Condition monitoring system and method

• US 9,477,223 B2
• Filed: 09/14/2011
• Issued: 10/25/2016
• Est. Priority Date: 09/14/2011
• Status: Active Grant

• Current Assignee: Baker Hughes Holdings LLC (Baker Hughes Company)
• Original Assignee: General Electric Company
• Inventors: Shaikh, Tauseef Ahmed, Agrawal, Meera Jitendra, Roaldson, Ryan
• Primary Examiner(s): Yacob, Sisay
• Application Number:
  US13/232,531
• Publication Number:
  US 20130063262A1
• Time in Patent Office: 1,868 Days
• Field of Search: 340/540, 340/3.1, 340/6.1, 340/8.1, 340/506, 340/507, 340/524, 340/525, 340/531, 340/533, 340/539.2, 702/35, 702/81, 702/182, 702/183, 702/184, 702/185, 702/188, 700/108, 700/109, 700/110, 703/2, 705/1.1, 705/28
• US Class Current: 1/1
• CPC Class Codes: G05B 23/0216 Human interface functionality, e.g. monitoring system providing help to the user in the selection of tests or in its configuration
• CPC Class Codes: G05B 23/0272 Presentation of monitored results, e.g. selection of status reports to be displayed; Filtering information to the user

Abstract

Embodiments of a condition monitoring system and method provide an interface with visual aids that facilitate diagnosis of problems on an asset (e.g., a turbine, motor, pump, etc.). In one embodiment, the visual aids display fault data that corresponds to a fault condition such as bearing failure and/or shaft misalignment. The fault data is collected by sensors on the asset and processed by the condition monitoring system for use with the interface. In one example, the interface can include one or more icons, which represent fault conditions for the asset, and which an end user may select to display the visual aids on the interface. Selection amongst the different icons will change the visuals aid, the fault data, and other aspects of the interface to enable diagnosis and promote effective maintenance of the asset.

Claims

1. A condition monitoring system, comprising:

a processor;

a memory coupled to the processor; and

one or more executable instructions stored on the memory and configured to be executed by the processor, the executable instructions comprising instructions that, when executed by the processor, cause the processor to;

determine one or more potential faults for one or more assets based on sensor data;

generate a user interface with asset icons and fault condition icons, wherein each fault condition icon visually depicts a fault condition for an asset, wherein each fault condition is based on the determined one or more potential faults;

receive a user input that corresponds to a selection of one of the fault condition icons from an end user, wherein the user input identifies a particular fault condition for the asset;

select fault data indicative of the particular fault condition in response to the user input; and

display the fault data in one or more visual aids on the user interface,

wherein the selection of one of the fault condition icons defines a theme for the user interface that configures a collection of data, including the one or more visual aids, for the end user to ascertain anomalies that occur during operation of the asset and which indicate the particular fault condition identified by the end user.

2. The condition monitoring system of claim 1, further comprising a plurality of sensors that can collect the fault data from the asset.

3. The condition monitoring system of claim 2, further comprising executable instructions for selecting a measurement location in response to the user input, wherein the measurement location defines a position on the asset for at least one of the sensors.

4. The condition monitoring system of claim 1, further comprising executable instructions that, when executed by the processor, cause the processor to display an alarm level on the visual aid, wherein the alarm level provides at least one threshold value indicative of a failure condition on the asset.

5. The condition monitoring system of claim 1, further comprising executable instructions that, when executed by the processor, cause the processor to display a fault signature on the visual aid, wherein the fault signature provides a visual indication of operation of the asset in real-time.

6. The condition monitoring system of claim 1, wherein the one or more visual aids are configured with data from previous testing of the asset.

7. The condition monitoring system of claim 1, wherein each fault condition comprises one of shaft misalignment, bearing misalignment, unbalance, resonance, looseness, rotor rub, variable air gap, broken rotor bar, cracked rotor bar, loose rotor bar, open rotor bar, stator deflection, bearing fault, and shaft bending.

8. An apparatus for monitoring operation of an asset, said apparatus comprising:

a processor;

a memory; and

one or more executable instructions stored on the memory and configured to be executed by the processor, the executable instructions comprising instructions for generating a user interface comprising;

an asset management component comprising asset icons;

a fault condition selection component comprising fault condition icons that represent one or more fault conditions for the asset, wherein each fault condition icon visually depicts a fault condition for the asset, wherein each fault condition is based on one or more potential faults associated with one or more assets based on sensor data, the fault condition selection component configured to receive a user input that corresponds to a selection of one of the fault condition icons and identifies a particular fault condition for the asset; and

a visual aid display component comprising one or more visual aids displaying fault data corresponding to the selection of one of the fault condition icons from the fault condition selection component,

wherein the selection of one of the fault condition icons defines a theme for the user interface that configures a collection of data, including the one or more visual aids, for an end user to ascertain anomalies that occur during operation of the asset and which indicate the particular fault condition identified by the end user.

9. The apparatus of claim 8, wherein the user interface further comprises an asset navigation tool that has one or more menu items that organizes information and data for the asset.

10. The apparatus of claim 8, further comprising a plurality of sensors coupled to the processor, wherein the plurality of sensors can generate the fault data.

11. The apparatus of claim 8, wherein the fault data on the visual aids represents operation of the asset in real-time.

12. The apparatus of claim 8, wherein the fault data on the visual aids is retrieved from memory.

13. The apparatus of claim 8, wherein each fault condition comprises one of shaft misalignment, bearing misalignment, unbalance, resonance, looseness, rotor rub, variable air gap, broken rotor bar, cracked rotor bar, loose rotor bar, open rotor bar, stator deflection, bearing fault, and shaft bending.

14. A method for displaying an interface on a condition monitoring system including an apparatus having a processor and a memory, said method comprising:

determining one or more potential faults for one or more assets based on sensor data;

generating a user interface with asset icons and fault condition icons, wherein each fault condition icon visually depicts a fault condition for an asset, wherein each fault condition is based on the determined one or more potential faults;

receiving a user input that corresponds to a selection of one of the fault condition icons from an end user and identifies a particular fault condition for the asset;

selecting fault data indicative of the particular fault condition in response to the user input; and

displaying the fault data in one or more visual aids on the user interface,

wherein the selection of one of the fault condition icons defines a theme for the user interface that configures a collection of data, including the one or more visual aids, for the end user to ascertain anomalies that occur during operation of the asset and which indicate the particular fault condition identified by the end user.

15. The method of claim 14, further comprising determining the visual aid for displaying the fault data on the user interface.

16. The method of claim 14, further comprising displaying an alarm level on the visual aid, wherein the alarm level provides at least one threshold value indicative of a failure condition on the asset.

17. The method of claim 14, further comprising displaying a fault signature on the visual aid, wherein the fault signature provides a visual indication of operation of the asset in real-time.

18. The method of claim 14, further comprising selecting a measurement location in response to the user input, wherein the measurement location defines a position for at least one sensor on the asset.

19. The method of claim 14, further comprising selecting a measurement type in response to the user input, wherein the measurement type defines at least one feature of the visual aid.

20. The method of claim 14, further comprising determining the fault conditions that are available based on instrumentation that is coupled to the asset.

21. The method of claim 14, further comprising retrieving the fault data from memory.

22. The condition monitoring system of claim 14, wherein the one or more visual aids are configured with data from previous testing of the asset.

23. The method of claim 14, wherein each fault condition comprises one of shaft misalignment, bearing misalignment, unbalance, resonance, looseness, rotor rub, variable air gap, broken rotor bar, cracked rotor bar, loose rotor bar, open rotor bar, stator deflection, bearing fault, and shaft bending.