Plant management system and plant management method

Abstract

To accurately determine an alternative means for substituting an existing facility component member when receiving manufacture stop information of the existing facility component member.SOLUTION: The alternative determination unit determines a first alternative to replace the existing equipment constituent member with the new equipment constituent member if the new equipment constituent member is in stock when the alternative determination unit receives the production discontinuation information, in a case where the first alternative means cannot be determined as the alternative means and a compatible member compatible with the facility configuration member is available, a second alternative means for replacing the existing facility configuration member with the compatible member is determined, and in a case where the first alternative means and the second alternative means cannot be determined as the alternative means, at least one of a third alternative means for replacing the existing facility configuration member with a remodeled replacement member replaceable with the existing facility configuration member by execution of remodelling and a fourth alternative means for replacing the existing plant configuration facility including the existing facility configuration member with a new plant configuration facility is determined.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] FIELD Embodiments of the present invention relate to a plant management system and a plant management method. [Background technology]

[0002] A plant such as a nuclear power plant is equipped with a large number of pieces of equipment (plant components). The equipment is constructed using a plurality of component parts (components, etc.), and as the operating time of the plant increases, the component parts (components, etc.) deteriorate. For this reason, plant maintenance work is performed periodically to keep the plant operating normally. In plant maintenance work, for example, deteriorated component parts (components, etc.) are replaced, and the plant's functionality is maintained until the end of its lifespan (the period from the start to the end of operation, which may be specified by law).

[0003] Various techniques have been proposed to support the replacement of equipment components (parts, etc.). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2003-108691 Summary of the Invention [Problem to be solved by the invention]

[0005] However, due to circumstances such as a manufacturer withdrawing from business, it may be possible to obtain information from a parts manufacturer that the production of existing equipment components (parts, etc.) has been discontinued. In such cases, it may be difficult to procure new equipment components (parts, etc.) to replace deteriorated existing parts, etc., during maintenance work.

[0006] However, in the past, when receiving information that an existing equipment component (part, etc.) had been discontinued, it was sometimes difficult to accurately determine an alternative means to replace the existing equipment component (part, etc.). As a result, in order to maintain the plant, it was sometimes difficult to create a maintenance plan that determined the timing and frequency of maintenance work, taking into account the costs required for plant maintenance over the plant's lifespan. As a result, it was sometimes difficult to continue work such as maintenance efficiently.

[0007] Therefore, the problem that the present invention aims to solve is to provide a plant management system and a plant management method that, when information is received that production of an existing equipment component (part, etc.) has been discontinued, can accurately determine an alternative means to replace the existing equipment component (part, etc.). [Means for solving the problem]

[0008] A plant management system according to an embodiment includes an alternative means determination unit that manages a plant including plant components configured using equipment components. When receiving discontinuation information indicating that production of an existing equipment component installed in the plant component equipment is to be discontinued, the alternative means determination unit determines an alternative means for replacing the existing equipment component. Here, if a new equipment component is available in stock, the alternative means determination unit determines a first alternative means of replacing the existing equipment component with the new equipment component as the alternative means. If the first alternative means cannot be determined as the alternative means and a compatible component that is compatible with the equipment component is available, the alternative means determination unit determines a second alternative means of replacing the existing equipment component with the compatible component as the alternative means. If the alternative means determination unit cannot determine the first alternative means and the second alternative means as alternative means, it determines at least one of a third alternative means of replacing the existing equipment component with a modified replacement part that can be replaced with the existing equipment component by performing a modification, and a fourth alternative means of replacing the existing plant component equipment including the existing equipment component with new plant component equipment, as alternative means. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a block diagram showing a concept of a plant 10 that is a management object managed by a plant management system according to an embodiment. [Figure 2] FIG. 2 is a block diagram schematically showing the functions of the plant management system 20 according to the embodiment. [Figure 3A] FIG. 3A is a flow diagram showing an outline of the operation of the plant management system 20 according to the embodiment. [Figure 3B] FIG. 3B is a flow diagram showing an outline of the operation when the alternative means determination unit 230 determines an alternative means in this embodiment. [Figure 4] FIG. 4 is a diagram illustrating an example of an outline of a maintenance plan created when no production discontinuation information is received in the plant management system 20 of the embodiment. [Figure 5A] FIG. 5A is a diagram illustrating an example of an outline of a maintenance plan created when an alternative measure is determined in response to discontinued production information in the plant management system 20 of the embodiment. [Figure 5B] FIG. 5B is a diagram illustrating an example of an outline of a maintenance plan created when an alternative measure is determined in response to discontinued production information in the plant management system 20 of the embodiment. [Figure 5C] FIG. 5C is a diagram illustrating an example of an outline of a maintenance plan created when an alternative measure is determined in response to discontinued production information in the plant management system 20 of the embodiment. [Figure 5D] FIG. 5D is a diagram illustrating an example of an outline of a maintenance plan created when an alternative measure is determined in response to discontinued production information in the plant management system 20 of the embodiment. [Figure 6] FIG. 6 is a diagram illustrating an example of an outline of a maintenance plan that is created when an alternative method is determined in response to discontinued production information in the first modification of the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0010] [A] Plant 10 Configuration Before describing the plant management system of the embodiment, the concept of a plant that is a management target managed by the plant management system of the embodiment will be described.

[0011] FIG. 1 is a block diagram showing a concept of a plant 10 that is a management object managed by a plant management system according to an embodiment.

[0012] 1, a plant 10 includes, for example, a plurality of pieces of equipment 11 and 12 (plant constituent equipment). In the plant 10, the equipment 11 is made up of, for example, a plurality of parts 111 and 112 (equipment constituent members), and another piece of equipment 12 is made up of, for example, a plurality of parts 121 and 122 (equipment constituent members).

[0013] In facility 11, part 111 is made up of, for example, a plurality of component elements 1111 and 1112, and another part 112 is made up of, for example, a plurality of component elements 1121 and 1122. In facility 12, part 121 is made up of, for example, a plurality of component elements 1211 and 1212, and another part 122 is made up of, for example, a plurality of component elements 1221 and 1222.

[0014] The plant 10 is, for example, a nuclear power plant. The equipment 11, 12 (plant constituent equipment) is, for example, transportation equipment. The parts 111, 112 are, for example, control parts for controlling the transportation equipment. The component elements 1111, 1112, 1121, 1122, 1211, 1212, 1221, 1222 are, for example, elements that constitute the control parts. Naturally, the plant 10 may be a plant other than a nuclear power plant, and the equipment 11, 12, etc. are not limited to the examples described above. Examples include capacitors that constitute control devices, backup batteries, and display panels.

[0015] [B] Configuration of plant management system 20 FIG. 2 is a block diagram schematically showing the functions of the plant management system 20 according to the embodiment.

[0016] As shown in FIG. 2, the plant management system 20 of this embodiment includes a computing unit 200 and a storage device 300, and is configured to manage the above-mentioned plant 10 (see FIG. 1).

[0017] In this plant management system 20, the computing unit 200 is configured to function as an equipment configuration management unit 210, a discontinuation information management unit 220, an alternative means determination unit 230, and a maintenance plan management unit 240 by performing arithmetic processing using programs and various data stored in the storage device 300. The storage device 300 is a database configured to store plant data D310, including part data D311, equipment data D312, design requirement specification data D313, and alternative means data D314. The storage device 300 is also configured to store discontinuation information D320 and maintenance plan data D340. The plant management system 20 may be configured as a cloud system. Details of the plant management system 20 are described below.

[0018] [B-1] Equipment configuration management department 210 The equipment configuration management unit 210 is provided to manage plant data D310 relating to the equipment 11, 12 (plant component equipment) that constitute the plant 10 and the parts 111, 112, 121, 122 (equipment component parts) that constitute the equipment 11, 12 (see FIG. 1).

[0019] The plant data D310 is stored in a database, which is the storage device 300. The plant data D310 is data input from outside. The plant data D310 is updated, for example, by an operator inputting changes using an input device. Furthermore, for example, when the configuration of the plant 10 is changed due to the execution of maintenance or the like, the plant data D310 is updated based on information related to the change.

[0020] In this embodiment, the plant data D310 includes part data D311, equipment data D312, design requirement specification data D313, and alternative means data D314.

[0021] The part data D311 is data related to the existing parts 111, 112, 121, and 122. Specifically, the part data D311 includes information related to the specifications (dimensions, performance, etc.) of the existing parts 111, 112, 121, and 122, and information related to the installation positions of the parts 111, 112, 121, and 122 in the equipment 11 and 12. The part data D311 also includes information related to the specifications (dimensions, performance, etc.) and installation positions of the multiple part elements 1111 and 1112 that make up the part 111, the part elements 1121 and 1122 that make up the part 112, the multiple part elements 1211 and 1212 that make up the part 121, and the part elements 1221 and 1222 that make up the part 122. In addition, the part data D311 includes data on the deterioration state of the existing parts 111, 112, 121, and 122 as they deteriorate over time, and the data on the deterioration state is updated when a maintenance implementation record or the like is obtained.

[0022] The equipment data D312 is data related to the existing equipment 11, 12. Specifically, the equipment data D312 includes information related to the specifications (dimensions, performance, etc.) of the existing equipment 11, 12, information related to the installation positions of the existing equipment 11, 12 in the plant 10, and the like.

[0023] The design requirement specification data D313 is data relating to the required specifications (dimensions, performance, etc.) required in designing the equipment 11, 12 and the parts 111, 112, 121, 122 in the plant 10.

[0024] The alternative means data D314 (applicability evaluation data) is data related to alternative means when replacing existing parts 111, 112, 121, and 122. Specifically, the alternative means data D314 includes information on new parts 111, 112, 121, and 122 that can be replaced with the existing parts 111, 112, 121, and 122. The alternative means data D314 includes information on compatible parts (compatible components) that are compatible with the existing parts 111, 112, 121, and 122. The alternative means data D314 includes information on modified replacement parts (modified replacement components) that can be replaced with the existing parts 111, 112, 121, and 122 by performing a modification. The alternative means data D314 includes information on new equipment 11 and 12 that can be replaced with the existing equipment 11 and 12. The alternative means data D314 includes information on new part elements 1111, 1112, 1121, 1122, 1211, 1212, 1221, 1222 that can be replaced with multiple existing part elements 1111, 1112, 1121, 1122, 1211, 1212, 1221, 1222 that make up the existing parts 111, 112, 121, 122. Here, the alternative means data D314 includes information on procurement of items to be used as alternative means (inventory quantity, procurement period, etc.), information on costs incurred when the alternative means are applied, etc.

[0025] Although details will be described later, when discontinuation information D320 regarding the discontinuation of production of the existing parts 111, 112, 121, and 122 (see FIG. 1) is received, the alternative means data D314 is used in the alternative means determination unit 230 to determine an alternative means to substitute for the existing parts 111, 112, 121, and 122. The alternative means data D314 may be data acquired before the discontinuation information D320 is received, or may be data acquired after the discontinuation information D320 is received.

[0026] In the above, compatible parts (compatible components) are parts that are evaluated as being applicable when replacing existing parts 111, 112, 121, and 122, and are certified as being interchangeable without modification. Modified replacement parts (modified replacement components) are parts that are evaluated as being applicable when replacing existing parts 111, 112, 121, and 122, and are certified as being interchangeable with existing parts 111, 112, 121, and 122 through modification. Modified replacement parts (modified replacement components) include parts that can be replaced with existing parts 111, 112, 121, and 122 by modifying the modified replacement parts (modified replacement components) themselves, as well as parts that can be replaced with existing parts 111, 112, 121, and 122 by modifying other parts related to the modified replacement parts (modified replacement components).

[0027] Applicability is evaluated using the part data D311, the equipment data D312, the design requirement specification data D313, etc. The evaluation of applicability takes into consideration the impact on the plant 10 and the equipment 11 and 12 that constitute the plant 10 (equipment impact), the impact on the functions of the equipment (system function impact), etc. Specifically, a compatible part (compatible member) is determined to be applicable if it has a shape that allows it to be installed in place of the existing parts 111, 112, 121, and 122 in the plant 10 and has specifications that satisfy the required specifications of the existing parts 111, 112, 121, and 122. A modified replacement part (modified replacement member) is determined to be applicable if it has a shape that allows it to be installed in place of the existing parts 111, 112, 121, and 122 in the plant 10 after the modification and has specifications that satisfy the required specifications of the existing parts 111, 112, 121, and 122 after the modification.

[0028] Furthermore, in the present embodiment, the equipment configuration management unit 210 manages the plurality of pieces of equipment 11 and 12 that make up the plant 10, but this is not limiting. For example, the equipment configuration management unit 210 may be configured to manage only a portion (e.g., equipment 11) of the plurality of pieces of equipment 11 and 12 depending on the need for maintenance.

[0029] [B-2] Manufacturing discontinuation information management department 220 The production discontinuation information management unit 220 is provided to manage production discontinuation information D320 relating to the discontinuation of production of the existing parts 111, 112, 121, and 122 (see FIG. 1).

[0030] Here, the discontinuation information D320 is information obtained from, for example, the parts manufacturers that manufacture the parts 111, 112, 121, and 122, and is stored in a database that is the storage device 300. Specifically, the discontinuation information D320 is information about the parts 111, 112, 121, and 122 that will be discontinued (such as the part name, the time of discontinuation, and the equipment that uses the discontinued parts).

[0031] [B-3] Alternative means determination unit 230 The alternative means determination unit 230 is provided to determine alternative means to substitute for the existing parts 111, 112, 121, and 122 when the production discontinuation information management unit 220 receives production discontinuation information D320 that discontinues production of the existing parts 111, 112, 121, and 122 (see FIG. 1).

[0032] Although details will be described later, the alternative means determination unit 230 of this embodiment determines an alternative means using the plant data D310 managed by the equipment configuration management unit 210.

[0033] [B-4] Maintenance Planning Management Department 240 The maintenance plan management unit 240 is configured to create and manage maintenance plans for maintaining the plant 10. Maintenance plan data D340 relating to the maintenance plans is stored in a database, which is the storage device 300. The maintenance plan data D340 includes information on the maintenance method, maintenance intervals, implementation timing, maintenance performance, etc. When the maintenance plan is changed, the maintenance plan data D340 is updated in accordance with the changes.

[0034] The maintenance plan is created by determining the timing and frequency of maintenance work, taking into account the costs required for maintaining the plant 10 over the life of the plant 10. As will be described in detail later, in the maintenance plan management unit 240 of this embodiment, the maintenance plan is created so as to correspond to the alternative measures determined by the alternative measure determination unit 230. Here, the maintenance plan is created based on the plant data D310 managed by the equipment configuration management unit 210, as well as information about the alternative measures determined by the alternative measure determination unit 230. In creating the maintenance plan, for example, a model constructed regarding the relationship between information about the alternative measures and each condition related to the maintenance plan is used. The model may be configured, for example, by a neural network created by machine learning.

[0035] [C] Operation of the plant management system 20 FIG. 3A is a flow diagram showing an outline of the operation of the plant management system 20 according to the embodiment.

[0036] In this embodiment, an example will be given of the operation in the case where the production of an existing part 111 installed in the equipment 11 in the plant 10 is discontinued (see FIG. 1).

[0037] [C-1] Enter discontinued production information (ST10) First, as shown in FIG. 3A, discontinued production information D320 is input (ST10).

[0038] As described above, the discontinuation information D320 is input based on information obtained from, for example, a parts manufacturer that produces the existing parts 111. The discontinuation information D320 is managed by being stored in a database by the discontinuation information management unit 220. The discontinuation information D320 includes information that identifies equipment that uses the discontinued parts using the plant data D310. The discontinuation information D320 is then output to the alternative means determination unit 230 (see FIG. 2).

[0039] The output of the discontinuation of production information D320 to the alternative means determination unit 230 is performed, for example, at the user's instruction when the user determines that it is necessary to determine an alternative means to replace the existing part 111 due to the discontinuation of production of the existing part 111.

[0040] [C-2] Selection of alternatives (ST20) Next, as shown in FIG. 3A, an alternative means is determined (ST20; alternative means determination step).

[0041] The determination of the alternative means is carried out in the alternative means determination unit 230 (see FIG. 2).

[0042] In this embodiment, for example, discontinuation information D320 for discontinuing the production of an existing part 111 (see FIG. 1) is input to the alternative means determination unit 230 from the discontinuation information management unit 220. Accordingly, the alternative means determination unit 230 selects an alternative means to substitute for the existing part 111. The alternative means is determined based on plant data D310 (parts data D311, equipment data D312, design requirement specification data D313, and alternative means data D314) managed by the equipment configuration management unit 210. Then, information regarding the alternative means determined by the alternative means determination unit 230 is output to the maintenance plan management unit 240 (see FIG. 2).

[0043] FIG. 3B is a flow diagram showing an outline of the operation when the alternative means determination unit 230 determines an alternative means in this embodiment.

[0044] In this embodiment, the alternative to replace the existing part 111 is determined from a first alternative (new part 111), a second alternative (compatible part 111B), a third alternative (modified replacement part 111C), and a fourth alternative (new equipment 11), as shown in FIG. 3B.

[0045] [C-2-1] First Alternative (New Part 111) Specifically, if it is determined that new part 111 is in stock (ST21a in Figure 3B is Yes (first alternative means is possible)), the first alternative means of replacing the existing part 111 with the new part 111 is determined as the alternative means (ST21b in Figure 3B).

[0046] [C-2-2] Second Alternative (Compatible Part 111B) If the first alternative cannot be determined as the alternative (ST21a in FIG. 3B is No), but it is determined that a compatible part 111B (compatible component) that is compatible with part 111 is available (ST22a in FIG. 3B is Yes (second alternative is possible)), then the second alternative, which is to replace the existing part 111 with the compatible part 111B, is determined as the alternative (ST22b in FIG. 3B).

[0047] [C-2-3] Third Alternative (Modified Replacement Part 111C) If the first alternative means and the second alternative means cannot be determined as alternative means (if ST22a in Figure 3B is No), and it is determined that a modified replacement part 111C (modified replacement material) that can be replaced with the existing part 111 can be obtained by performing a modification (ST23a in Figure 3B is Yes (third alternative means is possible)), then the third alternative means of replacing the existing part 111 with the modified replacement part 111C is determined as the alternative means (ST23b in Figure 3B).

[0048] [C-2-4] Fourth Alternative (New Equipment 11) If the first alternative means, the second alternative means, and the third alternative means cannot be determined as alternative means (if ST23a in Figure 3B is No), and new equipment 11 is available (if ST24a in Figure 3B is Yes (fourth alternative means is possible)), the fourth alternative means of replacing the existing equipment 11 including the existing parts 111 with new equipment 11 is determined as the alternative means (ST24b in Figure 3B).

[0049] [C-2-5] Other If the first, second, third, and fourth alternative means cannot be determined as an alternative means (ST24a in FIG. 3B is No), a notification is given, for example, that the alternative means need to be reconsidered (ST25 in FIG. 3B). The notification is given, for example, by outputting information to a display and displaying the information.

[0050] [C-3] Creation of a maintenance plan (ST30) Next, as shown in FIG. 3A, a maintenance plan is created (ST30).

[0051] The maintenance plan is created in the maintenance plan management unit 240 (see FIG. 2).

[0052] In this embodiment, information about the alternative means determined by the alternative means determination unit 230 is input to the maintenance plan management unit 240. Accordingly, the maintenance plan management unit 240 creates a maintenance plan corresponding to the determined alternative means.

[0053] FIG. 4 is a diagram illustrating an example of an outline of a maintenance plan created when no production discontinuation information is received in the plant management system 20 of the embodiment.

[0054] 5A to 5D are diagrams illustrating an example of an outline of a maintenance plan created when an alternative measure is determined in response to discontinued production information in the plant management system 20 of the embodiment. Fig. 5A shows a case where a first alternative measure is determined as the alternative measure, Fig. 5B shows a case where a second alternative measure is determined as the alternative measure, Fig. 5C shows a case where a third alternative measure is determined as the alternative measure, and Fig. 5D shows a case where a fourth alternative measure is determined as the alternative measure.

[0055] 4 and 5A to 5D, the horizontal axis is the time axis, T0 indicates the current time, TK indicates the recommended replacement deadline, EP is the replacement work period, T11 is the start point of the replacement work period EP, and T12 is the end point of the replacement work period EP.

[0056] [C-3-1] If there is no discontinued production information D320 4, in the maintenance plan, if the discontinuation information D320 has not been received, the replacement work period EP is set to, for example, before the recommended replacement deadline TK recommended by the parts manufacturer that produces the existing part 111. In this case, since the discontinuation information D320 regarding the existing part 111 has not been received, the maintenance plan indicates that replacement will be performed using a new part 111.

[0057] The replacement work period EP is set to a time optimized based on the time when new parts 111 can be procured, as well as data on maintenance costs, possible maintenance periods, maintenance frequency, plant operation plans, and the like.

[0058] [C-3-2] If there is discontinued production information D320 [C-3-2-1] First Alternative (New Part 111) When the discontinuation information D320 is received and the first alternative means is determined as the alternative means, as shown in Fig. 5A, the maintenance plan is created in the same way as when the discontinuation information D320 is not received (see Fig. 4). In this case, although the discontinuation information D320 has been received, new parts 111 are in stock, so the maintenance plan indicates that replacement will be performed using the new parts 111. In this case, in order to perform replacement during the replacement work period EP, the preparation period (not shown) for preparing (purchasing, etc.) the new parts 111 for which the discontinuation information D320 has been received may be found from the supply availability information of the new parts 111 and indicated in the maintenance plan.

[0059] [C-3-2-2] Second alternative (compatible part 111B) When discontinuation of production information D320 is received and the second alternative method is determined as the alternative method, the maintenance plan indicates that replacement will be carried out using a compatible part 111B (compatible component) that is compatible with the existing part 111, as shown in Figure 5B, unlike when the first alternative method is determined as the alternative method (see Figure 5A).

[0060] [C-3-2-3] Third Alternative (Modified Replacement Part 111C) When discontinuation of production information D320 is received and the third alternative is determined as the alternative, as shown in Figure 5C, the maintenance plan indicates that replacement will be carried out using a modified replacement part 111C (modified replacement material) that can be replaced with the existing part 111 by performing a modification, unlike when the first alternative is determined as the alternative (see Figure 5A).

[0061] Furthermore, when the third alternative is determined as the alternative, the maintenance plan indicates a modification work period KP during which work to modify the modified replacement part 111C (modified replacement member) is performed. The modification work period KP is set such that the start time T21 is, for example, before the start time T11 of the replacement work period EP, and the start time T21 is set such that the start time T11 is the same as the start time T11 of the replacement work period EP.

[0062] [C-3-2-4] Fourth Alternative (New Equipment 11) When the discontinuation of production information D320 is received and the fourth alternative is determined as the alternative, the maintenance plan indicates that the existing equipment 11 including the existing part 111 will be replaced with new equipment 11, as shown in Figure 5D, unlike when the first alternative is determined as the alternative (see Figure 5A).

[0063] [D] Summary As described above, the plant management system 20 of this embodiment has the alternative means determination unit 230. For example, when receiving production discontinuation information D320 that indicates that production of the existing part 111 installed in the facility 11 is to be discontinued, the alternative means determination unit 230 determines an alternative means to substitute for the existing part 111.

[0064] In this embodiment, as described above, if new parts 111 are available in stock, a first alternative method of replacing the existing parts 111 with the new parts 111 is determined as the alternative method. If the first alternative method cannot be determined as the alternative method and a compatible part 111B is available, a second alternative method of replacing the existing parts 111 with the compatible part 111B is determined as the alternative method. If the first alternative method and the second alternative method cannot be determined as the alternative method and a modified replacement part 111C is available, a third alternative method of replacing the existing parts 111 with the modified replacement part 111C is determined as the alternative method. If the first alternative method, the second alternative method, and the third alternative method cannot be determined as the alternative method and a new equipment 11 is available, a fourth alternative method of replacing the existing equipment 11 including the existing parts 111 with the new equipment 11 is determined as the alternative method.

[0065] Therefore, according to the plant management system 20 of this embodiment, when the discontinued production information D320 is received for an existing part, it is possible to accurately determine an alternative means for substituting the existing part.

[0066] [E] Variation A modification of the above embodiment will now be described.

[0067] [E-1] Variation 1 FIG. 6 is a diagram illustrating an example of an outline of a maintenance plan that is created when an alternative method is determined in response to discontinued production information in the first modification of the embodiment.

[0068] In FIG. 6, the lower graph shows an example of a deterioration state in which the performance CV of the existing part 111 (see FIG. 1) changes over time.

[0069] In Modification 1, the maintenance plan management unit 240 grasps the deterioration state in which the performance CV of the existing part 111 changes over time. The deterioration state is grasped based on data previously acquired about the existing part 111 as part data D311. Then, the maintenance plan management unit 240 sets a replacement deadline for replacing the existing part 111 in the maintenance plan according to the deterioration state.

[0070] Specifically, the time transition of the performance CV of the existing component 111 is obtained, for example, by performing an extrapolation process using actual measured values ​​of the performance CV of the existing component 111, as shown in the lower part of Figure 6. Then, the time transition of the performance CV of the existing component 111 is used to predict the time TKx at which the performance CV of the existing component 111 will drop to a predetermined threshold TCV. Then, for example, the replacement work period EP is set after the recommended replacement deadline TK and before the time TKx at which the performance CV will drop to the threshold TCV.

[0071] If the time TKx at which the value of the performance CV of the existing part 111 drops to the threshold TCV is before the recommended replacement deadline TK, the replacement work period EP is set to be before the recommended replacement deadline TK.

[0072] [E-2] Variation 2 In the above embodiment, the priority order when the alternative means determination unit 230 determines an alternative means is described as the first alternative means, the second alternative means, the third alternative means, and the fourth alternative means, in that order, but this is not limited to this.

[0073] In Modification 2, one of the third alternative means and the fourth alternative means is determined as the alternative means based on information regarding the demand for alternative means. That is, the alternative means determination unit 230 may be configured to determine one of the third alternative means and the fourth alternative means as the alternative means based on information regarding the demand for alternative means.

[0074] In this modified example, the information regarding the request for an alternative is, for example, information requesting an improvement to the equipment. For example, if an existing part 111 needs to be replaced to improve the equipment, and if a modified replacement part 111C that can meet the improvement request is available, the third alternative, in which the existing part 111 is replaced with the modified replacement part 111C, is selected with priority over the fourth alternative. On the other hand, if there is a request to replace the existing equipment 11 with new equipment 11, the fourth alternative is selected with priority over the third alternative, even if the third alternative is possible.

[0075] The information regarding the request for an alternative means is information that was input to the plant management system 20 before the production discontinuation information D320 was received. Alternatively, the information regarding the request for an alternative means may be information that was input to the plant management system 20 after the production discontinuation information D320 was received and before the process for determining an alternative means was started.

[0076] [E-3] Variation 3 In variant example 3, when the alternative means determination unit 230 determines the fourth alternative means as an alternative means, if the cost of the fourth alternative means exceeds a preset cost target value, it cancels the determination of the fourth alternative means and determines the fifth alternative means described below as an alternative means.

[0077] Specifically, if the cost of the fourth alternative exceeds a preset cost target value, a search for compatible equipment 11A (compatible plant component equipment; not shown) that is compatible with the existing equipment 11 is performed using the alternative data D314 of the plant data D310. In this modification, the alternative data D314 includes information on the compatible equipment 11A that is compatible with the existing equipment 11. The compatible equipment 11A is equipment that has been evaluated in advance for applicability when replacing the existing equipment 11 and certified as compatible. If the compatible equipment 11A is available and the cost of replacing the existing equipment 11 with the compatible equipment 11A is equal to or less than the cost target value, the fifth alternative, in which the existing equipment 11 is replaced with the compatible equipment 11A, is determined as the alternative.

[0078] [E-4] Variation 4 In variant example 4, when the alternative means determination unit 230 determines the third alternative means as an alternative means, if the cost of the third alternative means exceeds a preset cost target value, it cancels the determination of the third alternative means and determines the sixth alternative means shown below as the alternative means.

[0079] Specifically, when the cost of the third alternative exceeds a predetermined target cost value, a determination is made based on the component data D311 as to whether or not there are any existing component elements 1111, 1112 in the existing component 111 that have a predetermined degree of deterioration or greater (see FIG. 1). Then, for example, if it is determined that the existing component element 1111 of the multiple component elements 1111, 1112 that make up the existing component 111 has a predetermined degree of deterioration or greater, a sixth alternative, in which the existing component element 1111 is replaced with a new component element 1111, is determined as the alternative.

[0080] [E-5] Other variations In the above embodiment, the case where the replacement work period EP is indicated in the maintenance plan has been described, but this is not limiting. In the case of corrective maintenance, the replacement work period EP may not be indicated in the maintenance plan, and the maintenance plan may indicate that an alternative measure will be applied when an actual failure occurs in the existing part 111.

[0081] <Other> Although several embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, and are also included in the scope of the invention and its equivalents as defined in the claims. [Explanation of symbols]

[0082] 10: Plant, 20: Plant management system, 111: Parts, 111B: Compatible parts, 111C: Modified replacement parts, 112: Parts, 121: Parts, 122: Parts, 210: Equipment configuration management unit, 220: Discontinuation information management unit, 230: Alternative means determination unit, 240: Maintenance plan management unit, 1111: Part element, 1112: Part element, 1121: Part element, 1122: Part element, 1211: Part element, 1212: Part element, 1221: Part element, 1222: Part element

Claims

1. A plant management system that manages a plant including plant component equipment configured using equipment component members, an alternative means determination unit that, when receiving production discontinuation information that discontinues production of the existing equipment component installed in the plant constituent equipment, determines an alternative means to substitute for the existing equipment component; and The alternative means determination unit If the new equipment component is available in stock, a first alternative is determined as the alternative, which is to replace the existing equipment component with the new equipment component; If the first alternative means cannot be determined as the alternative means, and if a compatible member that is compatible with the equipment component is available, a second alternative means of replacing the existing equipment component with the compatible member is determined as the alternative means; When the first alternative means and the second alternative means cannot be determined as the alternative means, at least one of a third alternative means of replacing the existing equipment component with a modified replacement part that can be replaced with the existing equipment component by performing a modification, and a fourth alternative means of replacing the existing plant component equipment including the existing equipment component with new plant component equipment is determined as the alternative means. Plant management system.

2. The alternative means determination unit In a case where the first alternative means and the second alternative means cannot be determined as the alternative means, if the modified replacement part is available, determining the third alternative means as the alternative means; In a case where the first alternative means, the second alternative means, and the third alternative means cannot be determined as the alternative means, if new plant component equipment is available, determining the fourth alternative means as the alternative means. The plant management system according to claim 1 .

3. the alternative means determination unit determines one of the third alternative means and the fourth alternative means as the alternative means based on information regarding the demand for the alternative means; The plant management system according to claim 1 .

4. When the fourth alternative means is determined as the alternative means and the cost of the fourth alternative means exceeds a preset cost target value, the alternative means determination unit: A search is performed for compatible plant component equipment that is compatible with the existing plant component equipment; If the compatible plant component equipment is available and the cost of replacing the existing plant component equipment with the compatible plant component equipment is equal to or less than the target cost value, a fifth alternative of replacing the existing plant component equipment with the compatible plant component equipment is determined as the alternative. The plant management system according to claim 2 or 3.

5. When the alternative means determination unit determines the third alternative means as the alternative means, and if the cost of the third alternative means exceeds a predetermined target cost value, it determines a sixth alternative means as the alternative means, in which, if there is an existing part element among a plurality of existing part elements constituting the existing equipment component that has a predetermined degree of deterioration or more, the existing part element that has a predetermined degree of deterioration or more is replaced with a new part element. The plant management system according to claim 2 or 3.

6. a maintenance plan management unit that creates a maintenance plan for maintaining the plant so as to correspond to the alternative means determined by the alternative means determination unit; having The plant management system according to claim 1 .

7. the maintenance plan management unit sets a replacement deadline for replacing the existing equipment component according to a deterioration state of the existing equipment component; The plant management system according to claim 6 .

8. A plant management method for managing a plant including plant component equipment configured using equipment component members, an alternative means determination process for determining an alternative means to replace the existing equipment component when receiving information indicating that the production of the existing equipment component installed in the plant component equipment is to be discontinued; and In the alternative means determination step, If the new equipment component is available in stock, a first alternative is determined as the alternative, which is to replace the existing equipment component with the new equipment component; If the first alternative means cannot be determined as the alternative means, and if a compatible member that is compatible with the equipment component is available, a second alternative means of replacing the existing equipment component with the compatible member is determined as the alternative means; When the first alternative means and the second alternative means cannot be determined as the alternative means, at least one of a third alternative means of replacing the existing equipment component with a modified replacement part that can be replaced with the existing equipment component by performing a modification, and a fourth alternative means of replacing the existing plant component equipment including the existing equipment component with new plant component equipment is determined as the alternative means. Plant management techniques.

9. In the alternative means determination step, In a case where the first alternative means and the second alternative means cannot be determined as the alternative means, if the modified replacement part is available, determining the third alternative means as the alternative means; In a case where the first alternative means, the second alternative means, and the third alternative means cannot be determined as the alternative means, if new plant component equipment is available, determining the fourth alternative means as the alternative means. The plant management method according to claim 8.

10. In the alternative means determination step, one of the third alternative means and the fourth alternative means is determined as the alternative means based on information regarding the demand for the alternative means. The plant management method according to claim 8.

11. creating a maintenance plan for maintaining the plant in accordance with the alternative measures determined in the alternative measure determination step; The plant management method according to claim 8.

Images