Abnormality cause diagnosis device and abnormality cause diagnosis method

Abstract

To correctly identify various abnormality causes in a plant and present an appropriate countermeasure.SOLUTION: An abnormality cause diagnosis system in accordance with an embodiment performs first determination processing of determining whether operation data satisfies a predetermined requirement. When a cause of an abnormality can be identified based on a result of the first determination processing, the cause of the abnormality and information representing a countermeasure associated in advance with the cause of the abnormality are displayed. When a cause of an abnormality cannot be identified based on a result of the first determination processing, an inquiry addressed to a user is displayed, and second determination processing of determining whether non-operation data entered at a second input device in response to the inquiry satisfies a predetermined requirement is carried out. When the cause of the abnormality can be identified based on a result of the second determination processing, the cause of the abnormality and information representing a countermeasure associated in advance with the cause of the abnormality are displayed. When the cause of the abnormality cannot be identified based on a result of the second determination processing, predetermined displaying is carried out or another operation data is used to perform the first determination processing.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] An embodiment of the present invention relates to an abnormality cause diagnosis device and an abnormality cause diagnosis method. [Background technology]

[0002] When an abnormality occurs in any of the individual pieces of equipment that make up a plant such as a power plant, it is common for plant operators or engineers from the equipment manufacturer to conduct an investigation to identify the cause of the abnormality and take measures to recover from the abnormality.

[0003] On the other hand, there is also a known technology that inputs operating data (for example, data indicating physical quantities such as the number of rotations of rotating objects used in the equipment, the temperature, pressure, and degree of vacuum of materials, etc.) transmitted from individual devices to a designated monitoring system into a proprietary anomaly cause diagnosis device to identify the cause of the anomaly and quickly present countermeasures to the operator, without the need for an operator or engineer to conduct an investigation or identify the cause of the anomaly. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-229109 Summary of the Invention [Problem to be solved by the invention]

[0005] Every time an abnormality occurs in any of the individual devices in a plant, it is often time-consuming and costly for a person to identify the cause of the abnormality in the device where the abnormality occurred and take appropriate measures. In addition, unless the person is an experienced person, it is difficult to correctly identify the cause of the abnormality and take appropriate measures.

[0006] On the other hand, with technology that uses operational data transmitted from individual pieces of equipment in a plant to an abnormality cause diagnosis device, the operational data does not contain information that indicates phenomena that can be perceived by the human senses (such as wear, cracks, abnormal noises, odors, damage to parts that make up the equipment, and past inspection records), so it may not be possible to correctly identify the cause of the abnormality and present appropriate countermeasures to the user.

[0007] The problem to be solved by the present invention is to provide an abnormality cause diagnosis device and an abnormality cause diagnosis method that enable correct identification of various abnormality causes in a plant and suggest appropriate countermeasures. [Means for solving the problem]

[0008] An abnormality cause diagnosis apparatus according to an embodiment includes a first input device that inputs operation data transmitted from individual devices constituting an operating plant, a second input device that inputs non-operational data manually input in response to a question to a user, a processing device that identifies a cause of an abnormality occurring in the device and a countermeasure that is previously associated with the cause of the abnormality based on the operation data and the non-operational data in accordance with a predetermined processing flow, and an output device that displays the cause of the abnormality of the device and the countermeasure, which are identified by the processing device, and the processing device performs a first determination process that determines whether the operation data satisfies a predetermined condition, and if the cause of the abnormality can be identified from the result of the first determination process, and displaying, on the output device, information indicating a normal cause and a countermeasure that has been previously associated with the cause of the abnormality; if the cause of the abnormality cannot be identified from the result of the first determination process, displaying a question to a user on the output device, and performing a second determination process to determine whether or not the non-driving data input through the second input device in response to the question satisfies a predetermined condition; if the cause of the abnormality can be identified from the result of the second determination process, displaying, on the output device, information indicating the cause of the abnormality and a countermeasure that has been previously associated with the cause of the abnormality; if the cause of the abnormality cannot be identified from the result of the second determination process, performing a predetermined display, or performing the first determination process using other operating data. and displaying on the output device a diagnostic screen including a first display section including a photograph, image, or video of the device in which the abnormality has been detected, a second display section including the question, and a third display section in which the user can manually input an answer to the question. Moreover, an abnormality cause diagnosis apparatus according to an embodiment includes a first input device that inputs operation data transmitted from individual devices constituting an operating plant, a second input device that inputs non-operational data manually input in response to a question to a user, a processing device that identifies a cause of an abnormality occurring in the device and a countermeasure that has been previously associated with the cause of the abnormality based on the operation data and the non-operational data in accordance with a predetermined processing flow, and an output device that displays the cause of the abnormality of the device and the countermeasure, which have been previously associated with the cause of the abnormality, and the processing device performs a first determination process that determines whether the operation data satisfies a predetermined condition, and if the cause of the abnormality can be identified from the result of the first determination process, displays information indicating the cause of the abnormality and the countermeasure, which has been previously associated with the cause of the abnormality, on the output device, and If the cause of the abnormality cannot be identified, a question for the user is displayed on the output device, and a second judgment process is performed to determine whether the non-operating data input through the second input device in response to the question satisfies a predetermined condition.If the cause of the abnormality can be identified from the results of the second judgment process, information indicating the cause of the abnormality and countermeasures previously associated with the cause of the abnormality is displayed on the output device.If the cause of the abnormality cannot be identified from the results of the second judgment process, a predetermined display is performed, or the first judgment process is performed using other operating data, and a diagnosis result screen is displayed on the output device, the diagnosis result screen including a fourth display unit including a photo, image, or video of the equipment in which the abnormality was detected, a fifth display unit including an explanation of the cause of the abnormality and its mechanism, and a sixth display unit including an explanation of countermeasures to the abnormality. Moreover, an abnormality cause diagnosis apparatus according to an embodiment includes a first input device that inputs operation data transmitted from individual devices constituting an operating plant, a second input device that inputs non-operational data manually input in response to a question to a user, a processing device that identifies a cause of an abnormality occurring in the device and a countermeasure that has been previously associated with the cause of the abnormality based on the operation data and the non-operational data in accordance with a predetermined processing flow, and an output device that displays the cause of the abnormality of the device and the countermeasure, which have been previously associated with the cause of the abnormality, and the processing device performs a first determination process that determines whether the operation data satisfies a predetermined condition, and if the cause of the abnormality can be identified from the result of the first determination process, displays information indicating the cause of the abnormality and the countermeasure, which has been previously associated with the cause of the abnormality, on the output device, and If the cause of the abnormality cannot be identified, a question is displayed on the output device to the user, and a second judgment process is performed to determine whether the non-driving data input through the second input device in response to the question satisfies a predetermined condition.If the cause of the abnormality can be identified from the results of the second judgment process, information indicating the cause of the abnormality and countermeasures previously associated with the cause of the abnormality is displayed on the output device.If the cause of the abnormality cannot be identified from the results of the second judgment process, a predetermined display is performed, or the first judgment process is performed using other driving data.If the cause of the abnormality cannot be determined using the predetermined processing flow, the cause of the abnormality is determined from the remote monitoring center outside the abnormality cause diagnosis device by communicating with the remote monitoring center via a communication device. [Effects of the Invention]

[0009] According to the present invention, it is possible to correctly identify the causes of various abnormalities in a plant and propose appropriate countermeasures. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a diagram showing an example of the configuration of an abnormality cause diagnosis device that diagnoses the cause of an abnormality in each device that configures a plant according to an embodiment. [Figure 2] FIG. 1 is a diagram showing an example of the configuration of a turning device. [Figure 3] 10A and 10B are diagrams showing examples of various causes of mismatching. [Figure 4A] FIG. 10 is a diagram showing an example of the operation (first half) by the processing device 4. [Figure 4B] FIG. 10 is a diagram showing an example of the operation (second half) by the processing device 4. [Figure 5] FIG. 10 is a diagram showing an example of a diagnosis screen. [Figure 6] FIG. 10 is a diagram showing an example of a diagnosis result screen. [Figure 7A] 6 is a diagram showing a specific example (part 1) of the diagnostic screen 11-a of FIG. 5 that is displayed when an abnormality such as a misfit of the turning device is detected. FIG. [Figure 7B] FIG. 7B is a diagram showing a specific example (part 2) of another diagnostic screen 11-a different from the example of FIG. 7A. [Figure 8] 7 is a diagram showing a specific example of a diagnosis result screen 11-b in FIG. 6 that is displayed as a diagnosis result when an abnormality such as a misfit of the turning device is detected. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, embodiments will be described with reference to the drawings.

[0012] (Configuration of abnormality cause diagnosis device 100) FIG. 1 is a diagram showing an example of the configuration of an abnormality cause diagnosis device that diagnoses the cause of an abnormality in each device that configures a plant according to an embodiment.

[0013] The abnormality cause diagnosis device 100 shown in FIG. 1 is applied to a plant such as a thermal power plant, and has a function of presenting, when an abnormality occurs in any of the individual devices that make up the plant, the cause of the abnormality and countermeasures that are previously associated with the cause to a user such as an operator.

[0014] The abnormality cause diagnosis device 100 is realized, for example, by a computer, and includes as its components an input device 1 (first input device), an input device 2 (second input device), a memory device 3, a processing device 4, an output device 5A, and a communication device 5B.

[0015] However, the configuration of the abnormality cause diagnosis device 100 is not limited to the example shown in Fig. 1, and can be modified as appropriate. For example, the input devices 1 and 2 may be configured to be directly connected to the storage device 3. In that case, data from the input devices 1 and 2 is transmitted directly to the storage device 3 without passing through the processing device 4. Furthermore, if communication with the outside is not required, the communication device 5B does not need to be installed.

[0016] The input device 1 continuously inputs data (operation data) transmitted to a predetermined monitoring system from each piece of equipment constituting an operating plant, and supplies the input operation data to the processing device 4 or the storage device 3. The operation data is data indicating physical quantities such as the number of rotations of the rotor and the degree of vacuum in the exhaust chamber, and may be accompanied by identification information of the corresponding equipment.

[0017] The input device 2 is a device having a function (manual input function) that enables a user to manually input information. This input device 2 may be realized in the form of a touch panel, tablet, or the like, combined with a display, for example. In this case, the display may be the output device 5A. The input device 2 inputs data (hereinafter referred to as "non-operating data") that the user manually inputs in response to questions for the user displayed on the output device 5A from the processing device 4, for example, and supplies the input non-operating data to the processing device 4. The non-operating data is information that indicates phenomena that can be perceived by the human senses, such as wear, cracks, abnormal noises, odors, damage to parts that make up the equipment, and past inspection records, and is used in particular to identify the cause of an abnormality that cannot be found from the operating data.

[0018] The storage device 3 includes a storage area for storing a program (anomaly cause diagnosis program) for the processing device 4 to execute the process of abnormality cause diagnosis, a storage area for storing various information used by the processing device 4 for processing, and a storage area for storing data supplied from the input devices 1 and 2.

[0019] The processing device 4 corresponds to a processor, and performs various types of information processing by executing the abnormality cause diagnosis program stored in the storage device 3. The abnormality cause diagnosis program may be stored and executed on a cloud server, for example. Various types of information used when executing the abnormality cause diagnosis program may also be stored on the cloud server.

[0020] The processing device 4 has the functions of storing the operating data of each device supplied from the input device 1 and the non-operating data supplied from the input device 2 in the corresponding memory area within the memory device 3, detecting abnormalities in any device from the operating data, determining the cause of the detected abnormality using other operating data and / or non-operating data in accordance with a predetermined processing flow, displaying questions to the user on the output device 5A when determining the cause of the detected abnormality, obtaining non-operating data manually input by the user in response to the questions from the input device 2, and displaying the determined cause of the abnormality and countermeasures previously associated with the cause on the output device 5A.

[0021] In addition, when the processing device 4 cannot identify the cause of the abnormality by itself, it also has a function of communicating with a remote monitoring center (RMC) 200 located outside the abnormality cause diagnosis device 100 via the communication device 5B, and obtaining the cause of the abnormality from the RMC 200.

[0022] The output device 5A corresponds to a display device (display) or a printer (printer). In this example, the output device 5A will be described as a display device.

[0023] The communication device 5B performs communication between the processing device 4 and the RMC 200.

[0024] (Functional configuration of processing device 4) The processing device 4 has an abnormality detection unit 6, an operation data input processing unit 7-1, a non-operation data input processing unit 7-2, a data determination unit 8, and a screen output processing unit 10 as various functions.

[0025] The abnormality detection unit 6 detects an abnormality occurring in any of the devices based on the operation data of each device supplied from the operation data input processing unit 7-1, and if an abnormality is detected, notifies the data judgment unit 8 of the abnormality detection.

[0026] The operation data input processing unit 7-1 takes in the operation data of each device supplied from the input device 1 into the processing device 4, and supplies the taken-in operation data to the abnormality detection unit 6 and the data judgment unit 8.

[0027] The non-driving data input processing unit 7-2 takes in the non-driving data supplied from the input device 2 into the processing device 4, and supplies the taken-in non-driving data to the data determination unit 8.

[0028] The data judgment unit 8 stores the operation data of each device supplied from the operation data input processing unit 7-1 in a corresponding memory area within the storage device 3, and stores the non-operation data supplied from the non-operation data input processing unit 7-2 in a corresponding memory area within the storage device 3.

[0029] Furthermore, when the data judgment unit 8 receives a notification of an abnormality detection from the abnormality detection unit 6, it performs a series of processes according to a predetermined processing flow to identify the cause of the abnormality and identify countermeasures that are pre-associated with the cause of the identified abnormality. A specific example of the processing flow will be described in detail later.

[0030] Furthermore, the data determination unit 8 supplies the information on the processing flow to the screen output processing unit 10 to be used as part of the information to be displayed on the output device 5A.

[0031] Furthermore, the data determination unit 8 identifies a countermeasure that is previously associated with the cause of the identified abnormality, using information stored as a database in the storage device 3. Specifically, the database stores information including, for example, the cause of the abnormality and the corresponding countermeasure (hereinafter, this information will be collectively referred to as abnormality diagnosis result information), selects a countermeasure that corresponds to the cause of the abnormality transmitted from the data determination unit 8, and supplies the cause of the abnormality and the selected countermeasure as abnormality diagnosis result information to the screen output processing unit 10 for display on the screen.

[0032] The screen output processing unit 10 has the function of forming a diagnostic screen (a screen including questions for the user) described later and displaying the screen on the output device 5A, and forming a diagnostic result screen (a screen showing the cause of the abnormality and countermeasures therefor) described later and displaying the screen on the output device 5A.

[0033] (Specific examples) Next, as a specific example of an abnormality, a case where a misfit occurs in a turning device, which is one of the individual devices that make up a thermal power plant, will be described.

[0034] In thermal power plants, when starting or stopping a turbine, it is necessary to gradually heat up or remove heat by rotating the rotor at a low speed, taking into account the effects of thermal deformation. This rotation is called turning, and it is common to use a turning device to operate the turbine at a low speed.

[0035] FIG. 2 shows an example of the configuration of a turning device.

[0036] The turning motor 15 shown in Fig. 2 is an electric motor that uses an AC motor as its drive device. A gear 16 connected to the shaft of the turning motor 15 is connected via a reduction gear 17 to a spacer gear 18 on the rotor side by a clutch 19, and the device is configured to transmit the torque of the turning motor 15 to the rotating shafts of a turbine 20 and a generator 21, causing the rotor to rotate. A rotation speed detector 22 is installed on the turbine 20, which can detect the rotor's rotation speed or whether or not it is rotating. A control device 23 controls the start / stop of the turning motor 15 and the engagement / disengagement of the clutch 19 based on the detection signal from the rotation speed detector 22.

[0037] In this configuration, for example, the control device 23 starts the turning motor 15 and then immediately stops it, and while the rotation speed of the turning motor 15 is decreasing, it operates the clutch 19 to engage the reduction gear 17 with the spacer gear 18 to perform turning operation. At this time, an event called misfit may occur, in which the reduction gear 17 of the turning device does not mesh with the spacer gear 18 of the rotor and becomes disengaged.

[0038] When shutting down from normal operation, turning operation using the turning device must be performed to prevent deformation of the turbine, so once a misfit occurs, heat cannot be removed uniformly from inside the turbine 20, which could result in equipment damage due to thermal deformation. Furthermore, unplanned investigations of the cause, consideration of countermeasures, and adjustment work required for recovery may require significant costs and time.

[0039] There are various possible causes of mis-fitting. Figure 3 shows examples of various causes of mis-fitting.

[0040] Poor fitting events (types of abnormalities) include the following:

[0041] - Malfunction of the turning device itself Possible causes of this abnormality include gear damage, motor malfunction, chain damage, etc.

[0042] The rotation speed of the rotor exceeds the rotation speed of the reduction gear 17, causing the reduction gear 17 to be kicked and separated. The cause of this abnormality may be a high degree of vacuum in the exhaust chamber (a state in which the degree of vacuum is higher than a predetermined value).

[0043] - Logic failure Possible causes of this abnormality include changes in turning logic.

[0044] The various events described above can be classified into cases where the cause of the abnormality can be identified from the operation data transmitted to the monitoring system (such as the current value of the turning motor 15 and the degree of vacuum in the exhaust chamber), as shown by the circles in Figure 3, and cases where the cause of the abnormality can be identified from non-operation data that is not transmitted to the monitoring system (such as information indicating phenomena that can be perceived by the human senses, such as visual inspection of the condition of gear damage, the condition of a broken chain, or confirmation of the history of changes to the turning logic).

[0045] However, in the various events described above, as shown by the crosses in Figure 3, the cause of some abnormalities cannot be identified from the operating data transmitted to the monitoring system, and the cause of some abnormalities cannot be identified from the non-operating data that is not transmitted to the monitoring system.

[0046] For these reasons, in order to identify the cause of misalignment of the turning device, it is preferable to investigate the cause of the misalignment by combining two types of data: driving data that is transmitted to the monitoring system and non-driving data that is not transmitted to the monitoring system.

[0047] (Example of a flowchart) Next, an example of the operation of the processing device 4 in FIG. 1 will be described with reference to FIGS. 4A and 4B.

[0048] Here, an example of a flowchart that is applied to the operation when a misfit occurs in the turning device shown in the above example will be given.

[0049] The individual steps shown in the flowcharts of FIGS. 4A(a) and 4B(a) can be classified by type of processing as shown in the tables of FIGS. 4A(b) and 4B(b), respectively.

[0050] That is, the individual steps shown in the flowcharts of FIGS. 4A(a) and 4B(a) are classified into the following four types.

[0051] 1. "Anomaly detection processing" Step S1 in FIG. 4A corresponds to the abnormality detection process.

[0052] The "abnormality detection process" is a process in which the abnormality detection unit 6 detects an abnormality occurring in any of the devices based on the operation data of each device supplied from the operation data input processing unit 7-1.

[0053] 2. "Decision-making process based on driving data" (first decision-making process) Steps S2, S3, and S14 in FIG. 4A and step S21 in FIG. 4B correspond to the "determination process based on driving data."

[0054] The "determination process based on driving data" is a process (first determination process) in which the data determination unit 8 determines whether the "driving data" satisfies predetermined conditions in order to identify the cause of the abnormality detected by the abnormality detection unit 6.

[0055] If the cause of the abnormality can be identified from the results of the first determination process, the "display of a diagnosis result screen showing identification of the cause of the abnormality and countermeasures" (for example, the processing of steps S4, S15-S16 in FIG. 4A, or steps S22, S23-S24 in FIG. 4B) described below will be performed. On the other hand, if the cause of the abnormality cannot be identified from the results of the first determination process, the "display of a diagnosis screen including questions for the user" and the "determination process based on non-driving data" (for example, the processing of steps S5-S6, S9-S10 shown in bold frames in FIG. 4A, or steps S17-S18 shown in bold frames in FIG. 4B) described below will be performed.

[0056] 3. "Displaying a diagnostic screen including questions for the user" and "Decision-making process based on non-driving data" (second decision-making process) Steps S5-S6 and S9-S10 shown in bold frames in Fig. 4A and steps S17-S18 shown in bold frames in Fig. 4B correspond to "displaying a diagnostic screen including questions for the user" and "determination processing based on non-driving data." Specifically, steps S5, S9, and S17 correspond to "displaying a diagnostic screen including questions for the user," and steps S6, S10, and S18 correspond to "determination processing based on non-driving data."

[0057] "Displaying a diagnostic screen including questions for the user" is a process in which the screen output processing unit 10 displays a diagnostic screen including questions for the user on the output device 5A when the cause of the abnormality cannot be identified from the results of the first determination process. The diagnostic screen at this time is displayed in the form shown in Fig. 5. Details of the diagnostic screen in Fig. 5 will be described later.

[0058] The "judgment process based on non-driving data" is a process (second judgment process) in which the data judgment unit 8 judges whether the non-driving data input by the user through the input device 2 in response to the above question (i.e., the non-driving data supplied from the non-driving data input processing unit 7-2) satisfies predetermined conditions.

[0059] If the cause of the abnormality can be identified from the results of the second determination process, a "diagnosis result screen showing the identification of the cause of the abnormality and countermeasures" (for example, the processing of steps S7-S8, S12-S13 in FIG. 4A, or S19-S20 in FIG. 4B) will be displayed, as described below. On the other hand, if the cause of the abnormality cannot be identified from the results of the second determination process, a predetermined display (for example, the processing of step S11 in FIG. 4A) will be displayed, as described below, or a first determination process (for example, the determination processing of step S21 in FIG. 4B) will be performed using different operating data to subsequently identify the cause of the abnormality.

[0060] 4. "Displaying the diagnostic results screen showing the cause of the abnormality and the countermeasures" Steps S4, S11, S12-S13, and S15-S16 in FIG. 4A and steps S19-S20, S22, and S23-S24 in FIG. 4B correspond to "displaying a diagnosis result screen showing identification of the cause of the abnormality and countermeasures." However, since the cause of the abnormality could not be identified in step S11, a "diagnosis result screen showing countermeasures" is displayed without showing the cause of the abnormality. The diagnosis result screen in this case is displayed in the format shown in FIG. 6. Details of the diagnosis result screen in FIG. 6 will be described later.

[0061] The "display of a diagnosis result screen showing identification of the cause of the abnormality and countermeasures" performed in steps S4, S15-S16, S22, and S23-S24 is a process performed when the cause of the abnormality can be identified from the results of the first determination process.

[0062] The "display of a diagnosis result screen showing identification of the cause of the abnormality and countermeasures" performed in steps S7-S8, S12-S13, and S19-S20 is a process that is performed when the cause of the abnormality can be identified from the results of the second determination process.

[0063] The "display of a diagnosis result screen showing countermeasures" performed in step S11 is a process performed when the cause of the abnormality cannot be identified from the results of either the first or second determination process.

[0064] During plant operation, operation data transmitted from each piece of equipment (including the turning device described above) to a predetermined monitoring system is also transmitted to the abnormality cause diagnosis device 100, sent to the processing device 4 via the input device 1, and stored in the storage device 3. Within the processing device 4, the operation data input from the input device 1 is transmitted to the abnormality detection unit 6 via the operation data input processing unit 7-1.

[0065] For example, when starting up a turbine after a periodic inspection or shutdown of a thermal power plant, an abnormal situation occurs during turning-in using a turning device, whereby the reduction gear 17 cannot be engaged with the spacer gear 18. At this time, the operating data reflecting this abnormality is transmitted to the abnormality detection unit 6.

[0066] In step S1 in FIG. 4A, the abnormality detection unit 6 detects the abnormality.

[0067] Thereafter, the data determining unit 8 performs the determination process for the abnormality, and the screen output processing unit 10 performs the display process for the diagnosis screen of FIG. 5 and the diagnosis result screen of FIG.

[0068] In step S2, it is determined whether or not the rotor is in a zero speed state (i.e., a state in which the rotor is barely rotating) based on the corresponding operating data (e.g., operating data from a rotation speed detector). If this is the case (Yes), the process proceeds to step S3. On the other hand, if this is not the case (No), the process proceeds to step S14.

[0069] In step S3, it is determined whether the motor of the turning device is operating normally based on the corresponding operating data.

[0070] In step S4, the diagnosis result screen of FIG. 6, which includes messages indicating the cause of the abnormality and countermeasures, such as "The motor of the turning device is not operating normally" and "Please check if the motor is operating," is displayed on the output device 5A.

[0071] In step S5, the diagnostic screen of Fig. 5 including questions for the user is displayed on the output device 5A. Here, a diagnostic screen including a message requesting confirmation of whether or not there is an abnormality in the air pressure supplied to the air cylinder, as well as a message prompting the user to manually enter a response as to whether or not there is an abnormality, is displayed on the output device 5A. Specifically, the content shown in Fig. 7B is displayed. Fig. 7B will be explained later.

[0072] In step S6, it is determined whether or not there is an abnormality in the air pressure supplied to the air cylinder based on data (non-operating data) manually input by the user through the input device 2. If there is an abnormality (Yes), the process proceeds to step S9. On the other hand, if there is no abnormality (No), the process proceeds to step S7.

[0073] In steps S7 and S8, the diagnostic result screen shown in Figure 6 is displayed on the output device 5A, which includes a message indicating the cause of the abnormality, such as "The air cylinder is not operating normally because the air pressure supplied to the air cylinder is insufficient," as well as a message suggesting a countermeasure, such as "Adjust the air pressure supplied to the air cylinder to a normal value."

[0074] In step S9, the diagnostic screen of Fig. 5 including a question to the user is displayed on the output device 5A. Here, a diagnostic screen including a message requesting confirmation of whether or not there is damage to the turning gear chain and a message prompting the user to manually input whether or not there is damage is displayed on the output device 5A. Specifically, the screen is displayed as shown in Fig. 7A. Fig. 7A will be explained later.

[0075] In step S10, it is determined whether or not there is damage (such as breakage) in the turning gear chain based on data (non-driving data) manually input by the user through the input device 2. If there is damage (such as breakage) in the turning gear chain (if Yes), the process proceeds to step S12. On the other hand, if there is no damage (such as breakage) in the turning gear chain (if No), the process proceeds to step S11.

[0076] In step S11, the diagnosis result screen of FIG. 6, which includes messages suggesting countermeasures such as "Detailed investigation will be required to identify the cause of the abnormality" and "Please contact the equipment manufacturer," is displayed on the output device 5A.

[0077] In steps S12 and S13, the output device 5A displays the diagnosis result screen shown in FIG. 6, which includes a message indicating the cause of the abnormality, such as "The turning gear cannot be fitted due to damage caused by aging of the chain," as well as a message suggesting a countermeasure, such as "The chain needs to be replaced." Specifically, the screen displays the content shown in FIG. 8. FIG. 8 will be described later.

[0078] In step S14, it is determined based on the corresponding operating data whether the turning gear cannot be engaged when the rotor is rotating at a rotation speed equal to or greater than a certain value during turning-in. If this is the case (Yes), the process proceeds to step S17 in FIG. 4B. On the other hand, if this is not the case (No), the process proceeds to step S15.

[0079] In steps S15 and S16, the diagnosis result screen of FIG. 6 is displayed on the output device 5A, which includes a message indicating the cause of the abnormality, such as "There is an abnormality in the rotation speed detector," as well as a message indicating a countermeasure, such as "Please investigate the rotation speed detector."

[0080] In step S17 of Fig. 4B, the diagnostic screen of Fig. 5 including a question to the user is displayed on the output device 5A. Here, the diagnostic screen of Fig. 5 including a message requesting the user to check the history to see if the turning device start-up logic or timer has been modified in the past, and a message prompting the user to manually enter a response as to whether or not this has happened, is displayed on the output device 5A.

[0081] In step S18, it is determined whether the turning device activation logic has been modified or the timer changed in the past based on data (non-operation data) manually input by the user through the input device 2. If this is the case (Yes), the process proceeds to step S19. On the other hand, if this is not the case (No), the process proceeds to step S21.

[0082] In steps S19 and S20, the diagnosis result screen shown in FIG. 6 is displayed on the output device 5A, which includes a message indicating the cause of the abnormality, such as "The turning timer is set too early, so the gear cannot be engaged when the rotor rotation speed is high," as well as a message suggesting a countermeasure, such as "Try turning in again when the rotor rotation speed is sufficiently low."

[0083] In step S21, it is determined whether or not there is a change in the degree of vacuum in the low-pressure exhaust chamber (whether or not there is a change of a threshold or more compared to the normal value) based on the corresponding operating data. If there is a change (Yes), the process proceeds to step S23. On the other hand, if there is no change (No), the process proceeds to step S22.

[0084] In step S22, the diagnosis result screen of FIG. 6 including messages indicating the cause of the abnormality and countermeasures such as "The radial gap of the gland part may have widened" and "Please adjust the radial gap of the gland part" is displayed on the output device 5A.

[0085] In steps S23 and S24, the diagnostic result screen shown in Figure 6 is displayed on the output device 5A, which includes a message indicating the cause of the abnormality, such as "An increase in the vacuum level may cause steam to flow in, generating rotor rotational force," as well as a message suggesting a countermeasure, such as "Adjust the vacuum level to a normal value."

[0086] In this way, by investigating the cause of the mismatch by combining two types of data - operating data transmitted to the monitoring system and non-operating data that is not transmitted to the monitoring system (for example, information indicating phenomena that can be perceived by the human senses, such as visual inspection of gear damage, chain breakage, and confirmation of turning logic change history), it becomes possible to correctly identify the cause of the abnormality and present appropriate countermeasures to the user.

[0087] In this way, for example, it is possible to identify the cause of an abnormality that cannot be identified using only the operating data (for example, damage to a certain part due to aging, etc.) and present appropriate countermeasures, and it is also possible to identify the cause of an abnormality that cannot be identified using only the non-operating data (for example, the timer setting time is too short, etc.) and present appropriate countermeasures.

[0088] Furthermore, by displaying the entire process from the occurrence of an abnormality to identifying its cause in flowchart format on the screen (for example, by displaying the main parts of the flowcharts shown in Figures 4A and 4B and highlighting the relevant processing steps), and by displaying videos, related materials, information on replacement parts, etc. on the screen that explain the cause of the abnormality, its mechanism, and recovery response measures, it is possible to make it easier for users to understand the cause of the abnormality and the measures to be taken.In addition, it is possible to quickly recover from problems with individual equipment in the plant and to pass on know-how on how to respond to problems.

[0089] (Diagnosis screen 11-a and diagnosis result screen 11-b) Fig. 5 is a diagram showing an example of a diagnosis screen, and Fig. 6 is a diagram showing an example of a diagnosis result screen.

[0090] The diagnosis screen 11-a shown in FIG. 5 includes a guidance display section 12-a (first display section), a question display section 13-a (second display section), and a manual input section 14-a (third display section).

[0091] The guidance display section 12-a is a section that displays a photograph, image, or video of the equipment in which an abnormality has been detected. The guidance display section 12-a displays the areas of the equipment that should be investigated and the areas in the regular inspection records that should be checked. The question display section 13-a is a section that displays questions for the user. The manual input section 14-a is a section that allows the user to manually input answers to questions. The user can investigate the specified areas based on the information in the guidance display section 12-a and the question display section 13-a, and input the results of the investigation into the manual input section 14-a.

[0092] The diagnosis result screen 11-b shown in FIG. 6 includes a guidance display section 12-b (fourth display section), an abnormal mechanism display section 13-b (fifth display section), and a countermeasure display section 14-b (sixth display section).

[0093] The guidance display section 12-b displays a photograph, image, or video to explain the cause of the abnormality and countermeasures for the equipment in which the abnormality has been detected. The abnormality mechanism display section 13-b displays an explanation of the cause of the abnormality and its mechanism. The countermeasure display section 14-b displays an explanation of the countermeasures for the abnormality.

[0094] The guidance display unit 12-b may use videos and images to explain to the user the mechanism of the specific cause of the abnormality, countermeasures against the abnormality, and recovery methods by displaying videos, work instructions, etc. The guidance display unit 12-b may also display reports, reference books, etc. on similar abnormality cases that have occurred in the past.

[0095] For example, when it becomes necessary to ask a question to the user, the screen output processing unit 10 shown in FIG. 1 forms a diagnostic screen 11-a including the question and displays the screen on the output device 5A. The screen output processing unit 10 also displays a diagnostic result screen 11-b on the output device 5A, using the abnormality diagnosis result information and processing flow information supplied from the data evaluation unit 8. In this case, the screen output processing unit 10 may also display, on the diagnostic result screen 11-b, a schematic representation of the processing flow on the guidance display unit 12-b, as well as information indicating which processing step in the processing flow was used to identify the cause of the abnormality (i.e., information showing, in a flowchart format, the processing process from the start of the diagnosis to the acquisition of the diagnostic result). In this way, the user can visually confirm the causal relationships through which the cause of the abnormality was identified.

[0096] (Example of diagnostic screen 11-a (part 1)) FIG. 7A is a diagram showing a specific example (part 1) of the diagnostic screen 11-a of FIG. 5 that is displayed when a misfit abnormality in the turning device is detected, and corresponds to steps S9 and S10 of the flowchart of FIG. 4A.

[0097] FIG. 7A shows an example of a screen for asking the user whether or not the cause of the abnormality is chain damage when an abnormality due to misfit of the turning device is detected.

[0098] The guidance display unit 12-a displays a photograph, image, or video of a turning device in which a misfit abnormality has been detected. The display shows the location of the chain that needs to be inspected. The question display unit 13-a displays questions for the user, such as messages like "Please inspect the chain for damage" or "Please check the guidance screen for inspection methods." The manual input unit 14-a displays multiple options as possible answers to the questions, allowing the user to easily answer the questions. For example, multiple options such as "1. Damaged chain" and "2. No damage to chain" are displayed. The user can inspect the chain based on the information in the guidance display unit 12-a and the question display unit 13-a, and can easily manually input an answer based on the results of the inspection into the manual input unit 14-a.

[0099] (Example of diagnostic screen 11-a (part 2)) FIG. 7B is a diagram showing a specific example (part 2) of another diagnostic screen 11-a different from the example of FIG. 7A, and corresponds to steps S5 and S6 of the flowchart of FIG. 4A.

[0100] FIG. 7B shows an example of a screen for querying the user about the air cylinder supply pressure value displayed on the field instrument.

[0101] The guidance display unit 12-a displays a photo, image, or video of the air cylinder in which an abnormality has been detected. The display shows the areas that need to be investigated. The question display unit 13-a displays questions for the user, such as messages like "Please check the guidance screen" or "Please enter the air cylinder supply pressure." The manual input unit 14-a displays an area where a numerical value can be entered as an answer to the question, so that the user can easily answer the question. Based on the information in the guidance display unit 12-a and the question display unit 13-a, the user can check the value of the air cylinder supply pressure displayed on the field instrument and easily manually input that value into the manual input unit 14-a.

[0102] (Example of diagnosis result screen 11-b) FIG. 8 is a diagram showing a specific example of the diagnosis result screen 11-b of FIG. 6, which is displayed as a diagnosis result when an abnormality such as a misfit of the turning device is detected, and corresponds to steps S12 and S13 of the flowchart of FIG. 4A.

[0103] Figure 8 shows an example of the screen when the cause of the misalignment of the turning device is chain damage.

[0104] The guidance display unit 12-b displays photos, images, or videos explaining the cause of the misalignment of the turning device and countermeasures. The display clearly shows the location of the chain where damage is suspected. The abnormal mechanism display unit 13-b displays an explanation of the cause and mechanism of the abnormality, such as "The turning gear cannot be engaged due to damage caused by aging of the chain." The countermeasure display unit 14-b displays an explanation of the countermeasures to the abnormality, such as "The chain needs to be replaced" or "Please check the guidance screen for replacement procedures." At this time, the guidance display unit 12-b may also display guidance on related documentation, chain replacement procedures, and how to order replacement parts.

[0105] In addition, the guidance display unit 12-b may display a schematic representation of the processing flow, as well as information indicating which processing step in the processing flow led to chain damage (i.e., information showing in flowchart form the processing process from the start of diagnosis to obtaining the diagnostic results).

[0106] (Example using RMC200) For example, when an equipment abnormality occurs that has never been experienced before, an unexpected equipment abnormality, or an equipment abnormality occurs due to multiple causes, the cause of the abnormality may not be identified by the above-described abnormality cause diagnosis device 100 alone. In such cases, the cause of the abnormality may be identified through communication with the above-described RMC 200.

[0107] The RMC200 is the equipment manufacturer's service engineering center, where the equipment manufacturer's service engineers are stationed. By communicating with the RMC200 from the anomaly cause diagnosis device 100, users can inquire about the cause of an equipment anomaly and countermeasures in real time and take necessary measures. At this time, the equipment manufacturer's service engineer at the RMC200 may be able to check the information entered into the anomaly cause diagnosis device 100 and the anomaly diagnosis flowchart in real time via a cloud server. Based on this information, the service engineer identifies the cause of the anomaly and can quickly present the user with additional investigations into the cause of the anomaly and recovery measures. This allows even users with little equipment knowledge to easily understand the cause of the anomaly, its mechanism, and countermeasures.

[0108] (summary) As described above in detail, according to the embodiment, for example, it is possible to identify the cause of an abnormality that cannot be identified using only the operating data (for example, damage due to deterioration of a certain part over time) and present appropriate countermeasures, and it is also possible to identify the cause of an abnormality that cannot be identified using only the non-operating data (for example, the timer setting time is too short) and present appropriate countermeasures.

[0109] Furthermore, by displaying the entire process from the occurrence of an abnormality to identifying its cause in flowchart format on the screen (for example, by displaying the main parts of the flowchart and highlighting the relevant processing steps), and by displaying videos, related materials, information on replacement parts, etc. on the screen that explain the cause of the abnormality, its mechanism, and recovery response measures, it is possible to make it easier for users to understand the cause of the abnormality and countermeasures.In addition, it is possible to quickly recover from problems with individual equipment in the plant and pass on know-how on to those who have experienced problems.

[0110] Although several embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, and are also included in the scope of the invention and its equivalents as defined in the claims. [Explanation of symbols]

[0111] 1...input device (first input device), 2...input device (second input device), 3...storage device, 4...processing device, 5A...output device, 5B...communication device, 6...abnormality detection unit, 7-1...operation data input processing unit, 7-2...non-operation data input processing unit, 8...data judgment unit, 10...screen output processing unit, 11-a...diagnosis screen, 12-a...guidance display unit (first display unit), 13-a...question display unit (second display unit), 14-a...manual input unit ( (third display unit), 11-b...diagnosis result screen, 12-b...guidance display unit (fourth display unit), 13-b...abnormal mechanism display unit (fifth display unit), 14-b...countermeasure display unit (sixth display unit), 15...turning motor, 16...gear, 17...reduction gear, 18...spacer gear, 19...clutch, 20...turbine, 21...generator, 22...rotation speed detector, 23...control device, 100...abnormality cause diagnosis device, 200...RMC.

Claims

1. a first input device for inputting operation data transmitted from individual devices constituting the plant during operation; a second input device for inputting non-driving data manually input in response to a question to a user; a processing device that identifies a cause of an abnormality occurring in the device and a countermeasure that is previously associated with the cause of the abnormality, based on the operating data and the non-operating data, in accordance with a predetermined processing flow; an output device that displays the cause of the abnormality in the device identified by the processing device and a countermeasure; Equipped with The processing device includes: performing a first determination process for determining whether the driving data satisfies a predetermined condition; If the cause of the abnormality can be identified from the result of the first determination process, information indicating the cause of the abnormality and a countermeasure previously associated with the cause of the abnormality is displayed on the output device; If the cause of the abnormality cannot be identified from the result of the first determination process, a question is displayed on the output device to the user, and a second determination process is performed to determine whether the non-driving data input through the second input device in response to the question satisfies a predetermined condition; If the cause of the abnormality can be identified from the result of the second determination process, information indicating the cause of the abnormality and a countermeasure previously associated with the cause of the abnormality is displayed on the output device; If the cause of the abnormality cannot be identified from the result of the second determination process, a predetermined display is displayed, or the first determination process is performed using other operating data; displaying on the output device a diagnostic screen including a first display section including a photograph, image, or video of the device in which the abnormality has been detected, a second display section including the question, and a third display section in which the user can manually input an answer to the question; Abnormality cause diagnosis device.

2. The processing device includes: displaying a plurality of options as answer candidates to the question on the third display unit; The abnormality cause diagnosis device according to claim 1 .

3. The processing device includes: displaying on the third display unit an area in which a numerical value can be input as an answer to the question; The abnormality cause diagnosis device according to claim 1 .

4. a first input device for inputting operation data transmitted from individual devices constituting the plant during operation; a second input device for inputting non-driving data manually input in response to a question to a user; a processing device that identifies a cause of an abnormality occurring in the device and a countermeasure that is previously associated with the cause of the abnormality, based on the operating data and the non-operating data, in accordance with a predetermined processing flow; an output device that displays the cause of the abnormality in the device identified by the processing device and a countermeasure; Equipped with The processing device includes: performing a first determination process for determining whether the driving data satisfies a predetermined condition; If the cause of the abnormality can be identified from the result of the first determination process, information indicating the cause of the abnormality and a countermeasure previously associated with the cause of the abnormality is displayed on the output device; If the cause of the abnormality cannot be identified from the result of the first determination process, a question is displayed on the output device to the user, and a second determination process is performed to determine whether the non-driving data input through the second input device in response to the question satisfies a predetermined condition; If the cause of the abnormality can be identified from the result of the second determination process, information indicating the cause of the abnormality and a countermeasure previously associated with the cause of the abnormality is displayed on the output device; If the cause of the abnormality cannot be identified from the result of the second determination process, a predetermined display is displayed, or the first determination process is performed using other operating data; displaying on the output device a diagnosis result screen including a fourth display section including a photograph, image, or video of the device in which the abnormality has been detected, a fifth display section including an explanation of the cause of the abnormality and its mechanism, and a sixth display section including an explanation of measures to be taken against the abnormality; Abnormality cause diagnosis device.

5. The processing device includes: On the diagnosis result screen, the predetermined processing flow is displayed in a schematic manner, and information indicating through which processing step in the predetermined processing flow the cause of the abnormality was identified is displayed. The abnormality cause diagnosis device according to claim 4.

6. a first input device for inputting operation data transmitted from individual devices constituting the plant during operation; a second input device for inputting non-driving data manually input in response to a question to a user; a processing device that identifies a cause of an abnormality occurring in the device and a countermeasure that is previously associated with the cause of the abnormality, based on the operating data and the non-operating data, in accordance with a predetermined processing flow; an output device that displays the cause of the abnormality in the device identified by the processing device and a countermeasure; Equipped with The processing device includes: performing a first determination process for determining whether the driving data satisfies a predetermined condition; If the cause of the abnormality can be identified from the result of the first determination process, information indicating the cause of the abnormality and a countermeasure previously associated with the cause of the abnormality is displayed on the output device; If the cause of the abnormality cannot be identified from the result of the first determination process, a question is displayed on the output device to the user, and a second determination process is performed to determine whether the non-driving data input through the second input device in response to the question satisfies a predetermined condition; If the cause of the abnormality can be identified from the result of the second determination process, information indicating the cause of the abnormality and a countermeasure previously associated with the cause of the abnormality is displayed on the output device; If the cause of the abnormality cannot be identified from the result of the second determination process, a predetermined display is displayed, or the first determination process is performed using other operating data; If the cause of the abnormality cannot be determined by the predetermined processing flow, the cause of the abnormality is determined from a remote monitoring center located outside the abnormality cause diagnosis device by communicating with the remote monitoring center via a communication device. Abnormality cause diagnosis device.

7. inputting operation data transmitted from individual devices constituting the plant during operation by a first input device; inputting non-driving data manually input in response to a question to a user by a second input device; Identifying, by a processing device, a cause of an abnormality occurring in the device and a countermeasure that is previously associated with the cause of the abnormality, based on the operating data and the non-operating data, in accordance with a predetermined processing flow; an output device displays the cause of the abnormality of the device identified by the processing device and a countermeasure; Including, The processing by the processing device is performing a first determination process for determining whether the driving data satisfies a predetermined condition; When a cause of the abnormality can be identified from a result of the first determination process, displaying information indicating the cause of the abnormality and a countermeasure previously associated with the cause of the abnormality on the output device; If the cause of the abnormality cannot be identified from the result of the first determination process, a question is displayed on the output device to a user, and a second determination process is performed to determine whether the non-driving data input through the second input device in response to the question satisfies a predetermined condition. When a cause of the abnormality can be identified from a result of the second determination process, displaying information indicating the cause of the abnormality and a countermeasure previously associated with the cause of the abnormality on the output device; If the cause of the abnormality cannot be identified from the result of the second determination process, a predetermined display is displayed, or the first determination process is performed using other operating data. displaying on the output device a diagnostic screen including a first display section including a photograph, image, or video of the device in which the abnormality has been detected, a second display section including the question, and a third display section in which the user can manually input an answer to the question; Including, Methods for diagnosing the cause of abnormalities.

8. inputting operation data transmitted from individual devices constituting the plant during operation by a first input device; inputting non-driving data manually input in response to a question to a user by a second input device; Identifying, by a processing device, a cause of an abnormality occurring in the device and a countermeasure that is previously associated with the cause of the abnormality, based on the operating data and the non-operating data, in accordance with a predetermined processing flow; an output device displays the cause of the abnormality of the device identified by the processing device and a countermeasure; Including, The processing by the processing device is performing a first determination process for determining whether the driving data satisfies a predetermined condition; When a cause of the abnormality can be identified from a result of the first determination process, displaying information indicating the cause of the abnormality and a countermeasure previously associated with the cause of the abnormality on the output device; If the cause of the abnormality cannot be identified from the result of the first determination process, a question is displayed on the output device to a user, and a second determination process is performed to determine whether the non-driving data input through the second input device in response to the question satisfies a predetermined condition. When a cause of the abnormality can be identified from a result of the second determination process, displaying information indicating the cause of the abnormality and a countermeasure previously associated with the cause of the abnormality on the output device; If the cause of the abnormality cannot be identified from the result of the second determination process, a predetermined display is displayed, or the first determination process is performed using other operating data. displaying on the output device a diagnosis result screen including a fourth display section including a photograph, image, or video of the device in which the abnormality has been detected, a fifth display section including an explanation of the cause of the abnormality and its mechanism, and a sixth display section including an explanation of measures to address the abnormality; Including, Methods for diagnosing the cause of abnormalities.

9. inputting operation data transmitted from individual devices constituting the plant during operation by a first input device; inputting non-driving data manually input in response to a question to a user by a second input device; Identifying, by a processing device, a cause of an abnormality occurring in the device and a countermeasure that is previously associated with the cause of the abnormality, based on the operating data and the non-operating data, in accordance with a predetermined processing flow; an output device displays the cause of the abnormality of the device identified by the processing device and a countermeasure; Including, The processing by the processing device is performing a first determination process for determining whether the driving data satisfies a predetermined condition; When a cause of the abnormality can be identified from a result of the first determination process, displaying information indicating the cause of the abnormality and a countermeasure previously associated with the cause of the abnormality on the output device; If the cause of the abnormality cannot be identified from the result of the first determination process, a question is displayed on the output device to a user, and a second determination process is performed to determine whether the non-driving data input through the second input device in response to the question satisfies a predetermined condition. When a cause of the abnormality can be identified from a result of the second determination process, displaying information indicating the cause of the abnormality and a countermeasure previously associated with the cause of the abnormality on the output device; If the cause of the abnormality cannot be identified from the result of the second determination process, a predetermined display is displayed, or the first determination process is performed using other operating data. If the cause of the abnormality cannot be determined by the predetermined processing flow, the cause of the abnormality is determined from a remote monitoring center located outside the abnormality cause diagnosis device by communicating with the remote monitoring center through a communication device; Including, Methods for diagnosing the cause of abnormalities.

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