Conservative Planning Device and Conservative Planning Program

Abstract

To utilize good data obtained from maintenance to improve equipment reliability and / or reduce an amount of maintenance materials.SOLUTION: A maintenance plan formulation device 100 has a storage unit 20 that stores maintenance activities and monitoring items consisting of inspection contents related to a device and field data in which inspection results for each of a plurality of inspection contents are stored in time sequence, an integrity monitoring unit 12 that determines whether or not the plurality of inspection contents of the field data need to be addressed based on the maintenance effectiveness index table 23, and a corrective action unit 15 that optimizes the inspection content determined not to need to be addressed by the integrity monitoring unit 12.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a maintenance plan formulation device and a maintenance plan formulation program.

Background Art

[0002] For the high-level maintenance of nuclear power plants, technologies such as equipment reliability, work management, and configuration management have been developed. In nuclear power plants, regular inspections are carried out for the maintenance of equipment and facilities, and the data obtained from this maintenance is utilized. Patent Document 1 describes an invention in which a checklist is optimized by removing deteriorated check items from the checklist and leaving only necessary items in the checklist.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the maintenance of facilities including highly reliable equipment used in the aviation industry and nuclear power plants, it is desired to convert the data obtained from maintenance into valuable information and utilize it for maintenance. Specifically, from the maintenance of equipment that adjusts pressure such as water pressure, good data for which about 90% or more of maintenance activities such as repair and replacement are unnecessary and data for which normal maintenance activities such as replacement of several percent or less of parts are required are obtained. Conventionally, data for which about several percent or less of the entire maintenance activities are required has been utilized for maintenance. However, good data accounting for about 90% or more of the entire maintenance activities has not been utilized.

[0005] Therefore, an object of the present invention is to utilize good data obtained from maintenance for improving the reliability of equipment and / or reducing the amount of maintenance work.

Means for Solving the Problems

[0006] To solve the above problems, the maintenance plan formulation device of the present invention is based on a maintenance effectiveness index table including keywords indicating the maintenance level of equipment and corresponding states corresponding to the keywords, and relates to the equipment Multiple during inspection volumes and a plurality of the above inspection contents each related to field data in which inspection results are stored in time series contained in a plurality of the above inspections results and a soundness monitoring unit that determines whether or not to respond to the equipment from the sentences, and a corrective action unit that reduces the maintenance frequency or monitoring frequency of the equipment related to the inspection content determined not to require response by the soundness monitoring unit to optimize the maintenance cycle.

[0007] The maintenance plan formulation program of the present invention causes a computer to perform, based on a maintenance effectiveness index table including keywords indicating the maintenance level of equipment and corresponding states corresponding to the keywords, a plurality of inspections related to the equipment volumes and a plurality of the above inspection contents related to field data in which inspection results are stored in time series contained in a plurality of the above inspections results a procedure for determining whether or not to respond to the equipment from the sentences, and a procedure for reducing the maintenance frequency or monitoring frequency of the equipment related to the inspection content determined not to require response to optimize the maintenance cycle. Other means will be described in the mode for carrying out the invention.

Effects of the Invention

[0008] According to the present invention, it becomes possible to utilize good data obtained from maintenance for improving the reliability of facilities and / or reducing the amount of maintenance work.

Brief Description of the Drawings

[0009]

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Best Mode for Carrying Out the Invention

[0010] Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the respective drawings. FIG. 1 is a diagram showing the configuration of a maintenance plan formulation system 300 according to the present embodiment. The maintenance plan formulation system 300 includes a maintenance plan formulation device 100 and a database device 200 of an external storage device. The maintenance plan formulation device 100 includes a processing unit 10, a storage unit 20, an input unit 30, an output unit 40, and a communication unit 50.

[0011] The processing unit 10 includes an importance classification unit 11, a soundness monitoring unit 12, a reliability improvement unit 13, a preventive maintenance plan unit 14, a corrective action unit 15, a life cycle management unit 16, and the like.

[0012] The importance classification unit 11 determines the importance of inspection items related to a device based on the importance of the device constituting the system function. The soundness monitoring unit 12 monitors the performance and reliability of the device based on the importance of consumables.

[0013] The reliability improvement unit 13 predicts the remaining life of a consumable from the state information of the consumable, and evaluates the soundness based on the predicted remaining life of the consumable. The preventive maintenance plan unit 14 plans preventive maintenance based on the evaluation by the soundness monitoring unit 12. The corrective action unit 15 corrects the margin of the life of the consumable based on the importance of the consumable. The life cycle management unit 16 aggregates the performance history, life history, margin change history, etc. of the consumable in the soundness monitoring unit 12, the reliability improvement unit 13, and the corrective action unit 15 to grasp the state of the consumable from installation to replacement.

[0014] The storage unit 20 stores a defect event table 21, an aggregation table 22, a maintenance effectiveness index table 23, a maintenance plan formulation program 24, equipment configuration information 25 related to inspection items, physical configuration information 26, and design requirements 27. is stored.

[0015] In FIG. 1, the processing unit 10 is a central processing unit (CPU), and executes various programs stored in a RAM (Random Access Memory), an HDD (Hard Disk Drive), or the like. By executing the maintenance plan formulation program 24, each functional unit is embodied.

[0016] Here, the storage unit 20 is an HDD, and stores various data for the maintenance plan formulation apparatus 100 to execute processing. The input unit 30 is a device for inputting instructions to a computer such as a keyboard or a mouse, and inputs instructions such as program startup. The output unit 40 is a display or the like, and displays the execution status, execution results, etc. of the processing by the maintenance plan formulation apparatus 100. The communication unit 50 exchanges various data and commands with other devices via the network 9.

[0017] The database apparatus 200 includes a configuration management database 210, a maintenance activity / monitoring item database 220, a sensing database 230, a deterioration database 240, a field data database 250, and the like. Note that DB in the figure means a database. FMEA is an abbreviation for Failure Mode and Effect Analysis, and is a systematic analysis method for potential failures aimed at preventing failures and malfunctions.

[0018] The data stored in each database will be described. The configuration management database 210 is a database composed of design requirements, design drawings, and entity data for a power generation plant.

[0019] The maintenance activity / monitoring item database 220 is a database including information on maintenance activities and monitoring items of a power generation plant, that is, the content, frequency, and deterioration events to be targeted. The maintenance activity / monitoring item database 220 is configured to include inspection contents related to equipment.

[0020] The sensing database 230 is a database that includes the degradation modes to be covered and measurement methods (principles, sensor installation locations, etc.) regarding sensing technologies applicable to power generation plants.

[0021] The degradation database 240 is a database that stores the degradation modes for the equipment constituting the power generation plant. That is, the degradation database 240 includes the failure location, degradation mechanism, impact of degradation, severity of degradation, frequency of degradation, and effective maintenance activities and monitoring items, etc.

[0022] The field data database 250 is a database that includes data acquired on-site, such as the results of maintenance activities (inspection results, test results, etc.), data before inspection, and daily monitoring data. In this field data database 250, the inspection results for each of a plurality of inspection contents are stored in chronological order.

[0023] 《Overview of the Maintenance Plan Formulation Device 100》 FIG. 2 is a block diagram showing the configuration of the maintenance plan formulation device 100. The overview of the consumable management process is shown using FIG. 2.

[0024] The importance classification unit 11 classifies the importance of the inspection contents related to the equipment based on the importance of the equipment to be maintained in the nuclear power plant. The importance classification unit 11 extracts the system, the element functions of the system, and the relationship of the equipment constituting the system, and classifies (judges) the importance of this equipment.

[0025] The importance classification unit 11 may determine the importance of the inspection contents by utilizing the importance of consumables, the radiation dose information of the operator, the work information from the loss of equipment function to recovery and the time information therefor, and the impact information on the plant operation in the case of loss of function.

[0026] Based on the importance of the equipment, the soundness monitoring unit 12 refers to the maintenance activity and monitoring item database 220 composed of the inspection contents related to this equipment, and monitors the performance and reliability of this equipment. The monitoring frequency and content of the equipment vary according to the importance of this equipment. The soundness monitoring unit 12 refers to the determination result of the importance classification unit 11, the evaluation result of the reliability improvement unit 13, the maintenance plan result of the preventive maintenance planning unit 14, and the correction result of the corrective action unit 15, and implements the inspection contents. Based on the maintenance effectiveness index table 23, the soundness monitoring unit 12 determines the necessity of corresponding to multiple inspection contents in the field data database 250.

[0027] Based on the state information of the consumables used in the equipment, the reliability improvement unit 13 predicts the remaining life of this consumable, and evaluates the soundness of the equipment based on the predicted remaining life of the consumable. The reliability improvement unit 13 predicts the degradation curve indicating the degradation of the equipment (consumables) over time. Further, if the degree of degradation of the time-series inspection results of the equipment diverges again after divergence and convergence, the reliability improvement unit 13 determines that the soundness of the equipment is poor. At this time, the soundness monitoring unit 12 determines that it is necessary to take action on this equipment.

[0028] Based on the determination result of the importance classification unit 11, the evaluation result of the reliability improvement unit 13, and the correction result of the corrective action unit 15, the reliability improvement unit 13 evaluates the soundness of the equipment. The reliability improvement unit 13 predicts the degradation of the equipment over time related to the inspection contents. When there is a deviation between the degradation indicated by the inspection results and the predicted value of the degradation related to the inspection contents by the reliability improvement unit 13, the soundness monitoring unit 12 determines that it is necessary to take action on the equipment related to the inspection contents. In addition, the reliability improvement unit 13 determines whether or not the degree of degradation of the time-series inspection results diverges again after divergence and convergence. In this case, the soundness monitoring unit 12 determines that it is necessary to take action on the equipment related to the inspection results.

[0029] Based on the evaluation result of the soundness of the equipment by the reliability improvement unit 13, the preventive maintenance planning unit 14 plans preventive maintenance. The preventive maintenance planning unit 14 plans, for example, whether to shorten or extend the inspection cycle of the equipment.

[0030] The correction measure unit 15 corrects the margin of the life of the consumables used for this device based on the importance of the device. For example, the correction measure unit 15 determines the threshold value of the life of the consumables used for this device based on the importance of the device. Further, the correction measure unit 15 optimizes the maintenance cycle of the inspection content determined by the soundness monitoring unit 12 as not requiring countermeasures.

[0031] The life cycle management unit 16 manages the life cycle of the device based on the evaluation result of the reliability improvement unit 13, the correction result of the correction measure unit 15, and the monitoring result of the soundness monitoring unit 12.

[0032] 《Example of the configuration data of each database》 FIG. 3 is a diagram showing an example of the configuration data of the device management database. The configuration management database 210 is composed of a category column and its configuration data column. The category column describes design requirements, facility configuration information, and physical configuration. In the configuration data column of the design requirements, legal regulations, design standard documents, and calculation / analysis results are stored. In the configuration data column of the facility configuration information, a master device list, design basis documents, procedure manuals, and drawings are stored. In the configuration data column of the physical configuration, component equivalence and engineering design changes are stored.

[0033] Although not shown, the configuration management database 210 also includes, for example, consumable information indicating the content of the consumables to be replaced as maintenance of EQ (Environmental Qualification) devices. The consumable information includes consumable name, consumable model number, EQ device used, consumable specifications, consumable price, available period, replacement time, operation procedure, last replacement date, recommended life, remaining life, limit test results, interchangeable product names, etc.

[0034] The consumable name is the name of the target consumable to be replaced. The consumable model number is the identification information of the part to be replaced. The EQ device name used is the name of the EQ device that uses the consumable. The consumable specifications are information indicating dimensions, shape, material, performance, environmental resistance specifications, etc.

[0035] The consumable price is the purchase price of the consumable. The available period is the period during which the consumable can be obtained. The replacement time is the replacement time of the consumable in the EQ device. The operation procedure is information for indicating the procedure of the replacement operation of the consumable in the EQ device. It may be a procedure manual file or link information of a web page indicating the procedure.

[0036] The previous replacement date is the time of the previous consumable replacement. The elapsed time from the previous replacement date to the current replacement is the operating time of the consumable. In addition, when the equipment in which the consumable is used is operated intermittently, the operating time is the total time of the time when the equipment is operated. The recommended life is the recommended operating time of the operating time in a predetermined usage environment. The consumable is replaced so that the operating time does not exceed the recommended time. The remaining life indicates the remaining time of the operating time in the usage environment. When the remaining life is longer than the period until the next maintenance work time, it is not necessary to replace it in the current maintenance work.

[0037] The limit test result is information for referring to the limit test result of the life characteristics of the consumable for each usage environment. It may also be link information of a test result file. The compatible product name is information indicating the consumable name of the replaceable consumable.

[0038] Figure 4 is a diagram showing a configuration data example of the maintenance activity and monitoring item database 220. The maintenance activity and monitoring item database 220 is configured to include a maintenance activity column, a frequency column, a deterioration event column to be targeted, and the like.

[0039] In the maintenance activity column, the maintenance activity of the target equipment is described in text. Here, the maintenance activity refers to the inspection content. In the frequency column, the frequency of the maintenance activity is stored. Here, the cycle for performing maintenance is stored as the frequency. In the deterioration event column to be targeted, the deterioration event to be targeted in the maintenance activity is described in text.

[0040] Specifically, in the first record of this maintenance activity and monitoring item database 220, when the target device is an XX valve, it can be seen that non-destructive inspection of XX is carried out as a maintenance activity, and this maintenance activity is carried out every X years.

[0041] The maintenance activity and monitoring item database 220 is further composed of a monitoring item column, a frequency column, a target deterioration event column, etc. In the monitoring item column, the monitoring items of the target device are described in text. Here, in the monitoring item column, the text indicating the inspection content is described. In the frequency column, the monitoring frequency is stored. Here, in the frequency column, the cycle for performing monitoring is stored. In the target deterioration event column, the deterioration events targeted by the monitoring are described in text.

[0042] Figure 5 is a diagram showing an example of the configuration data of the sensing database 230. The sensing database 230 is composed of a device name column, a failure location column, a deterioration mechanism column, a cause of deterioration column, a measurement target column, a measurement method column, a sensor installation location column, etc. In the device name column, the name of the device to be measured is stored. In the failure location column, the name of the failure location of the device to be measured is stored. In the deterioration mechanism column, the deterioration mechanism of this failure location is stored in text. In the cause of deterioration column, the cause of deterioration of this failure location is stored. In the measurement target column, the measurement target of this failure location is stored. In the measurement method column, the measurement method of this failure location is stored. In the sensor installation location column, the installation location of the sensor for measuring this failure location is stored.

[0043] Specifically, in the case of an XX valve, it can be seen that there is a seal part as the failure location, and packing deterioration is expected. One of the causes of this packing deterioration is resin deterioration, the measurement target is temperature, the measurement method is vibration measurement, and the sensor installation location is shown to be on the outer surface of the motor.

[0044] FIG. 6 is a diagram showing an example of configuration data of the deterioration database 240. The deterioration database 240 is configured to include a device name column, a deterioration mode column, an effective maintenance activity / monitoring item column, and the like. The deterioration mode column is configured to include a failure location column, a deterioration mechanism column, an influence of deterioration column, a severity of deterioration column, and a frequency of deterioration column.

[0045] The device name column stores the name of the device. The deterioration mode column stores columns such as a failure location column, a deterioration mechanism column, an influence of deterioration column, a severity of deterioration column, and a frequency of deterioration column.

[0046] The deterioration mechanism column describes the text of the deterioration mechanism related to the failure of this device. The influence of deterioration column stores the influence of the deterioration of this failure location. The severity of deterioration column stores the severity of the deterioration of this failure location. The frequency of deterioration column stores the frequency of the deterioration of this failure location.

[0047] And the effective maintenance activity / monitoring item column stores the effective maintenance activities or monitoring items for this deterioration mode. The failure location column stores the failure location of this device.

[0048] FIG. 7 is a diagram showing an example of configuration data of the field data database 250. The field data database 250 is data corresponding to the maintenance activity / monitoring item database 220, and is configured to include a regular inspection cycle column, a maintenance activity column, a frequency column, and a maintenance activity result column.

[0049] The regular inspection cycle column stores the number indicating the cycle of the periodic inspection related to this event. The maintenance activity column stores the maintenance activities for the device. The maintenance activity refers to the inspection content for this device.

[0050] The frequency column stores the frequency of this maintenance activity. In the maintenance activity result column, the results of this maintenance activity are stored. The results of the maintenance activity correspond to the inspection results of this equipment.

[0051] The field data database 250 is further composed of a regular inspection cycle column, a monitoring item column, a frequency column, and a monitoring result column. In the regular inspection cycle column, a number indicating the cycle of the regular inspection related to this event is stored.

[0052] In the monitoring item column, the monitoring items for the equipment are stored. The monitoring items refer to the inspection contents for this equipment. In the frequency column, the frequency of this monitoring item is stored. In the monitoring result column, the results of this monitoring are stored. The results of the monitoring correspond to the inspection results of this equipment.

[0053] Figure 8 is a diagram showing an example of the defect event table 21. This defect event table 21 summarizes the defect events stored in the field data database 250 during the regular inspection. The defect event table 21 is composed of a number column labeled "No.", a location information column, a valve number column labeled "Valve No.", an event column, a treatment status column for the current regular inspection, and a treatment column for after the next regular inspection.

[0054] In the number column, the sequential number assigned to this defect event data is stored. In the location information column, the location information of the equipment related to this defect event data is stored. In the valve number column, the number of the valve related to this defect event data is stored.

[0055] In the event column, this defect event is stored in text. A defect event is, for example, when the maintenance activity result column or the monitoring result column of the field data database 250 is other than "sound".

[0056] In the treatment status column for the current regular inspection, the treatment status in this regular inspection is stored in text. In the treatment column for after the next regular inspection, the treatments planned for the regular inspections after the next one are stored in text.

[0057] FIG. 9 is a diagram showing an aggregated table 22 obtained by aggregating the field data database 250. The aggregated table 22 is composed of a regular inspection cycle column, an inspection count column, and columns L5 to L1. In the regular inspection cycle column, a number indicating the cycle of the regular inspection related to this event is stored.

[0058] In the inspection count column, the number of pieces of equipment in the plant that have been inspected is stored. In the L5 column, the number of results where almost no deterioration is observed and it is determined that no countermeasure is required is stored as a result of the inspection. In the L4 column, the number of inspection results where deterioration is observed but it is determined that no countermeasure is required is stored. In the L3 column, the number of inspection results where the deterioration has progressed more than L4 and it is determined that early countermeasures are recommended is stored. In the L2 column, the number of inspection results where it is determined that the next countermeasure is recommended is stored. In the L1 column, the number of inspection results where it is determined that immediate countermeasures are required is stored.

[0059] FIG. 10 is a diagram showing an example of a maintenance effectiveness index table 23. The maintenance effectiveness index table 23 is composed of a level column, a keyword column, and a status column. The level column is a column for storing the maintenance level, which is divided into five levels from L1 to L5 here. The keyword column is a column for storing a plurality of keywords for determining the maintenance level to be addressed from the text of the inspection results. The status column is a column for storing, with respect to the inspection results, the status of whether or not countermeasures should be taken for the equipment related to this inspection result.

[0060] "Apply field data to each process of equipment reliability, work management, and configuration management" FIG. 11 is a flowchart of the maintainability determination process. First, the soundness monitoring unit 12 acquires inspection results from the field data database 250 (step S20). Then, the soundness monitoring unit 12 collates the inspection results with the maintenance effectiveness index table 23 defined by the customer to determine the maintainability of the equipment related to the inspection content (step S21). Here, the maintainability of the equipment is, for example, any one of L1 to L5 shown in the aggregation table 22 of FIG. 9. If the inspection result is L4 or L5, the soundness monitoring unit 12 determines that the inspection content of the equipment does not require countermeasures.

[0061] Next, the corrective action unit 15 determines the maintainability of the equipment (step S22). If the maintainability of the equipment is L4 or L5 and there is a tendency to over-maintain, the corrective action unit 15 reduces the maintenance frequency or monitoring frequency (step S23) and ends the process of FIG. 11. Here, the maintenance frequency or monitoring frequency is the frequency column in the maintenance activity and monitoring item database 220. By reducing the maintenance frequency or monitoring frequency in this way, the maintenance cycle of the inspection content can be optimized and the amount of maintenance work can be reduced.

[0062] If the maintainability of the equipment is L3 and it is proper maintenance, the corrective action unit 15 maintains the maintenance frequency or monitoring frequency (step S24) and ends the process of FIG. 11. If the maintainability of the equipment is L2 or L1 and monitoring should be strengthened, the corrective action unit 15 improves the maintenance frequency or monitoring frequency (step S25) and ends the process of FIG. 11.

[0063] 《Utilization of Field Data Information for Maintenance Importance》 The frequency of deterioration occurrence of the same equipment in the same system is the same. Also, the frequency of deterioration occurrence of the same equipment in the same environment is the same. The frequency of deterioration occurrence of the same equipment in the same environment in different plants is theoretically the same. That is, there was a problem that it was not possible to weight the deterioration according to the equipment. Therefore, by weighting the maintenance importance from the inspection results, maintenance activities can be carried out according to the state of the equipment.

[0064] FIG. 12 is a flowchart of the deterioration frequency determination process. First, the soundness monitoring unit 12 acquires inspection results from the field data database 250 (step S30). Specifically, the inspection results are stored in the result column of the maintenance activity or the monitoring result column of the field data database 250.

[0065] Then, the soundness monitoring unit 12 calculates the deterioration occurrence frequency from the inspection results (step S31). The deterioration occurrence frequency is calculated by dividing the number of times a defect event is included in the inspection results by the target period.

[0066] Next, the corrective action unit 15 determines the deterioration occurrence frequency of the equipment related to this inspection result (step S32). If the deterioration occurrence frequency is less than the first threshold and is low, the corrective action unit 15 reduces the importance of the equipment related to this inspection result (step S33) and ends the process of FIG. 12. The importance of the equipment is indicated in the severity column of the deterioration database 240 stored in the storage unit 20. The corrective action unit 15 reduces the importance of the equipment by reducing the value in the severity column of the deterioration database 240.

[0067] In step S32, if the deterioration occurrence frequency is equal to or greater than the first threshold and less than the second threshold and is medium, the corrective action unit 15 maintains the importance of the equipment related to this inspection content (step S34) and ends the process of FIG. 12. In step S32, if the deterioration occurrence frequency is equal to or greater than the second threshold and is high, the corrective action unit 15 improves the importance of the equipment related to this inspection content (step S35) and ends the process of FIG. 12. That is, the corrective action unit 15 calculates the deterioration occurrence frequency from the inspection results, increases or decreases the importance of the equipment according to the deterioration occurrence frequency, and reflects it in the value of the severity column of the deterioration database 240. Thereby, the amount of maintenance can be reduced.

[0068] 《Utilization of Field Data Information for Performance Monitoring》 FIG. 13 is a graph showing the field data and the deterioration curve of equipment for adjusting pressure such as hydraulic pressure and water pressure. The vertical axis represents the compression set. The horizontal axis represents time. The thin dashed line represents the degradation curve derived from the results of the EQ test. The thick dashed line represents the degradation curve derived from the EQ test and field data. The solid line represents the measured data. Also, for general industrial products, the compression set is acceptable up to the thick horizontal dashed line, but for high-reliability equipment used in the aviation and nuclear industries, etc., the thin horizontal dashed line is the acceptable range. This is because the risk of leakage increases when exceeding the hatched area.

[0069] In the conventional view, the measured data shown by the solid line is judged as "good". However, since it greatly deviates from the convergence trend of the degradation curve and the assumed life, the possibility of, for example, a defect in the sensor related to the inspection content or an error by the inspector cannot be denied. Therefore, the maintenance plan formulation device 100 determines such an event as "requiring inspection". As a result, the good data obtained from maintenance can be utilized to improve the reliability of the equipment.

[0070] Figure 14 is a flowchart showing the determination of deviation from the degradation curve. First, the soundness monitoring unit 12 acquires the inspection results from the field data database 250 (step S40). The soundness monitoring unit 12 obtains the degradation degree of the equipment from this inspection result (step S41). Then, the reliability improvement unit 13 estimates the degradation degree of the equipment from the cumulative operation time of the equipment and the degradation curve (step S42).

[0071] Next, the corrective action unit 15 determines the deviation between the degradation degree of the equipment obtained from the inspection results and the degradation degree estimated from the cumulative operation time of the equipment and the degradation curve (step S43). If the degradation degree deviates (Yes), the corrective action unit 15 determines that the inspection of the equipment related to this inspection content is required (step S44), and ends the process of Figure 14. In step S43, if the degradation degree does not deviate (No), the corrective action unit 15 ends the process of Figure 14.

[0072] 《Utilization of Field Data Information for Performance Monitoring》 Figure 15 is a graph showing the time series of field data. The vertical axis of the graph indicates the degree of deterioration. The horizontal axis of the graph indicates time. The solid line indicates the normal degree of deterioration of the device. After the degree of deterioration diverges from time T0 to T1, it converges after time T1 and maintains a predetermined value. The dashed-dotted line indicates the degree of deterioration due to the initial defect of the device.

[0073] The dashed line after time T2 indicates that the degree of deterioration is diverging. These are often signs of device failure. Therefore, if a pattern in which the degree of deterioration diverges, converges, and then diverges again is detected here, it is determined that immediate countermeasures are necessary.

[0074] Figure 16 is a flowchart showing the determination process of the time series of field data. First, the health monitoring unit 12 acquires the time series inspection results from the field data database 250 (step S50). The health monitoring unit 12 obtains the degree of deterioration of the device in time series from this inspection result (step S51). Then, the reliability improvement unit 13 determines whether the degree of deterioration of the device in time series is in the order of divergence ⇒ convergence ⇒ divergence (step S52).

[0075] In step S52, if the corrective action unit 15 determines that the degree of deterioration has changed in the order of divergence ⇒ convergence ⇒ divergence (Yes), it determines that immediate countermeasures are required for the device related to this inspection content (step S53), and ends the process of Figure 16. In step S52, if the corrective action unit 15 determines that the degree of deterioration has not changed in the order of divergence ⇒ convergence ⇒ divergence (No), it ends the process of Figure 16.

[0076] 《Utilization of Field Data for Configuration Management》 Currently, configuration management changes are applied based on equipment configuration information, regulation information, etc. However, it is not known whether all processes are up-to-date, and omissions cannot be checked. Regulations require being up-to-date. Data that has been judged satisfactory over a long period has not been changed. Therefore, there is a risk of omission. Thus, the fact that there has been no change over a long period is introduced as a new change constraint condition.

[0077] Figure 17 is a flowchart showing the utilization process of field data. First, the soundness monitoring unit 12 performs performance monitoring (step S60). Then, the corrective action unit 15 conducts an evaluation of problems and changes (step S61). Here, the corrective action unit 15 performs sharing of information for solution selection, identification of solution options, and selection of the best solution.

[0078] When it is determined to execute corrective actions, the user determines whether changes to the design requirements in Figure 17 are required (step S62). If changes to the design requirements are required (Yes), the user implements the design requirement change process (step S63) and proceeds to step S64. The design requirement change process includes calculations or analyses for revising design requirements, evaluation of solutions, revision of design requirements, changes to approval conditions, etc. The changed design requirements are reflected in the changes to the equipment configuration information described later. In step S62, if changes to the design requirements are not required (No), the process proceeds to step S64.

[0079] In step S64, the user determines whether changes to the physical configuration are required. If changes to the physical configuration are required (Yes), the user implements the physical configuration change process (step S65) and proceeds to step S66. The physical configuration change process includes determination of the impact of regulations, creation of approval documents, approval of physical changes for design and operation changes, ordering of long-lead items and engineering, etc. The changed physical configuration is reflected in the changes to the equipment configuration information described later. In step S64, if changes to the physical configuration are not required (No), the process proceeds to step S66.

[0080] In step S66, the user determines whether there is a need to change the installation configuration information. If the user needs to change the installation configuration information (Yes), the user performs the installation configuration information change process (step S67) and returns to step S61. The installation configuration information change process includes extracting equipment configuration information affected, changing and approving the extracted equipment configuration information, reviewing, approving, and issuing information from the vendor and revising existing information, revising the equipment configuration information after physical changes, and reflecting the change in the equipment configuration information. In step S66, if there is no need to change the installation configuration information (No), the process proceeds to step S68.

[0081] In step S68, the user extracts items among the design requirements, physical configuration, and installation configuration information that have not had changes for a long time and then returns to step S61. As a result, the user can recognize that items without changes for a long time pose risks.

[0082] 《Review of Items such as the Maintenance Cycle of the Soundness Monitoring Unit 12》 The embodiment of the review of items such as the maintenance cycle of the soundness monitoring unit 12 will be described with reference to the drawings. Note that the description of the same configurations from FIG. 1 to FIG. 17 will be omitted, and the different parts will be described.

[0083] In this embodiment, the review of items such as the maintenance cycle is performed using the inspection results of the field data database 250.

[0084] FIG. 18 is a flowchart showing the time-series determination process of field data. In step S80, the soundness monitoring unit 12 checks from the inspection results of the field data database 250 whether a problem has occurred in the current inspection results. If there is a problem in the inspection results (Yes), the soundness monitoring unit 12 proceeds to step S84, maintains the item of the corresponding inspection content as an item to be considered in the subsequent inspection plan, stores this information in the storage unit 20 of the maintenance plan formulation device 100, and ends the process of FIG. 18.

[0085] If there is no problem in step S80 (No), the soundness monitoring unit 12 proceeds to step S81 and compares each item of the inspection result over time. Then, the soundness monitoring unit 12 determines whether there is a convergence trend in the time series of data from the past to the present (step S82).

[0086] FIG. 19 is a graph showing the time series data of field data. The vertical axis of the graph indicates the working time. The horizontal axis of the graph indicates the maintenance cycle. The dashed line indicates the working time related to the maintenance of device A in the first case. The solid line indicates the working time related to the maintenance of device A in the second case. Here, the working time related to the maintenance of device A is one of the items of the inspection result of device A.

[0087] In the first case indicated by the dashed line, regarding the maintenance of device A, the working time has converged (decreased) to a certain value, such as 7.8 hours, 6 hours, and 5.5 hours, compared to the past. At this time, in step S82, the soundness monitoring unit 12 determines that this item has a convergence trend and proceeds to step S83.

[0088] In step S83, the soundness monitoring unit 12 updates the corresponding item as a fixed item for the next and subsequent times in the maintenance plan determination device 100. That is, if there is a convergence trend in the time series of the inspection results from the past to the present, the soundness monitoring unit 12 determines that no corresponding action is required for the inspection content.

[0089] In the second case indicated by the solid line, regarding the maintenance of device A, the working time has maintained a predetermined value of 8 hours compared to the past. At this time, in step S82, the soundness monitoring unit 12 determines that the time series of the inspection result items does not have a convergence trend and proceeds to step S84. The soundness monitoring unit 12 maintains the corresponding item as an item to be considered in the next and subsequent inspection plans (step S84), stores this information in the storage unit 20 of the maintenance plan determination device 100, and ends.

[0090] Here, when the work items for the maintenance of equipment A are composed of multiple operations such as operation P, operation Q, operation R, operation S, and operation T, in actual work, operation T may not be necessary. In that case, operation T is an item that should originally be reviewed, but it may not be reviewed if there are no particular problems. Compared with this, if operation T is reviewed reflecting the actual work, the work time will be optimized by that much, and the work time will be shortened from 7.8 hours to 6 hours. In addition, here, the change in work time is used as an indicator to capture the trend of work, and it has been explained that it is possible to determine whether corresponding measures are required for the inspection content. Similarly, changes in the items of maintenance work, the implementation intervals or cycles of maintenance work, changes in the number of personnel required for work, changes in the number of parts and equipment replaced in work, etc. can also be used as indicators to capture the trend of work, and it is possible to determine whether corresponding measures are required for the inspection content.

[0091] When looking at a certain item for the items that have been actually reviewed like this, they converge to a certain value, and the optimal maintenance items are reviewed. By determining whether there is a convergence trend by focusing on a certain item in the past maintenance data like this, it is possible to determine whether it is necessary to review the current inspection content. As a result, it becomes possible to utilize the good data obtained from maintenance for improving the reliability of equipment and / or reducing the amount of maintenance work.

[0092] 《Prioritization of Inspection Work by the Soundness Monitoring Department》 When prioritizing which inspection work to review among multiple inspection works, the time-series data of inspection results can be utilized.

[0093] Figure 20 is a graph showing the time-series data of field data. The vertical axis of the graph indicates the work time. The horizontal axis of the graph indicates the number of maintenance times. The thin dashed line indicates the work time for the maintenance of equipment A in the first case. The solid line indicates the work time for the maintenance of equipment A in the second case. The thick dashed line indicates the work time for the maintenance of equipment A in the third case.

[0094] For example, looking at the 12th maintenance in the graph of FIG. 20, the inspection result data indicated by the fine dashed line has a high convergence tendency, while the inspection result data indicated by the solid line and the thick dashed line has a low convergence tendency. By comparing these tendencies among multiple operations, when it is desired to review multiple operations collectively, it becomes possible to know which operation should be preferentially reviewed. As a result, when reviewing multiple operations, it becomes possible to utilize the good data obtained from maintenance for improving the reliability of the equipment and / or reducing the amount of maintenance work.

[0095] FIG. 21 is a flowchart showing the priority determination process. The soundness monitoring unit 12 compares each item of the inspection result data in time series (step S88). Then, according to the level of the convergence tendency of each item of the inspection result data from the past to the present, the inspection contents are prioritized (step S89), and this information is stored in the storage unit 20 of the maintenance plan formulation device 100 and the process ends.

[0096] (Modification example) The present invention is not limited to the above-described embodiments and includes various modification examples. For example, the above-described embodiments have been described in detail for easy understanding of the present invention, and are not necessarily limited to those having all the configurations described. It is possible to replace a part of the configuration of one embodiment with the configuration of another embodiment, and it is also possible to add the configuration of another embodiment to the configuration of one embodiment. Further, it is also possible to add, delete, or replace a part of the configuration of each embodiment with another configuration.

[0097] Each of the above configurations, functions, processing units, processing means, etc. may be realized, in part or in whole, by hardware such as an integrated circuit. Each of the above configurations, functions, etc. may also be realized by software by a processor interpreting and executing a program that realizes each function. Information such as programs, tables, and files that realize each function can be stored in a recording device such as a memory, a hard disk, an SSD (Solid State Drive), or a recording medium such as a flash memory card or a DVD (Digital Versatile Disk).

[0098] In each embodiment, the control lines and information lines show those considered necessary for explanation, and not necessarily all control lines and information lines are shown in the product. In reality, it may be considered that almost all components are interconnected.

Explanation of Reference Numerals

[0099] 10 Processing Unit 11 Importance Classification Unit 12 Soundness Monitoring Unit 13 Reliability Improvement Unit 14 Preventive Maintenance Planning Unit 15 Corrective Action Unit 16 Life Cycle Management Unit 20 Storage Unit 21 Defect Event Table 22 Aggregation Table 23 Maintenance Effectiveness Index Table 24 Maintenance Plan Formulation Program 30 Input Unit 40 Output Unit 50 Communication Unit 100 Maintenance Plan Formulation Device 200 Database Device 210 Configuration Management Database 220 Maintenance Activity / Monitoring Item Database 230 Sensing Database 240 Deterioration Database 250 Field Data Database 300 Conservative Plan Development System

Claims

1. Based on a maintenance effectiveness index table including keywords indicating the maintenance level of a machine and corresponding states corresponding to the keywords, a plurality of inspection items related to the machine, and a plurality of inspection results included in field data in which each inspection result related to the plurality of inspection items is stored in time series, a soundness monitoring unit that determines whether it is necessary to take action on the machine from the sentences of the plurality of inspection results; A corrective action unit that reduces the maintenance frequency or monitoring frequency of the machine related to the inspection items determined to not require action by the soundness monitoring unit and optimizes the maintenance cycle; A maintenance plan formulation device, characterized by comprising the above.

2. The corrective action unit fixes the inspection results of the inspection items determined to not require action among the plurality of inspection items as the inspection results by the next inspection items. The maintenance plan formulation device according to claim 1, characterized by the above.

3. The corrective action unit reflects the inspection results in the importance of the machine related to the inspection items. The maintenance plan formulation device according to claim 1, characterized by comprising the above.

4. Further comprising a reliability improvement unit that predicts the deterioration of the machine related to the inspection items over time, The soundness monitoring unit determines that it is necessary to take action on the machine related to the inspection items when the deterioration indicated by the inspection results deviates from the predicted value of the deterioration related to the inspection items. The maintenance plan formulation device according to claim 1, characterized by the above.

5. Further comprising a reliability improvement unit that determines that the degree of deterioration of the time-series inspection results of the field data has diverged again after divergence and convergence, The soundness monitoring unit determines that it is necessary to take action on the machine related to the inspection results if the degree of deterioration of the time-series inspection results of the field data has diverged again after divergence and convergence. The maintenance plan formulation device according to claim 1, characterized by the above.

6. The soundness monitoring unit refers to the equipment configuration information, physical configuration, and design requirement information related to the inspection items, and if there are items that have not been changed over a long period among the equipment configuration information, the physical configuration, and the design requirements, it determines that it is necessary to take action on the inspection items related to the items. The maintenance plan formulation device according to claim 1, characterized by the above.

7. The soundness monitoring unit identifies items with a converging trend in the time series from the past to the present among the inspection results based on the field data, and determines that no action is required for the inspection items related to the inspection results. The maintenance plan formulation device according to claim 1, characterized by the above.

8. The soundness monitoring unit is characterized in that, based on the field data, it sets the priority order of the inspection items related to the inspection results according to the level of the convergence trend of the time series from the past to the present of the inspection results. The maintenance plan formulation device according to claim 1.

9. On a computer, Based on a maintenance effectiveness index table including keywords indicating the maintenance level of the equipment and the corresponding states corresponding to the keywords, a procedure for determining the necessity of taking action on the equipment from the sentences of a plurality of inspection results included in the field data in which a plurality of inspection items related to the equipment and inspection results regarding the plurality of inspection items are stored in time series, A procedure for optimizing the maintenance cycle by reducing the maintenance frequency or monitoring frequency of the equipment related to the inspection items determined to not require action, A maintenance plan formulation program for causing the computer to execute the procedures.

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