Information processing device and information processing program

Abstract

To provide an information processor and information processing program that optimize the number of times of inspection of a plant and make inspection efficient.SOLUTION: A data acquisition unit 11 acquires information of an installation site of a maintenance apparatus arranged in a plant 1, ambient environment information of the maintenance apparatus, and system condition information of the maintenance apparatus. A replacement cycle calculation unit 13 estimates the apparatus condition of the maintenance apparatus on the basis of the information of the installation site, the ambient environment information, and the system condition information, and calculates a tentative replacement cycle of a replacement component on the basis of the apparatus condition, a recommended replacement cycle of the replacement component incorporated in the maintenance apparatus, and a proposed replacement cycle of the replacement component which has previously been proposed. An inspection cycle arithmetic unit 16 calculates a proposed replacement cycle of the replacement component on the basis of the tentative replacement cycle, the recommended replacement cycle, and an inspection record of the maintenance apparatus, and calculates an inspection cycle of the maintenance apparatus.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an information processing device and an information processing program. [Background technology]

[0002] Control systems used in various plants that use petroleum, petrochemical, chemical, gas, etc. require regular maintenance to ensure stable operation over a long period of time. Many of the parts used in plant control systems have a limited lifespan, and standards such as estimated useful life are specified in advance. Based on these standards, long-term maintenance plans are formulated, including replacement and cleaning work for each part.

[0003] Although the estimated service life of each component is specified by the manufacturer, the rate at which the component deteriorates or wears out varies greatly depending on the conditions and environment in which it is used. For example, in an ideal environment such as a server room, the component can be used up to the maximum service life. However, in places with high temperatures and humidity or corrosive gases, the risk of breakdown increases even before the end of the service life.

[0004] In order to maintain the safe operation of various equipment such as plant instrumentation and computer equipment, the environmental conditions that must be considered include the temperature inside the equipment, the ambient temperature and humidity around the equipment, the amount of suspended dust around the equipment, and the concentration of corrosive gases around the equipment.

[0005] Generally, the temperature, humidity, dust, corrosive gases, and other environmental conditions of installation continue to stress various equipment over long periods of time. As this stress gradually accumulates, the functionality of the equipment deteriorates and declines, eventually leading to a shutdown and a significant loss of opportunity for the user.

[0006] To prevent lost opportunities due to such equipment shutdowns, it is extremely important to accurately measure and understand the installation environment conditions, and then develop and execute equipment maintenance plans based on those measurement results to maintain the reliability of the equipment over the long term.

[0007] Conventionally, maintenance plans are formulated by service engineers who make comprehensive judgments based on installation environment diagnostic data, failure data, and past inspection history, and then propose maintenance intervals and maintenance measures. Installation environment data is data measured for temperature, humidity, dust, corrosive gases, etc. in the installation environment of the device in which each component is built. Failure data is information on the history of past equipment failures.

[0008] The following technologies have been proposed as techniques related to inspection planning. For example, there is a technology that generates an inspection plan that allocates each deterioration event to a regular inspection based on maintenance information including inspection locations in each area of ​​a plant, each deterioration event, and the inspection cycle, calculates the inspection volume for the regular inspection from the inspection plan, and levels out the inspection volume for the regular inspection (e.g., Patent Document 1). Another technology stores past construction records and management reference values ​​for equipment to be maintained in association with data items, performs regression analysis for each equipment to be maintained based on the stored data, and changes the next inspection cycle based on the results of the regression analysis (e.g., Patent Document 2). Another technology determines an inspection plan that minimizes total costs by calculating the probability of state transitions between the normal state and each failure state of an inspection object and between each failure state, the damage amount and repair cost corresponding to each failure state, and the expected value of the damage amount and repair cost using a state transition model based on state changes (e.g., Patent Document 3). [Prior art documents] [Patent documents]

[0009] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-014958 [Patent Document 2] Japanese Patent Application Laid-Open No. 2002-297810 [Patent Document 3] Japanese Patent Application Laid-Open No. 2004-334457 Summary of the Invention [Problem to be solved by the invention]

[0010] However, this method of formulating a maintenance plan by having service engineers make a comprehensive judgment after referring to various data relies on the qualitative judgment of the service engineer, making it difficult for inexperienced service engineers to formulate an appropriate plan. As a result, situations arise where an appropriate maintenance plan is not proposed, making it difficult to carry out inspections efficiently. Furthermore, traditional maintenance plan formulation does not take into account information about the environment in which the inspection target is installed, making it difficult to calculate an appropriate inspection cycle based on the environment, and making it difficult to carry out inspections efficiently.

[0011] The disclosed technology aims to provide an information processing device and an information processing program that optimize the number of plant inspections and make inspections more efficient. [Means for solving the problem]

[0012] In one aspect of the information processing device and information processing program disclosed in the present application, a data collection unit acquires information on installation locations of maintenance devices arranged in a plant, information on the surrounding environment of the maintenance devices, and system status information indicating the operation history of the maintenance devices. A replacement cycle calculation unit estimates an equipment status indicating the state of the operating environment of the maintenance devices based on the information on the installation locations, the surrounding environment information, and the system status information acquired by the data collection unit, and calculates the estimated equipment status. Based onand calculates a first replacement period by correcting a recommended replacement period that is a replacement period recommended as a specification of the replacement part mounted on the maintenance equipment, and corrects the calculated first replacement period based on a proposed replacement period of the replacement part that was proposed in the past to calculate a tentative replacement period that is a provisional replacement period before applying the replacement part to actual operation.The inspection period calculation unit calculates a tentative replacement period that is a provisional replacement period before applying the replacement part to actual operation based on the tentative replacement period calculated by the replacement period calculation unit, the recommended replacement period, and inspection records of the maintenance equipment including calibration information, failure information, and replacement history of the replacement part, and determines whether the replacement part can be replaced while the plant is operating within the estimated replacement period. Based on actual operation determining the proposed replacement period for the replacement part; Decided An inspection cycle for the entire maintenance equipment is calculated based on the proposed replacement cycle of the replacement part. [Effects of the Invention]

[0013] In one aspect, the present invention can optimize the frequency of plant inspections and improve the efficiency of inspections. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is a diagram illustrating an example of the overall configuration of a system according to an embodiment. [Figure 2] FIG. 2 is a diagram showing a list of information stored in the information processing device. [Figure 3] FIG. 3 is a diagram showing an example of an equipment replacement plan table created by the inspection cycle calculation unit. [Figure 4] FIG. 4 is a diagram showing an example of parameters for adjustment depending on the user. [Figure 5] FIG. 5 is a diagram showing an example of a maintenance report in the case where the maintenance device is installed in a good environment with no installation environment problems. [Figure 6] FIG. 6 is a diagram showing an example of a maintenance report in the case where a maintenance device is installed in an environment with some problems. [Figure 7] FIG. 7 is a flowchart of a maintenance plan formulation process performed by the information processing device according to the embodiment. [Figure 8] FIG. 8 is a hardware configuration diagram of the information processing device. DETAILED DESCRIPTION OF THE INVENTION

[0015] The following describes in detail examples of the information processing device and information processing program disclosed herein with reference to the accompanying drawings. Note that the present invention is not limited to these examples. In addition, the same elements are given the same reference numerals, redundant descriptions are omitted as appropriate, and the embodiments can be combined as appropriate within a consistent range.

[0016] [Embodiment Mode] [Overall configuration] 1 is a diagram illustrating an example of the overall configuration of an information processing device according to an embodiment. As shown in Fig. 1, an information processing device 10 is connected to a plant 1 and a terminal device 2 via a network, whether wired or wireless.

[0017] Plant 1 is an example of various plants that use petroleum, petrochemicals, chemicals, gas, etc., and includes factories and the like equipped with various facilities for obtaining products. Examples of products are LNG (liquefied natural gas), resins (plastics, nylon, etc.), chemical products, etc. Examples of facilities are factory facilities, machinery facilities, production facilities, power generation facilities, storage facilities, wellhead facilities for extracting petroleum, natural gas, etc.

[0018] The plant 1 is constructed using a distributed control system (DCS) or the like. For example, although not shown, a control system in the plant 1 uses process data used in the plant 1 to execute various controls on control devices such as field devices installed in the equipment to be controlled and operation devices corresponding to the equipment to be controlled. The control system includes a computer such as a server.

[0019] [Information processing device] The information processing device 10 is a device that creates maintenance plans for various replacement parts that are to be maintained and are installed in a control system arranged in the plant 1. In the following explanation, the control system, industrial computer, etc. that are to be maintained are referred to as "maintenance equipment." Furthermore, aging parts and consumables that are built into the maintenance equipment and are to be replaced periodically are referred to as "replacement parts."

[0020] Replacement parts include, for example, hard disks, filters, packings, gaskets, and the like installed in industrial computers. In Plant 1, various computers are sometimes placed in locations other than the computer room, close to the work site, in order to be used to control work support devices and the like. Locations close to the work site are likely to be subject to various environments that can deteriorate replacement parts, such as environments with high levels of suspended dust, highly corrosive atmospheres, and environments with strong magnetic field effects. Therefore, unlike equipment located in the computer room, it is strongly required to perform maintenance that is appropriate for the environment specific to Plant 1.

[0021] As shown in FIG. 1, the information processing device 10 includes a data collection unit 11, an equipment data storage unit 12, a replacement cycle calculation unit 13, a learning data storage unit 14, a basic replacement data storage unit 15, and an inspection cycle calculation unit 16.

[0022] The device data storage unit 12, the learning data storage unit 14, and the exchange basic data storage unit 15 are storage devices. Fig. 2 is a diagram showing a list of information stored in the information processing device.

[0023] As shown in FIG. 2, the equipment data storage unit 12 stores system status data, a maintenance equipment list, and installation environment data. The system status data is information acquired from each maintenance equipment, such as the internal voltage and battery voltage of each maintenance equipment, and the number of operations. The control system maintenance equipment list is a list of maintenance equipment to be maintained, including replacement parts such as aging parts and consumables that are periodically replaced. The maintenance equipment list is created based on equipment specifications and pre-stored in the equipment data storage unit 12. The maintenance equipment list also registers information on the installation location of each maintenance equipment and the replacement parts installed in each maintenance equipment. Examples of installation locations include a central control room, a field control panel, and an electrical room. The installation environment data includes ambient environment information that indicates the environment surrounding the maintenance equipment. The ambient environment information includes information such as temperature and humidity, corrosion level, magnetic field strength, and the amount of suspended dust. The corrosion level is expressed, for example, by the concentration of corrosive gases. The installation environment data can be acquired from an installation environment measurement unit installed in the space where the maintenance equipment is installed within the plant 1.

[0024] The learning data storage unit 14 stores learning data used when correcting the replacement period. The learning data includes information on past proposed replacement periods determined by the information processing device 10 based on the system status and installation environment of each maintenance device. The learning data stored in the learning data storage unit 14 includes information on proposed replacement periods obtained from a maintenance plan created by a maintenance plan formulation process described below.

[0025] The replacement basic data storage unit 15 stores inspection record data and information on recommended replacement periods. The inspection record data is information on the inspection records of maintenance equipment, including calibration information, failure information, and replacement history of replacement parts in each maintenance equipment measured during regular inspections. The inspection record data is created based on regular inspection reports and is stored in advance in the replacement basic data storage unit 15. The recommended replacement period is information on recommended replacement periods provided by manufacturers of replacement parts that are limited-life parts and parts that deteriorate over time that make up the control system. Information on the recommended replacement period is stated in specifications provided by manufacturers of replacement parts, and the information stated in these specifications is stored in advance in the replacement basic data storage unit 15.

[0026] Returning to Fig. 1, the explanation will be continued. The data collection unit 11 acquires system status information from each maintenance device installed in the plant 1, including data such as the internal voltage and battery voltage of each maintenance device, and operation information of the maintenance target device such as the number of operations. The data collection unit 11 also acquires, from each maintenance device installed in the plant 1, ambient environment information specific to the plant 1 in which the maintenance device is installed, including information such as temperature and humidity, corrosion level, magnetic field strength, and amount of suspended dust. The data collection unit 11 then generates system status data and installation environment data based on the collected information and stores them in the device data storage unit 12. The maintenance plan formulation process in the information processing device 10 is performed sequentially for all maintenance devices listed in the maintenance device list.

[0027] The replacement period calculation unit 13 calculates a provisional replacement period, which is a provisional replacement period for each replacement part before application to actual operation of each maintenance device, based on environmental information specific to the plant 1 in which each maintenance device is located, the recommended replacement period, and past proposed replacement periods of replacement parts. The replacement period calculation unit 13 will be described in detail below. The replacement period calculation unit 13 includes, for example, an equipment state estimation unit 131 and a correction unit 132.

[0028] The equipment state estimation unit 131 acquires the system state data, the maintained equipment list, and the installation environment data from the equipment data storage unit 12. Then, the equipment state estimation unit 131 extracts the maintained equipment for which the inspection interval is to be calculated from the maintained equipment list.

[0029] Next, the device state estimation unit 131 performs multiple regression analysis on the extracted maintained devices using the system state data and the installation environment data to determine the device state. For example, the device state estimation unit 131 classifies the device state of each maintained device into four levels from good to poor.

[0030] More specifically, the equipment state estimation unit 131 grasps the environmental state by determining, based on the installation environment data, for example, the amount of suspended dust, sulfur dioxide gas concentration, hydrogen sulfide concentration, and chlorine gas concentration specific to plant 1 in four stages, such as no problem, follow-up observation, re-inspection, and detailed inspection required.

[0031] Furthermore, the following relationships are considered for each type of replacement part with respect to each environmental condition. For example, high ambient temperatures may accelerate deterioration of batteries and power supply units (electrolytic capacitors). High dust levels may accumulate on moving parts (rotating bodies, etc.) such as filters and DVD players, further accelerating their deterioration. High concentrations of corrosive gases may corrode electronic circuit boards, accelerating their deterioration. While the gas components affect slightly different metals, corrosive gases are generally considered to affect electronic components. Specifically, sulfur dioxide gas is believed to deteriorate copper, iron, zinc, and aluminum; hydrogen sulfide deteriorates copper and silver; and chlorine gas deteriorates copper, tin, silver, and iron. In other words, in a highly corrosive environment, the replacement cycle of maintenance equipment such as computers and control systems should be shortened. Therefore, the equipment status estimation unit 131 determines the equipment status of each maintenance device by taking into account the impact of the environmental conditions identified using the above-described method on the deterioration of each replacement part.

[0032] Next, the equipment state estimation unit 131 acquires information on the recommended replacement period for each type of replacement part installed in the extracted maintained equipment from the replacement basic data storage unit 15. Then, the equipment state estimation unit 131 corrects the recommended replacement period for each replacement part according to the determination result of the equipment state of the maintained equipment, and sets a first replacement period. Thereafter, the equipment state estimation unit 131 outputs information on the first replacement period for each replacement part installed in the maintained equipment to the correction unit 132.

[0033] For example, the equipment state estimation unit 131 calculates the first replacement period using the following method. The equipment state estimation unit 131 performs learning to set the first replacement period by modifying the recommended replacement period in accordance with the equipment state. Specifically, the equipment state estimation unit 131 learns to set the first replacement period of the installed replacement part longer than the recommended replacement period if the equipment state is good, and to set the first replacement period of the installed replacement part shorter than the recommended replacement period if the equipment state is poor. Then, the equipment state estimation unit 131 determines the first replacement period by modifying the recommended replacement period from the learning results using the equipment state of the maintenance equipment in which the replacement part is installed and the recommended replacement period of that replacement part.

[0034] The correction unit 132 receives an input of the first replacement period for each replacement part mounted on the target maintenance device from the device state estimation unit 131. Next, the correction unit 132 acquires learning data from the learning data storage unit 14. Then, the correction unit 132 acquires from the learning data a proposed replacement period for each replacement part that was previously proposed to the user P2 by the service engineer P1, according to the device state of each maintenance device.

[0035] Here, the correction unit 132 stores in advance a correction rate according to the difference between the learning data and the first replacement cycle set by the equipment state estimation unit 131, as input from the service engineer P1. Then, the correction unit 132 compares the learning data with the replacement cycle set by the equipment state estimation unit 131, and creates a second replacement cycle for each replacement part by correcting the rate set by the service engineer P1 according to the difference. Thereafter, the correction unit 132 outputs the created second replacement cycle to the inspection cycle calculation unit 16 as a tentative replacement cycle.

[0036] Here, a description will be given of an example of calculation of the tentative replacement period by the replacement period calculation unit 13. For example, the replacement period calculation unit 13 holds the following mathematical formula (1).

[0037]

number

[0038] Here, Dn is the identification information of the maintenance device, Cn is the customer name, Yn is the proposed year, a1 is the installation environment, a2 is the recommended replacement period, and a3 is the proposed replacement period. The replacement period calculation unit 13 performs multiple regression analysis on the data sets a1 to a3 for each replacement part using formula (1) to learn the proposed replacement period.

[0039] Furthermore, the replacement period calculation unit 13 holds the following mathematical formula (2).

[0040]

number

[0041] Here, Pn is a weighting for each suggestion, and is a parameter that can be changed by the service engineer P1, and f is learning data.

[0042] The replacement period calculation unit 13 performs a regression analysis for each proposal on S calculated by formula (1). Then, the replacement period calculation unit 13 calculates a tentative replacement period for each replacement part for each maintenance device of a specific customer by adding the learning data calculated by formula (2) to the estimation result of the device status of the maintenance device having the same identification information. In this case, the replacement period calculation unit 13 calculates a first replacement period using the device status and a second replacement period using the learning data together through calculations based on learning using formulas (1) and (2), thereby calculating the tentative replacement period.

[0043] The inspection cycle calculation unit 16 receives input of the tentative replacement cycle for each replacement part mounted on the target maintenance device from the correction unit 132. The inspection cycle calculation unit 16 also receives the inspection record data and the recommended replacement cycle from the replacement basic data storage unit 15. Next, the inspection cycle calculation unit 16 uses the acquired tentative replacement cycle to determine a proposed replacement cycle that matches the actual operation in accordance with the inspection record and the recommended replacement cycle, and calculates the inspection cycle.

[0044] For example, for replacement parts that can be replaced while the plant is operating, the inspection cycle calculation unit 16 determines the inspection cycle by using the tentative replacement cycle as the proposed replacement cycle. For replacement parts that are replaced during regular maintenance, the inspection cycle calculation unit 16 determines the proposed replacement cycle based on the tentative replacement cycle, taking into account the inspection record data and the regular maintenance cycle, so that the proposed replacement cycle does not exceed the recommended replacement cycle. Then, the inspection cycle calculation unit 16 calculates the inspection cycle for the maintenance equipment according to the proposed replacement cycles for each replacement part that have been determined.

[0045] Then, the inspection cycle calculation unit 16 compiles the inspection cycles of the maintained devices, including the calculated proposed replacement cycles for each replacement part, into a table to generate an equipment replacement plan table 20. After that, the inspection cycle calculation unit 16 transmits the equipment replacement plan table 20 to the terminal device 2 operated by the service engineer P1.

[0046] FIG. 3 is a diagram of an example of an equipment replacement plan table created by the inspection cycle calculation unit. The maintenance equipment #1 shown in FIG. 3 is equipped with three replacement parts, replacement parts A to C. The equipment replacement plan table 20 registers the recommended replacement period, the judgment result of the equipment installation status, the proposed replacement period, and past proposed case data. Furthermore, the equipment replacement plan table 20 registers, as a future maintenance plan, when, for each of replacement parts A to C, the replacement will be performed during regular maintenance, or when the replacement will be performed outside of regular maintenance. The equipment replacement plan table 20 is created for each maintenance equipment.

[0047] Thereafter, when the service engineer P1 decides to make adjustments to the equipment replacement plan table 20 output by the inspection cycle calculation unit 16 to suit the user P2, the inspection cycle calculation unit 16 receives input of adjustment values ​​for the parameters according to the user P2 from the terminal device 2. Then, the inspection cycle calculation unit 16 adjusts the calculation used to calculate the inspection cycle according to the acquired adjustment values ​​for the parameters, recalculates the inspection cycles for each replacement part mounted on the target maintenance equipment using the adjusted calculation, and creates a new equipment replacement plan table 20 and transmits it to the terminal device 2.

[0048] The terminal device 2 receives the input of the equipment replacement plan table 20 from the inspection cycle calculation unit 16. Then, the terminal device 2 provides the received equipment replacement plan table 20 to the service engineer P1 by, for example, displaying it on a monitor.

[0049] The service engineer P1 uses the terminal device 2 to check the equipment replacement plan table 20 provided by the information processing device 10. Then, the service engineer P1 determines whether or not to make adjustments to the equipment replacement plan table 20 to suit the user P2, i.e., whether the equipment replacement plan table 20 is incomplete or completed.

[0050] When making adjustments to suit user P2, service engineer P1 takes into consideration conditions such as user P2's budget, risk sensitivity, and repair period, and adjusts parameters related to these conditions in the calculation by inspection cycle calculation unit 16 to calculate the inspection cycle.

[0051] FIG. 4 is a diagram showing an example of parameters for adjustment according to a user. For example, the parameters include the risk of breakdown, the maintenance budget, and the repair period. An adjustment value expressed in four levels is set for each parameter. The service engineer P1 determines the adjustment value of each parameter for the user P2. For example, the service engineer P1 determines that the risk of breakdown for the user P2 is "high," the maintenance budget is "slightly large," and the repair period is "short." The service engineer P1 then inputs the determined adjustment values ​​of each parameter to the inspection interval calculation unit 16 using the terminal device 2.

[0052] On the other hand, if the maintenance plan is complete and no adjustments are required to suit user P2, service engineer P1 uses terminal device 2 to convert equipment replacement plan table 20 into a report format and generate and output maintenance report 25. For example, service engineer P1 generates maintenance report 25 by organizing maintenance equipment by installation location and further converting the equipment replacement plan table 20 into a format that allows for the entry of a cover page, summary, etc. Thereafter, service engineer P1 fills in the necessary information in maintenance report 25 and provides it to user P2.

[0053] Furthermore, the service engineer P1 uses the terminal device 2 to generate learning data including information on the replacement cycles of each replacement part proposed to the user P2 and the status of each device, and transmits the learning data to the learning data storage unit 14 for storage.

[0054] FIG. 5 is a diagram showing an example of a maintenance report for a case where maintenance equipment is installed in a good environment with no installation environment problems. As shown in FIG. 5, the maintenance report 25 registers customer information, including, for example, the name of user P2, the type of plant, the delivery date, and the installation location. The maintenance report 25 also includes an installation environment diagnosis result indicating the condition of the installation location of the maintenance equipment. In this example, the installation environment is good, so all of the installation environment diagnosis results are judged to be OK. Furthermore, the maintenance report 25 lists a control system and an industrial PC as installation environment maintenance equipment. The recommended replacement interval and proposed replacement interval are also listed for each replacement part installed in the maintenance equipment. In this case, because the equipment condition is good, the proposed replacement intervals for all replacement parts match the recommended replacement intervals.

[0055] FIG. 6 shows an example of a maintenance report for a case where maintenance equipment is installed in a somewhat problematic installation environment. In this case, the maintenance equipment is installed in a location with a high ambient temperature and a chlorine gas atmosphere. As shown in FIG. 6, the maintenance report 25, like FIG. 5, includes customer information and installation environment diagnosis results. Because this is an example of a location with a high ambient temperature and a chlorine gas atmosphere, the ambient temperature and chlorine gas concentration are NG, as shown in columns 101 and 102 of the installation environment diagnosis results. Additionally, the NG result for the amount of suspended dust indicates a high level of dust. The overall inspection result is NG. The maintenance report 25 also lists a control system and an industrial PC as installation environment maintenance equipment. Because the installation environment is somewhat problematic, for example, the power supply unit shown in column 103 has a suggested replacement interval of 6 years, compared with a recommended replacement interval of 8 years. Furthermore, it can be seen that the battery and DVD player are easily affected by the installation environment, suggesting that their replacement intervals should be shortened. In this way, when it is preferable to replace replacement parts at a replacement period different from the normal recommended replacement period due to the unique environment of plant 1, the information processing device 10 of this embodiment can provide a suggested replacement period that is suitable for the unique environment of plant 1.

[0056] 5 and 6 show the maintenance report 25 in a format that provides the user P2 with the recommended replacement interval and the proposed replacement interval for each replacement part, but the content provided is not limited to this. For example, all of the information in the equipment replacement schedule table 20 shown in FIG. 3 may be included in the part replacement interval section of FIG. 5.

[0057] [Maintenance plan formulation process flow] Fig. 7 is a flowchart of a maintenance plan formulation process by an information processing device according to an embodiment. Next, the flow of the maintenance plan formulation process by the information processing device 10 according to an embodiment will be described with reference to Fig. 7. Here, the case where the system status data, the maintenance device list, and the installation environment data are already stored in the device data storage unit 12 will be described.

[0058] The device state estimation unit 131 reads the system state data, the maintained device list, and the installation environment data from the device data storage unit 12 (step S1).

[0059] Next, the equipment state estimation unit 131 performs calculations using the acquired system state data, maintenance equipment list, and installation environment data to estimate the equipment state of each maintenance target equipment. Furthermore, the equipment state estimation unit 131 uses the equipment state estimation result to modify the recommended replacement period acquired from the replacement basic data storage unit 15, and calculates the first replacement period for each replacement part in each maintenance equipment (step S2).

[0060] The correction unit 132 acquires the learning data from the learning data storage unit 14. Then, the correction unit 132 corrects the first replacement period calculated by the equipment state estimation unit 131 using the learning data, calculates a second replacement period for each replacement part in each maintained equipment, and sets the second replacement period as a tentative replacement period (step S3).

[0061] The inspection cycle calculation unit 16 performs calculations based on the provisional replacement cycle, taking into consideration the cycle of regular repairs and the recommended replacement cycle, determines a proposed replacement cycle for each replacement part in each maintenance device, and calculates the inspection cycle (step S4).

[0062] Thereafter, the inspection cycle calculation unit 16 generates the equipment replacement plan table 20 by tabulating the calculated inspection cycles, and transmits the same to the terminal device 2 (step S5).

[0063] The service engineer P1 checks the equipment replacement plan table 20 sent to the terminal device 2 and determines whether the maintenance plan has been completed (step S6).

[0064] If the maintenance plan is not complete and the parameters need to be adjusted to suit the user P2 (step S6: No), the service engineer P1 determines the adjustment values ​​for each parameter and transmits them to the inspection cycle calculation unit 16 using the terminal device 2. This adjusts the calculation for calculating the inspection cycle performed by the inspection cycle calculation unit 16, and adjusts the parameters according to the user P2 (step S7). Thereafter, the maintenance plan formulation process returns to step S4.

[0065] On the other hand, if the maintenance plan is completed (step S6: Yes), the service engineer P1 uses the terminal device 2 to convert the equipment replacement plan table 20 into a report format and create and output a maintenance report 25. Furthermore, the service engineer P1 uses the terminal device 2 to create learning data including the proposed replacement cycle and equipment status of each replacement part and stores the learning data in the learning data storage unit 14 (step S8).

[0066] [effect] As described above, the information processing device according to the embodiment calculates the equipment status of the maintenance equipment based on environmental information about the installation location of the maintenance equipment and corrects the replacement intervals of each replacement part installed in the maintenance equipment based on the equipment status. Furthermore, the information processing device corrects the replacement intervals using previously proposed replacement intervals as learning data to determine a tentative replacement interval. Thereafter, the information processing device determines a proposed replacement interval based on the tentative replacement interval based on inspection data, etc., and calculates an inspection interval. Furthermore, if adjustments are made for each user, the parameters are adjusted and the inspection interval is recalculated, and a maintenance report is created. In this way, by using machine learning to learn quantitative data such as inspection data and the installation environment, an appropriate inspection interval can be calculated. This allows the number of plant inspections to be optimized and inspections to be made more efficient. Furthermore, the information processing device according to the embodiment allows young engineers and others other than experienced engineers to make similar suggestions, making it possible to optimize the number of plant inspections without relying on experience.

[0067] [system] The information including the processing procedures, control procedures, specific names, various data and parameters shown in the above documents and drawings can be changed arbitrarily unless otherwise specified.

[0068] Furthermore, the components of each device shown in the figure are functional concepts and do not necessarily have to be physically configured as shown. In other words, the specific form of distribution and integration of each device is not limited to that shown. In other words, all or part of them can be functionally or physically distributed and integrated in any unit depending on various loads, usage conditions, etc.

[0069] Furthermore, each processing function performed by each device can be realized, in whole or in part, by a CPU (Central Processing Unit) and a program analyzed and executed by the CPU, or can be realized as hardware using wired logic.

[0070] [Hardware] Next, an example of the hardware configuration of the information processing device 10 will be described. Fig. 8 is a hardware configuration diagram of the information processing device. As shown in Fig. 8, the information processing device 10 has a processor 91, a memory 92, a communication device 93, and an HDD (Hard Disk Drive) 94. The processor 91 is connected to the memory 92, the communication device 93, and the HDD 94 via a bus.

[0071] The communication device 93 is a network interface card or the like, and is used for communication with other information processing devices. For example, the communication device 93 relays communication between the processor 91 and maintenance devices such as a control system installed in the plant 1.

[0072] The HDD 94 is an auxiliary storage device. The HDD 94 realizes the functions of the equipment data storage unit 12, the learning data storage unit 14, and the exchange basic data storage unit 15. The HDD 94 also stores various programs including programs for realizing the functions of the data collection unit 11, the equipment state estimation unit 131, the correction unit 132, and the inspection period calculation unit 16.

[0073] The processor 91 reads out various programs stored in the HDD 94, expands them into the memory 92, and executes them. In this way, the processor 91 realizes the functions of the data collection unit 11, the equipment state estimation unit 131, the correction unit 132, and the inspection cycle calculation unit 16.

[0074] In this way, the information processing device 10 operates as an information processing device that executes various processing methods by reading and executing a program. The information processing device 10 can also realize functions similar to those of the above-described embodiments by reading the program from a recording medium using a medium reading device and executing the read program. Note that the program referred to here is not limited to being executed by the information processing device 10. For example, the present invention can also be applied in a similar manner to cases where another computer or server executes a program, or where these execute a program in cooperation with each other.

[0075] This program can be distributed via a network such as the Internet. In addition, this program can be recorded on a computer-readable recording medium such as a hard disk, a flexible disk (FD), a CD-ROM, a magneto-optical disk (MO), or a digital versatile disk (DVD), and can be executed by being read from the recording medium by a computer. [Explanation of symbols]

[0076] 1. Plant 2. Terminal Device 10. Information processing equipment 11 Data Collection Department 12 Equipment data storage section 13 Replacement cycle calculation section 14 Learning data storage unit 15 Exchange basic data storage section 16 Inspection period calculation section 20 Equipment Replacement Plan 25 Maintenance Report 131 Equipment status estimation unit 132 Correction unit

Claims

1. a data collection unit that acquires information on the installation locations of maintenance devices installed in a plant, information on the surrounding environment of the maintenance devices, and system status information that indicates the operation history of the maintenance devices; a replacement period calculation unit that estimates an equipment state indicating the state of the operating environment of the maintenance equipment based on the installation location information, the surrounding environment information, and the system state information acquired by the data collection unit, calculates a first replacement period by correcting a recommended replacement period that is a replacement period recommended as a specification of a replacement part mounted on the maintenance equipment based on the estimated equipment state, and corrects the calculated first replacement period based on a proposed replacement period of the replacement part that was proposed in the past to calculate a provisional replacement period that is a provisional replacement period before applying the replacement part to actual operation; an inspection cycle calculation unit that determines a proposed replacement cycle of the replacement part that is suited to actual operation within the estimated replacement cycle depending on whether or not the replacement part can be replaced while the plant is in operation, based on the tentative replacement cycle calculated by the replacement cycle calculation unit, the recommended replacement cycle, and inspection records of the maintenance equipment including calibration information, failure information, and replacement history of the replacement part, and calculates an inspection cycle for all of the maintenance equipment based on the determined proposed replacement cycle of the replacement part; An information processing device comprising:

2. 2. The information processing apparatus according to claim 1, wherein the inspection cycle calculation unit creates and outputs an equipment replacement plan table that presents the inspection cycle in a tabular format.

3. 3. The information processing device according to claim 1, wherein the inspection period calculation unit receives input of information for adjusting parameters included in a calculation used to calculate the proposed replacement period, which is determined based on the proposed replacement period, and performs the calculation with the parameters adjusted to determine a new proposed replacement period.

4. 4. The information processing apparatus according to claim 1, wherein the ambient environment information includes temperature and humidity, the amount of floating dust, and the concentration of corrosive gases.

5. acquiring information on the installation locations of maintenance devices arranged in a plant, information on the surrounding environment of the installation locations, and system status information indicating the operation history of the maintenance devices; Estimating an equipment state indicating a state of an operating environment of the maintenance equipment based on the installation location information, the surrounding environment information, and the system state information; Based on the estimated equipment state, a recommended replacement period, which is a replacement period recommended as a specification of the replacement part installed in the maintenance equipment, is corrected to calculate a first replacement period, and a provisional replacement period, which is a provisional replacement period before applying the replacement part to actual operation, is calculated by correcting the calculated first replacement period based on a proposed replacement period of the replacement part that was previously proposed, Based on the tentative replacement period, the recommended replacement period, and inspection records of the maintenance equipment including calibration information, failure information, and replacement history of the replacement parts, a proposed replacement period of the replacement parts that is suited to actual operation within the estimated replacement period is determined depending on whether the replacement parts can be replaced while the plant is in operation, and an inspection period for all of the maintenance equipment is calculated based on the determined proposed replacement period of the replacement parts. An information processing program that causes a computer to execute a process.

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