Equipment maintenance support method

Abstract

To enable the cause of abnormal events having occurred in facility to be investigated and countermeasures for the abnormal events to be presented, without using the past operation data and failure history of the facility.SOLUTION: Regarding facility 1 composed of element equipment 2, a digital model 5 is created which has element equipment model 6 obtained by modeling the element equipment. When an abnormal event occurs in the facility, simulations are carried out using the digital model, including a normal event simulation of the facility which is carried out using the design document, specification, etc. of the element equipment and adopting the characteristic value of the element equipment model as a variable, and an abnormal event simulation of the facility which is carried out on the basis of the behavior, etc. of the facility at abnormal event occurrence time and adopting the characteristic value of the element equipment model as a variable. In the abnormal event simulation, the characteristic value of the element equipment model is determined so that a simulation result is obtained which is close to the behavior of the abnormal event, the characteristic values of the element equipment model obtained from the normal event and abnormal event simulation results are compared to determine the element equipment model in the abnormal state, and the element equipment which has caused the abnormal event is identified.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] An embodiment of the present invention relates to a maintenance support method for equipment. [Background technology]

[0002] Factories and other facilities that have equipment for manufacturing products own mechanical and electrical equipment, such as power plants and substations. Many of these facilities perform maintenance management to ensure stable operation of the equipment. For the above-mentioned mechanical and electrical equipment that requires stable operation over a long period of time, technologies such as predictive maintenance are applied that continuously measure and monitor the condition of the equipment, and if a sign of an abnormal event is detected before it occurs, measures are taken promptly. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6984786 [Patent Document 2] Patent No. 6264473 [Patent Document 3] Patent No. 6856443 Summary of the Invention [Problem to be solved by the invention]

[0004] It has been proposed that when an abnormality occurs, the setting information of the equipment before and after the occurrence is compared, the changes are extracted and displayed, and measures or support are taken (Patent Document 1), or the location and cause of the failure are identified based on past data, and an inspection plan is formulated (Patent Document 2).In addition, a diagnostic system has been proposed that creates a database in which normal and abnormal behavior of the equipment is stored in advance, and a database of simulated abnormal data created by setting abnormal conditions in a mathematical or physical model of the equipment, and performs abnormality diagnosis and comparison (Patent Document 3).

[0005] Furthermore, the aforementioned predictive maintenance requires many measuring devices to detect signs of abnormal events (failures). If the signs are not detected properly, abnormal events will occur. When an abnormal event occurs, if there is insufficient past operating data or failure history, or if there is no database of abnormal equipment behavior, it may take a long time to identify the cause.

[0006] An embodiment of the present invention has been made in consideration of the above-mentioned circumstances, and aims to provide an equipment maintenance support method that can identify the cause of an abnormal event that has occurred in equipment and suggest countermeasures for the event, without using past operation data or fault history of the equipment. [Means for solving the problem]

[0007] In an embodiment of the present invention, a method for supporting maintenance of equipment includes the steps of: creating in advance a digital model having a plurality of element equipment models, each of which is a model of element equipment having characteristic values ​​that are set and controlled within a range between minimum and maximum values, for equipment configured with a plurality of element equipment that are related to each other and that produce output in response to an input; and, when an abnormal event occurs in the equipment, using the digital model, performing a normal event simulation of the equipment using information including at least one of design drawings, specifications, and catalogs of the element equipment and characteristic values ​​of the element equipment models as variables; and performing an abnormal event simulation of the equipment using characteristic values ​​of the element equipment models as variables based on information regarding the behavior of the equipment and a failure of the element equipment when the abnormal event occurs; determining, in the abnormal event simulation, characteristic values ​​of the element equipment models so as to obtain a simulation result close to the behavior when an abnormal event occurs in the equipment; comparing characteristic values ​​of the element equipment models obtained from the respective simulation results of the normal event and the abnormal event; determining that the element equipment model having different characteristic values ​​is the element equipment model in an abnormal state; and identifying the element equipment corresponding to the determined element equipment model as the element equipment that caused the abnormal event. Effect of the Invention

[0008] According to an embodiment of the present invention, it is possible to investigate the cause of an abnormal event that has occurred in equipment and present a countermeasure therefor, without using past operation data or failure history of the equipment. [Brief description of the drawings]

[0009] [Figure 1] 1A and 1B are block diagrams showing an outline of an equipment to be maintained and its digital model when implementing an equipment maintenance support method according to a first embodiment, in which (A) is a block diagram showing the configuration of the equipment, and (B) is a block diagram showing the configuration of the digital model. [Diagram 2] 13A and 13B are block diagrams showing an outline of the equipment to be maintained and its digital model when implementing an equipment maintenance support method according to a second embodiment, in which (A) is a block diagram showing the configuration of the equipment, and (B) is a block diagram showing the configuration of the digital model. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0011] [A] First embodiment (Fig. 1) FIG. 1 shows an outline of equipment to be maintained and its digital model when implementing an equipment maintenance support method according to a first embodiment, in which (A) is a block diagram showing the configuration of the equipment, and (B) is a block diagram showing the configuration of the digital model.

[0012] As shown in Fig. 1(A), the equipment 1 to be maintained is configured to have at least one, for example, one or more element devices 2 (element devices 2A, 2B, 2C). Each element device 2 outputs an output in response to an input while relating to the others. This input / output can take various forms, such as an output in response to an input of an electrical signal, an output of a product in response to an input of a part, or power generation as an output in response to an input of a fluid such as a liquid or gas.

[0013] Each element device 2 has a characteristic value, such as heat output for a heater, opening for a valve, and discharge flow rate and discharge pressure for a pump. These characteristic values ​​are set and controlled within a range of minimum and maximum values ​​so that the element device 2 can obtain an output that suits its purpose. The element device 2 does not have to have just one type of characteristic value; for example, in the case of a pump, one element device may have multiple characteristic values, such as discharge pressure and discharge flow rate.

[0014] Furthermore, each element device 2 is connected by connecting members 4 such as pipes and electric wires to form a system 3. By monitoring process values ​​such as temperature, pressure, current, and voltage in each element device 2 or connecting members 4, it becomes possible to monitor the state of the system 3. When the state of the facility 1 and system 3 is normal, the characteristic value of each element device 2 is set to a predetermined value within the specification range.

[0015] As shown in FIG. 1(B), the digital model 5 of the facility 1 has element equipment models 6 (element equipment models 6A, 6B, 6C) that model element equipment 2 (element equipment 2A, 2B, 2C) that configure the facility 1, and a connection member model 7 that models a connection member 4, and is created in advance. This digital model 5 has at least one element equipment model 6, for example, one or more (element equipment models 6A, 6B, 6C). The digital model 5 also has a system model 8 in which the element equipment models 6 are connected by the connection member models 7. In such a digital model 5, the characteristic values ​​of the element equipment models 6 can be set arbitrarily beyond the range of the specifications of the actual element equipment 2.

[0016] Next, a method for supporting maintenance of the facility 1 using the digital model 5 when an abnormal event occurs in the facility 1 will be described. When an abnormal event occurs in the equipment 1, the output of the equipment 1 or the process value of the system 3 exhibits a value different from normal. Therefore, first, when an abnormal event occurs in the equipment 1, the characteristic values ​​of the element equipment model 6 are changed as variables using the digital model 5 to simulate normal and abnormal events in the equipment 1.

[0017] A simulation of a normal event of the equipment 1 (i.e., a simulation that mimics (reproduces) a normal event of the equipment 1) is performed without using information on the operation history of the equipment 1 before an abnormal event occurs in the equipment 1. In other words, a simulation of a normal event of the equipment 1 is performed by changing the characteristic values ​​of the element equipment model 6 as variables, using information that does not include time-series information, but includes at least one of the design drawings, specifications, and catalogs of the element equipment 2.

[0018] A simulation of an abnormal event in the equipment 1 (i.e., a simulation to mimic (reproduce) an abnormal event in the equipment 1) is performed by changing the characteristic values ​​of the element equipment models 6 as variables using the behavior of the equipment 1 when an abnormal event occurs, without using information on the operation history of the equipment 1 before the abnormal event occurred in the equipment 1 or the past failure history of the element equipment 2. In this abnormal event simulation, the characteristic values ​​of the element equipment models 6 are determined so that the simulation results of the output of the digital model 5 and the process value of the system model 8 are close to the behavior of the equipment 1 when an abnormal event occurs (the output of the equipment 1, the process value of the system 3). In addition, in the above-mentioned abnormal event simulation, it is possible to respond to, for example, complex abnormal events by changing not only the characteristic value of one element equipment model 6 but also the characteristic values ​​of multiple element equipment models 6.

[0019] Next, the characteristic values ​​of the element equipment model 6 obtained from the respective simulation results of the normal event and the abnormal event obtained as described above are compared. At this time, if the characteristic value of the element equipment model 6 obtained from the simulation result of the abnormal event differs from the characteristic value of the element equipment model 6 obtained from the simulation result of the normal event, the element equipment model 6 with the different characteristic value is determined to be an element equipment model in an abnormal (fault) state. Then, the element equipment 2 corresponding to the element equipment model 6 determined to be in an abnormal (fault) state is identified as the element equipment 2 that caused the abnormal event of the facility 1. Therefore, it becomes possible to present countermeasures such as replacing the identified element equipment 2 or adjusting the setting value of this element equipment 2.

[0020] In addition, in the method for supporting maintenance of equipment 1 using digital model 5, when, for example, replacement of element device 2 of equipment 1 is necessary but it is difficult to obtain the same model of element device 2, the following maintenance support is provided.

[0021] That is, one or more of the element equipment models 6 of the digital model 5 of the facility 1 are replaced with another element equipment model having different specifications or bypassed by a bypass line to modify the digital model 5. Then, a simulation of a normal event of the facility 1 is performed using this modified digital model 5, and whether or not the digital model 5 operates normally is confirmed by the simulation. This makes it possible to present countermeasures such as replacing an element equipment 2 in an abnormal (failed) state of the facility 1 with another element equipment 2 having different specifications or bypassing the element equipment 2 in an abnormal (failed) state by a bypass line.

[0022] As configured as above, the first embodiment provides the following advantages (1) and (2). (1) According to the first embodiment, a digital model 5 of the equipment 1 having an element equipment model 6 that models an element equipment 2 is used to simulate normal and abnormal events of the equipment 1, and characteristic values ​​of the element equipment model 6 obtained from the simulation results of the normal and abnormal events are compared to determine which element equipment model 6 is in an abnormal (faulty) state, thereby identifying the element equipment 2 that caused the abnormal event. As a result, it is possible to investigate the cause of an abnormal event that occurred in the equipment 1 and present a countermeasure for it without using past operation data or fault history of the equipment 1. This makes it possible to reduce the cost and time required for disassembly and inspection of the equipment 1 in which an abnormal event occurred.

[0023] (2) Among the element equipment models 6 held by the digital model 5 of the facility 1, one or more element equipment models 6 are replaced with other element equipment models 6 having different specifications or bypassed via a bypass line to modify the digital model 5, and this modified digital model 5 is used to simulate normal events of the facility 1 to confirm whether the digital model 5 operates normally. Therefore, for an element equipment 2 that needs to be replaced but is difficult to obtain of the same model, it is possible to propose measures to replace this element equipment 2 with another element equipment 2 or to bypass it. This makes it possible to quickly present a provisional proposal, although it is not permanent.

[0024] [B] Second embodiment (Figure 2) 2A and 2B are block diagrams showing the configuration of the digital model of the equipment to be maintained when implementing the equipment maintenance support method according to the second embodiment. In the second embodiment, the same reference numerals as in the first embodiment are used to simplify or omit the description of the same parts as in the first embodiment.

[0025] The equipment maintenance support method of the second embodiment differs from the first embodiment in that information about failures of element devices 2 in equipment 1 stored in database 11 is reflected to simulate an abnormal event in equipment 1.

[0026] The database 11 stores information about failures of element devices 2 constituting the facility 1 for each element device 2, and is created and prepared in advance. The information about failures of the element devices 2 described above is information about the element devices 2, such as the failure probability and service life of the element devices 2, and the behavior of the element devices 2 when a failure occurs. This information about failures of the element devices 2 does not need to be information obtained from the element devices 2 of the facility 1 that is the subject of maintenance, but may be information about general failure probability and service life of element devices 2 of the same model, or information about failures that have occurred in element devices 2 constituting other facilities.

[0027] In the second embodiment, the simulation of an abnormal event in the facility 1, which is performed by changing the characteristic values ​​of the element equipment models 6 in the digital model 5 as variables, is performed by reflecting information on the failure of the element equipment 2 stored in the database 11. For example, when selecting the element equipment models 6 for which the characteristic values ​​are changed in the digital model 5, the element equipment models 6 corresponding to the element equipment 2 having a high failure probability stored in the database 11 or the element equipment models 6 corresponding to the element equipment 2 having a short useful life are preferentially selected. Furthermore, the element equipment models 6 corresponding to the element equipment 2 are preferentially selected in the digital model 5 so as to reproduce the "behavior of the element equipment 2 when a failure occurs" stored in the database 11.

[0028] As configured as above, the second embodiment provides the following effect (3) in addition to the effects (1) and (2) of the first embodiment.

[0029] (3) The simulation of an abnormal event in the facility 1 is performed by reflecting information on the failure of the element devices 2 stored in the database 11, that is, by giving priority to the element device model 6 corresponding to the element device 2 whose failure information is stored in the database 11 and changing its characteristic values. Therefore, it is possible to quickly select a combination of element devices 2 with a high probability of failure from the large number of combinations of failures of the element devices 2 in the facility 1 and perform a simulation of an abnormal event. As a result, it is possible to quickly identify the element device 2 that caused the abnormal event in the facility 1 and present a countermeasure for it.

[0030] Although several embodiments of the present invention have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These embodiments can be implemented in various other forms, and various omissions, substitutions, changes, and combinations can be made without departing from the spirit of the invention. Furthermore, these substitutions, changes, and combinations are included in the scope and spirit of the invention, and are included in the scope of the invention and its equivalents described in the claims. [Explanation of symbols]

[0031] 1...Facility, 2...Component equipment, 5...Digital model, 6...Component equipment model, 11...Database

Claims

1. For a facility that is composed of a plurality of element devices that are related to each other and produce an output in response to an input, a digital model is created in advance that has a plurality of element device models that model the element devices having characteristic values ​​that are set and controlled within a range between a minimum value and a maximum value; When an abnormal event occurs in the equipment, the digital model is used to perform a simulation of a normal event of the equipment using information including at least one of design drawings, specifications, and catalogs of the element equipment and characteristic values ​​of the element equipment model as variables, and a simulation of an abnormal event of the equipment using information regarding the behavior of the equipment and a failure of the element equipment when the abnormal event occurs and characteristic values ​​of the element equipment model as variables, In the simulation of the abnormal event, characteristic values ​​of the element equipment model are determined so as to produce a simulation result close to the behavior of the facility when the abnormal event occurs; An equipment maintenance support method comprising the steps of: comparing characteristic values ​​of the element equipment model obtained from simulation results of a normal event and an abnormal event; determining that the element equipment model for which these characteristic values ​​are different is the element equipment model in an abnormal state; and identifying the element equipment corresponding to the determined element equipment model as the element equipment that caused the abnormal event.

2. 2. The facility maintenance support method according to claim 1, wherein the simulation of a normal event in the facility is performed without using information on an operation history before the occurrence of an abnormal event in the facility.

3. preparing a database for storing information regarding failures of element devices in the facility for each of the element devices; 2. The facility maintenance support method according to claim 1, wherein a simulation of an abnormal event in the facility is performed by reflecting information on failures stored in the database and using characteristic values ​​of element equipment models as variables.

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