stages; and

providing an indicator identifying the fault.