JP2004170225A - Life cycle maintenance schedule planning system for plant - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To grasp long term tendencies of deterioration with the lapse of time and performance lowering in a plant, a system and equipments, and to plan a maintenance schedule over a plant life to exhibit it to an electric power company via the Internet. <P>SOLUTION: A control means 26 analyzes an operation history data and a maintenance history data of the plant received by a reception means 25 to manage hierarchically operation history information obtained therein as a chart according to functional structure ranging over the plant, the system and the equipments. A condition grasping means 27 grasps the long term tendencies of the deterioration with the lapse of time and the performance lowering in the plant, the system and the equipments, based on the chart managed by the control means 26. A maintenance schedule planning means 28 plans the maintenance schedule over the plant life to exhibit it to the electric power company via the Internet by an exhibition means 29. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a plant life cycle maintenance plan formulation system that formulates a maintenance plan over the life of a plant based on long-term trends of aging and performance degradation of plants and system equipment.
[0002]
[Prior art]
The maintenance system provides a maintenance service to a power company having a large-scale plant such as a nuclear power plant, for example, by a maintenance department or a maintenance company of a plant manufacturer. That is, plant information from the power company is transmitted to the maintenance service center, which is a plant maker, via the Internet, and the maintenance service center provides plant maintenance data based on the information from the power company.
[0003]
The power company has a system for monitoring the operation of the plant and a system for collecting and managing maintenance data such as periodic inspections of the plant and troubleshooting, and the maintenance service center operates the maintenance and operation field from these systems. Data is captured via the Internet and stored in a maintenance database. Then, based on these field data, monitoring diagnosis based on physical rules corresponding to the monitoring diagnosis target is performed, and consultation for early detection of abnormality and support for troubleshooting is performed.
[0004]
Similarly, the device analyzes the aging status of the device based on the field data, predicts the progress of the degradation, determines the inspection time, and provides an appropriate short-term to long-term maintenance plan. In addition, it provides past cases and design information, analyzes and provides design code usage right provision services in response to user requests. In this case, in order to keep the data being transmitted and received, the analysis result, and the customer information confidential, security is ensured by encrypting the data.
[0005]
In this way, diagnosis / inspection / maintenance consultation based on field data of operation / maintenance can be performed, and if a sign of abnormality or deterioration is detected from field data analysis, a signal list required for more detailed diagnosis Can be presented. In addition, the result of the detailed diagnosis can be presented, and the inspection frequency can be determined by monitoring the operating state of the device and grasping the deterioration state.
[0006]
[Problems to be solved by the invention]
However, conventional maintenance systems can provide diagnosis, inspection, and maintenance consultations based on operation and maintenance field data.However, monitoring and diagnosis of current plant and equipment conditions, and equipment to be inspected in the next and subsequent periodic inspections are performed. The function of drafting a long-term maintenance plan throughout the life of the plant is lacking only by extraction. In addition, when an indication of abnormality or deterioration is detected from field data analysis, a signal list required for more detailed diagnosis can be presented.However, data collection conditions, collection frequency, collection timing, etc., must be provided. Cannot provide a specific data collection plan.
[0007]
In addition, although the results of the detailed diagnosis can be presented, the technical support for consulting specific measures with expert judgment is insufficient. Furthermore, it is possible to determine the frequency of inspection by grasping the deterioration state while monitoring the operation state of the equipment, but it is possible to determine the inspection frequency by comparing the integrated value of the maintenance cost of the equipment with the replacement cost, and considering the replacement time. There was a problem that it could not be planned.
[0008]
Therefore, an object of the present invention is to provide a life cycle maintenance planning system for a plant that is excellent in operability and economy.
[0009]
[Means for Solving the Problems]
A plant life cycle maintenance planning system according to the invention of claim 1 transmits information from a power company having a plant to a maintenance service center via the Internet, and the maintenance service center performs a process based on the information from the power company. A maintenance service center for receiving operation history data and maintenance history data from the plant via the Internet; and receiving the operation history data and maintenance history data received by the reception means. The operation and maintenance information obtained by analyzing the plant, system, management means for hierarchically managing the medical record according to the functional structure of the equipment, and the plant, system, equipment based on the medical record managed by the management means Grasping the state to grasp the long-term tendency of aging and performance degradation And the stage,
A maintenance plan drafting unit for drafting a maintenance plan over the life of the plant based on the long-term tendency grasped by the state grasping unit, and a recommended maintenance plan drafted by the maintenance plan planning unit are presented to the power company via the Internet. Presentation means.
[0010]
In the plant life cycle maintenance planning system according to the first aspect of the present invention, the management unit converts the operation and maintenance information obtained by analyzing the operation history data and the maintenance history data of the plant received by the receiving unit into a plant, It is managed as a medical chart hierarchically according to the functional structure of the system and equipment. The state grasping means grasps long-term trends of aging and performance degradation of plants, systems and equipment based on the medical records managed by the management means, and the maintenance plan drafting means grasps long-term trends grasped by the state grasping means. A maintenance plan over the life of the plant based on the The recommended maintenance plan drafted by the maintenance plan drafting means is presented to the power company via the Internet by the presentation means. As a result, a long-term maintenance plan can be formulated throughout the life of the plant, and a life cycle maintenance service excellent in operability and economy can be provided.
[0011]
In the plant life cycle maintenance plan planning system according to the second aspect of the present invention, in the first aspect of the invention, the maintenance plan drafting unit is configured such that when the state grasping unit detects a sign of aging or performance degradation, The data type, the collection condition, the collection time, and the collection frequency required for diagnosing the state of the target are determined, and a data collection plan is drafted.
[0012]
In the plant life cycle maintenance planning system according to the second aspect of the present invention, in addition to the operation of the first aspect of the present invention, the maintenance plan drafting unit detects a sign of aging or performance degradation by the state grasping unit. First, the type of data, collection conditions, collection timing, and collection frequency necessary for diagnosing the state of the target are determined, and a data collection plan is drafted. As a result, a specific data collection plan can be presented, and a life cycle maintenance service excellent in operability and economy can be provided.
[0013]
In the plant life cycle maintenance plan planning system according to the third aspect of the present invention, in the first aspect of the invention, the maintenance plan drafting means detects the signs of aging or performance degradation by the state grasping means and generates additional data. When collected, a deterioration state is diagnosed, and a response is consulted based on the diagnosis result.
[0014]
In the plant life cycle maintenance planning system according to the third aspect of the present invention, in addition to the operation of the first aspect of the invention, the maintenance plan planning means is added by detecting signs of aging or performance degradation by the state grasping means. When the data is collected, the deterioration state is diagnosed, and a response is consulted based on the diagnosis result. This enables a consultation on a specific response with expert judgment.
[0015]
According to a fourth aspect of the present invention, in the plant life cycle maintenance planning system according to the first aspect of the present invention, the maintenance plan planning unit determines a future life cycle maintenance or performance degradation based on a long-term trend analysis by the state grasping unit. Is characterized by estimating the state of the equipment and evaluating the cost versus the risk to determine the time to replace the equipment.
[0016]
In the plant life cycle maintenance planning system according to the fourth aspect of the present invention, in addition to the operation of the first aspect, the maintenance plan planning means is based on a long-term trend analysis of aging and performance degradation by the state grasping means. , Predict future conditions, evaluate cost versus risk and determine when to replace equipment. This makes it possible to compare the integrated value of the equipment maintenance cost and the replacement cost, and to formulate a maintenance plan that takes into account the replacement time.
[0017]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described. FIG. 1 is a block diagram of a maintenance service center of a plant life cycle maintenance planning system according to an embodiment of the present invention. FIG. 2 is a block diagram of a plant life cycle maintenance planning system according to an embodiment of the present invention. It is a whole block diagram of a maintenance service center.
[0018]
In FIG. 2, a power company 11 has a plant 12 such as a nuclear power plant or a thermal power plant, a process computer 13 for monitoring the operation performance of the plant, and a plant / monitor for monitoring abnormality of the plant or equipment. An equipment monitoring system 14 is installed and monitors the operating state of the plant 12 in real time. Since the process computer 13 and the plant / equipment monitoring system 14 are on an operation control network, they have a configuration independent of a general intra network in order to ensure security.
[0019]
A data server 15 is provided between the operation control network and the intra network, and accumulates process data (operation history data) in the data server 15 online while ensuring security. Thus, the engineer of the plant 12 can easily use the operation history data.
[0020]
In addition to the business PC 16, a mobile terminal 17 such as a PHS or a mobile phone used at the site, a wearable PC 18, a portable monitoring device 19, and the like can be connected to the intra network. As a result, site data (maintenance history data) such as site inspection / inspection data, operation log data, and patrol log data is input and stored in the data server. The stored maintenance history data can be accessed from the business PC 16, a portable terminal 17 such as a PHS or a mobile phone, a wearable PC 18, and a portable monitoring device 19, similarly to the operation history data. The operation history data and the maintenance history data are sent from the Web server 20 to the maintenance service center 21 of the plant manufacturer via the Internet.
[0021]
The maintenance service center 21 receives the operation history data and the maintenance history data transmitted from the power company 11 via the Web server 22 and stores them in the database 23. Then, the analysis PC 24 computes the operation and maintenance information based on the operation history data and the maintenance history data, stores the result in the database 23, and transmits the result to the power company 11 as necessary.
[0022]
That is, the maintenance service center 21 compares the behavior of the current field data with the past history, and analyzes the design data and the simulation using the analysis code to determine a state such as aging or low performance. Based on this result, a long-term maintenance plan over the life cycle of the plant 12 is drafted and presented to a technician of the power company 11.
[0023]
FIG. 1 is a block diagram of the maintenance service center 21. The operation history data and the maintenance history data from the plant 12 of the power company 11 are stored in the database 23 via the receiving means 24 from the Internet. The operation history data and the maintenance history data stored in the database 23 are analyzed by the management unit 26, and the operation and maintenance information obtained as a result of the analysis is managed by the management unit 26 as a medical record. The medical chart includes a system chart, an equipment chart, and a plant chart, and is formed hierarchically according to a functional structure.
[0024]
The state grasping means 27 grasps long-term trends of aging deterioration and performance deterioration of devices, systems and plants based on the medical records managed by the management means 26. Then, the maintenance plan drafting unit 28 drafts a maintenance plan over the life of the plant based on the long-term tendency grasped by the state grasping unit 27, and supplies the recommended maintenance plan by the presentation unit 29 via the transmission unit 30 via the Internet. Present it to company 11.
[0025]
FIG. 3 summarizes the analysis results of the field data (operation history data and maintenance history data) by the management means 26, and is an explanatory diagram of a chart in which the operation and maintenance information of the plant is integrated. As shown in FIG. 3, field data related to operation includes environmental data, process data, equipment monitoring data, operation history data, and the like, and field data related to maintenance includes inspection history data, process management data, and the like. These field data are periodically recorded by the power company 11 and stored in the database 23 of the maintenance service center 21 via the Internet. The management means 26 analyzes the behavior of these field data using design information and an analysis method. Then, the results are put together in the three hierarchical structures of the equipment chart, the system chart, and the plant chart and stored in the database 23.
[0026]
Analysis results based on FMEA (Failure Modes and Effects Analysis: Failure Mode Impact Analysis), RCM (Reliability Emphasis Maintenance), failure physics, and the like are accumulated in the device chart. For example, there are device performance such as the relationship between the discharge pressure and the flow rate of the pump and the opening and closing speed of the valve, aging information of the device such as the current deterioration state and its tendency characteristics, and crack and corrosion progress prediction information.
[0027]
The system chart integrates the lower-level device information, and accumulates information including design drawing information such as P & ID (Piping Instrumentation Diagram) and system performance evaluation by analysis using static characteristics and dynamic characteristics simulation models. . For example, system performance such as response characteristics of a control system and core stability, static characteristics evaluation such as sensor drift and minute leak, and dynamic characteristics evaluation such as a transient event.
[0028]
The plant chart integrates the lower-level equipment and system information, accumulates information such as operating procedure manuals and information on risk assessments such as scrums and unplanned outages. For example, plant thermal efficiency and long-term maintenance plans.
[0029]
As described above, by combining the field data, the design information, and various analysis methods, and integrating the maintenance information in a hierarchical structure of devices, systems, and plants, maintenance activities over the life cycle of the plant can be performed. As described above, the operation data recorded by the operation monitoring system of the plant and the system equipment installed in the power company 11 and the maintenance data obtained by the periodic inspection and troubleshooting are taken into the maintenance service center 21 from the Internet, The results of diagnosing aging and performance degradation due to physical rules and signal processing are stored as medical records.
[0030]
FIG. 4 is an explanatory diagram of FMEA in the state grasping means 27. FIG. 4 shows a case where the heat exchanger is used. If the monitoring of the field data detects that certain parameters relating to the heat exchanger deviate from normal levels, it searches for possible failure modes based on the information provided in the FMEA, and may further change in relation thereto. Extracted parameters with.
[0031]
Next, as shown in FIG. 5, the maintenance plan formulation means 28 extrapolates the time change of the changed parameter to obtain a time margin until the alert level is reached, and sufficiently changes the related parameter during that time. Develop a monitoring plan by finding the data evaluation frequency that can be observed in detail. That is, the type of data, sampling conditions, sampling time, and sampling frequency necessary for diagnosing the state of the target (heat exchanger) are determined, and a data sampling plan is drafted. The data collection plan is presented to the maintenance staff of the power company 11 by the presentation means 29.
[0032]
As described above, when a deterioration sign is detected from the field data (operation history data and maintenance history data), a plan for collecting additional data necessary for detailed diagnosis is formulated based on a failure effect analysis prepared in advance. The information is presented to the power company 11 via the Internet. Therefore, it is possible to provide a detailed monitoring enhancement measure when a change is recognized.
[0033]
Next, FIG. 6 is an explanatory diagram of technical support and consultation by the maintenance plan drafting means 28. If signs of aging or performance degradation are detected and additional data is collected, the deterioration state is diagnosed, and if any action is required based on the results of the diagnosis, the electric power company will provide technical assistance information. 11 is presented.
[0034]
That is, the maintenance plan drafting means 28 provides technical support relating to both the operation monitoring and the inspection and maintenance fields from the field data and the analysis software library. The contents of the consultation services include periodic evaluations related to monitoring and diagnosis of plants, equipment and sites, investigation of causes and planning of countermeasures when troubles occur, work support for periodic inspections, planning of long-term maintenance plans, analysis support, information provision support, etc. And so on.
[0035]
Routine tasks such as primary evaluation of field data and judgment of necessity of inspection for each device are automated, and maintenance center specialists respond to troubles and draft long-term maintenance plans. In addition, problems that require expert judgment can be addressed in detail.
[0036]
Further, the maintenance plan drafting means 28 predicts a future state based on the long-term trend analysis of aging and performance degradation by the state grasping means 27, evaluates cost versus risk, and determines the time to replace the equipment. FIG. 7 is an explanatory diagram of support by the maintenance plan drafting means 28 at the time of device replacement.
[0037]
If condition monitoring maintenance is applied to a device and used over the life of the plant, the frequency and cost of condition monitoring and overhaul increase as the aging progresses, and the cumulative maintenance cost increases gradually. I do. However, if the device is replaced with a new one at a certain time, the replacement cost associated with the device body price and the installation work is newly generated, but it is possible to suppress an increase in maintenance cost due to aging deterioration thereafter.
[0038]
In the present invention, since the tendency management over the life cycle of the plant is possible, the difference between the accumulated maintenance costs until the plant is abolished due to the presence or absence of replacement is calculated, and the cost merit of replacement and the appropriate replacement time are presented. Can be.
[0039]
【The invention's effect】
As described above, according to the present invention, a plant life cycle maintenance planning system that is excellent in operability and economy is realized.
[Brief description of the drawings]
FIG. 1 is a block configuration diagram of a maintenance service center of a plant life cycle maintenance planning system according to an embodiment of the present invention.
FIG. 2 is an overall configuration diagram of a maintenance service center according to the embodiment of the present invention.
FIG. 3 is an explanatory diagram of a device chart, a system chart, and a plant chart managed by a management unit according to the embodiment of the present invention.
FIG. 4 is an explanatory diagram of FMEA (failure mode analysis) in the state grasping means according to the embodiment of the present invention.
FIG. 5 is an explanatory diagram of an example of a data collection plan created by a planning unit according to the embodiment of the present invention.
FIG. 6 is an explanatory diagram of technical support and consultation performed by a maintenance plan drafting unit according to the embodiment of the present invention.
FIG. 7 is an explanatory diagram of assistance in replacement timing of equipment by maintenance plan formulation means in the embodiment of the present invention.
[Explanation of symbols]
11 ... power company, 12 ... plant, 13 ... process computer, 14 ... plant / crisis monitoring system, 15 ... data server, 16 ... business PC, 17 ... portable terminal, 18 ... wearable PC, 19 ... portable monitoring device, Reference numeral 20: Web server, 21: Maintenance service center, 22: Web server, 23: Database, 24: Analysis PC, 25: Receiving means, 26: Management means, 27: Status grasping means, 28: Maintenance plan drafting means, 29: Presentation means, 30 ... transmission means

Claims (4)

A system for transmitting information from a power company having a plant to a maintenance service center via the Internet, wherein the maintenance service center provides maintenance data of a plant based on information from the power company. A receiving unit for receiving operation history data and maintenance history data from the plant via the Internet, and operating / maintenance information obtained by analyzing the operation history data and maintenance history data received by the reception unit; Management means for hierarchically managing as a medical record according to a functional structure leading to a plant, and a state grasping means for grasping long-term trends of aging and performance degradation of plants, systems, and equipment based on the medical record managed by the management means, Based on long-term trends ascertained by the status Plan maintenance means for drafting a maintenance plan to be developed, and a presentation means for presenting a recommended maintenance plan drafted by the maintenance plan drafting means to a power company via the Internet. Planning system. The maintenance plan drafting means, when the state grasping means detects signs of aging or performance degradation, the type of data necessary for diagnosing the state of the object, the sampling conditions, the sampling time, and the sampling time. The plant life cycle maintenance planning system according to claim 1, wherein the frequency is determined and a data collection plan is drafted. The maintenance plan formulating means, when signs of aging or performance deterioration are detected by the state grasping means and additional data is collected, diagnoses the deterioration state and consults for a response based on the diagnosis result. The plant life cycle maintenance planning system according to claim 1, wherein: The maintenance plan drafting means predicts a future state based on a long-term trend analysis of aging and performance deterioration by the state grasping means, evaluates cost versus risk, and determines a replacement time of equipment. The plant life cycle maintenance planning system according to claim 1.

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