JP5468041B2 - Plant equipment maintenance management system - Google Patents

Description

  The present invention relates to an equipment maintenance and management system for a plant capable of diagnosing a failure caused by a defective equipment lot that occurs in a plant such as a water and sewage system.

  As a conventional plant equipment maintenance management system, there are a portable terminal that sends a failure information and traceability information of a plant control device to a service provider, a mail server that receives a mail via the Internet, and a received mail as a service provider. The system comprises a web server provided with an acceptance allocation device provided to the side, a failure history information database used for failure diagnosis, an error search database for failure location estimation, and the like.

In such a plant equipment maintenance management system, countermeasures are taken when a failure occurs in the following procedure.
(1) Plant operation / maintenance personnel (hereinafter referred to as users) use the Internet when the faulty plant control device cannot determine the cause of the failure. Record the failure information and traceability information of the plant control device in a portable terminal that is in an environment where it can be used.
(2) The recorded failure information and traceability information are sent via the Internet to a mail server installed by the service provider.
(3) The service provider receives the failure information and traceability information mail received by the mail server at the reception allocation terminal device.
(4) The reception allocator judges the contents of the mail and transfers the mail to a system manager terminal managed by the corresponding system manager or a hardware management terminal device managed by the hardware manager.
(5) The system, system administrator, and hardware administrator confirm the contents of the email and start investigation.
For example, the failure location is analyzed by accessing a web server and using an error search database that estimates the failure location from the error log code of failure information and related information.
Further, the history information of the corresponding plant control device is retrieved from the failure history information database from the traceability information and analyzed.

  As described above, when a failure occurs in the plant control device, the failure information and the traceability information are transmitted from the portable terminal to the service provider, and the failure history and failure location estimation database managed on the service provider side are transmitted. Based on the above, diagnosis is performed (see, for example, Patent Document 1).

Japanese Patent Laying-Open No. 2005-43953 (paragraphs 0017 to 0025)

  Since the conventional equipment maintenance management system is configured as described above, it is possible to diagnose individual failures notified by the user. However, as seen in the recent automobile recall problem, there are problems. There was no mechanism for analyzing the tendency of failure, such as concentration in a certain production unit (lot), and there was room for improvement in terms of horizontal development against failure and prevention of recurrence.

  The present invention has been made to solve such a problem, and an event that has occurred in equipment used in a plant such as a water and sewage facility is collated with an event that has occurred in the past by searching a failure database. It is possible to make a diagnosis based on conventional experience such as notifying the cause and coping method. It is an object of the present invention to provide a plant equipment maintenance management system that enables analysis of defects.

The plant equipment maintenance management system according to the present invention,
A plant monitoring device for transmitting inquiry data for inquiring about events of equipment constituting the plant;
Because the inquiry data is compared and referred to in advance in the failure registration data registered in advance for the failure that has occurred in the process of the plant or the failure that has occurred in the equipment or the event related to the abnormality and the first countermeasure that was the countermeasure. In the inspection database that has been registered in advance for the second diagnostic method that was a countermeasure against the event related to the failure or abnormality of the device with the same specifications as the above device and the failure or abnormality of the device with the same specifications as the above-mentioned device. An integrated management server comprising means capable of accessing a diagnostic server having an information processing unit for diagnosing a failure or an abnormality of the device of the same specification by comparing and referring to the inquiry data;
In the equipment maintenance management system of a plant provided with the inspection terminal which displays the said 1st or 2nd countermeasure method,
The diagnosis server receives the event, the device name, and the device serial number from the integrated management server, and acquires the lot number of the device acquired from the product database based on the event, the device name, the device serial number, and the serial number. Is registered in the database for lot defect analysis, and if the number of registrations related to the device related to the same lot exceeds a predetermined threshold, it is determined that the device is a lot defect and the device is used via the integrated management server. It is provided with a lot defect diagnosing unit that notifies the inspection terminal of the plant.

The diagnosis server of the plant equipment maintenance management system according to the present invention receives the event, the equipment name, and the equipment serial number from the integrated management server, and the product based on the event, the equipment name, the equipment serial number, and the serial number. Register the lot number of the equipment acquired from the database in the database for lot defect analysis, and if the number of registrations related to the equipment related to the same lot exceeds the predetermined threshold, it is determined that the equipment is defective and integrated. Since it has a lot defect diagnosis unit that notifies the inspection terminal of the plant that uses the equipment via the management server,
When a lot defect is detected in a device, the device manufactured in that lot can be immediately notified to the machine in use, and the failure treatment can be deployed horizontally.

It is a block which shows the whole structure of the equipment maintenance management system 100 of the water and sewage plant which concerns on Embodiment 1 of this invention. It is a block diagram which shows the detailed structure of the equipment maintenance management system 100 of the plant which concerns on Embodiment 1 of this invention. It is a flowchart which shows operation | movement of the equipment maintenance management system 100 of the plant which concerns on Embodiment 1 of this invention. It is a block diagram which shows the detailed structure of the equipment maintenance management system 200 of the plant which concerns on Embodiment 2 of this invention. It is a block diagram which shows the detailed structure of the equipment maintenance management system 300 of the plant which concerns on Embodiment 3 of this invention. It is an example of the graph displayed on the inspection terminal 22 of the equipment maintenance management system 300 of the plant which concerns on Embodiment 3 of this invention.

Embodiment 1 FIG.
A first embodiment of the present invention will be described with reference to FIGS.
FIG. 1 is a diagram showing an overall configuration of an equipment maintenance management system 100 provided in a water and sewage plant according to this embodiment.
FIG. 2 is a diagram showing a detailed configuration of the equipment maintenance management system 100 of the water and sewage plant according to this embodiment.
As shown in FIG. 1, a plant monitoring device 21 that monitors events from various devices installed in a water supply / sewerage machine 20 and inspections necessary for inspection of plant process status and devices for site managers. Both the inspection terminals 22 for displaying items and the like are connected to the transmission / reception unit 23. The transmission / reception unit 23 can perform transmission / reception with the integrated management server 30 via a communication network 50 such as the Internet.
In addition, a diagnostic server 40 including an inspection database 42 that stores diagnostic information such as the performance of each device and its component parts is connected to the communication network 50, for example, for each manufacturer. The machine place 20 and the diagnosis server 40 do not have to be one place, and the integrated management server 30 can transmit and receive with the machine place 20 and the diagnosis server 40 at a plurality of places.

  In a water and sewage plant, measuring equipment that measures the flow rate and temperature of water and sewage flowing through the plant, mechanical equipment such as pumps and on-off valves for mechanically adjusting the process quantity, and mechanical equipment Various sensing devices such as a control device for controlling the sound, a sound detection device such as a microphone provided for confirming the mechanical or electrical condition of each mechanical device or control device, or a signal detection device for detecting an electric signal Equipment is provided. Data relating to an event necessary for plant monitoring is transmitted from these devices to the plant monitoring device 21.

The plant monitoring device 21 includes a calculation unit (not shown) that performs a calculation for determining a failure occurring in a plant or a failure or an abnormality occurring in those devices from data related to events received from various devices. For example, by comparing and referring to the data transition of the measuring device that measures the process amount and the command data of the control device that gives a command to the mechanical device that adjusts it, the control state of the process operation can be calculated and evaluated. ing.
At this time, when it is determined that some trouble has occurred in the responsiveness of the process amount to be controlled, the plant monitoring device 21 transmits and receives the inquiry data having the event data related to the trouble. 23.
In addition, even when unusual noise or special noise is detected from the signal detection equipment provided to confirm the condition of the mechanical equipment or control equipment, it is judged that the equipment condition has changed. Inquiry data having data related to the abnormality (an event that may be a failure or a sign of failure) is transmitted to the transmission / reception unit 23.

The transmission / reception unit 23 that has received the inquiry data transmits the inquiry data to the integrated management server 30 via the communication network 50. The private diagnosis unit 31 of the integrated management server 30 compares and refers to the received inquiry data and the device registration data and failure registration data registered in advance in the device database 32 or the failure database 33, so that the state of the malfunction of the current process is determined. Also, diagnose the condition of the device with the abnormality, search for the cause of the process failure or the failure or abnormality of the device and the countermeasure (first countermeasure) according to the diagnosis result, and send and receive the result 23.
The device registration data includes the device name, model, date of manufacture, part information, manufacturer, address number of the manufacturer or the address number of the department that collected the device information, etc. is there. The failure registration data is a record of contents relating to process failures and device changes that have occurred in the past and the first countermeasures and the like.

In the integrated management server 30, when the failure database 33 cannot cope with the inquiry data from the plant monitoring device 21, and the cause of process failure or equipment change cannot be identified, the following measures are taken.
For a process failure, an emergency countermeasure request is sent from the integrated management server 30 to the inspection terminal 22 of the machine station 20 to notify the site manager of the occurrence of a failure such as a process amount. For device changes, the address of the manufacturer that manufactured the target device is retrieved from the device database 32, and the integrated management server 30 accesses the manufacturer's diagnostic server 40 via the communication line network 50. Send inquiry data.
Here, when inquiry data including events related to process failures and device changes are sent to the integrated management server 30, process failures and device changes may be related to each other. In that case, by sending the inquiry data to the diagnostic server 40 of the manufacturer, the probability that the cause of the process failure and the coping method can be quickly understood increases.

  The information processing unit 41 of the diagnosis server 40 of the manufacturer makes a diagnosis by comparing and referring to the received inquiry data and the diagnosis registration data registered in the inspection database 42, and causes and countermeasures for the device abnormality or the like (first step) 2), and the result is displayed on the inspection terminal 22 of the machine station 20 via the communication network 50 to inform the site manager of the countermeasure. The diagnosis registration data is registered in advance by associating the failure or change contents experienced in the past with the event of the inspection target part by the device having the same specification as the plant device.

  When the inquiry data and the diagnostic registration data cannot be compared (referenced), and the information processing unit 41 cannot identify the cause of the failure or abnormal content of the device (for example, after sending the inquiry data from the integrated management server 30, After a lapse of time, if there is no response regarding the second countermeasure from the manufacturer's diagnostic server 40), the integrated management server 30 or the information processing unit 41 identifies the cause of the device failure or abnormal content from the inquiry data. An inquiry message notifying that it is not possible is transmitted to the terminal 46 to be monitored by the person in charge of the manufacturer and the inspection terminal 22 of the machine station 20. As a result, the person in charge enters the investigation confirmation to confirm the inquiry message displayed on the terminal 46 in charge and to find out the cause and the second countermeasure for the failure or abnormal contents of the device, and the result of confirming the countermeasure is displayed. The transmitter / receiver 23 is prompted to transmit. The site manager is also prompted to take action to find the necessary second action to confirm the inquiry message.

Next, a case will be described in which when there is a defective lot in the equipment of the machine place 20, this is analyzed and a device manufactured in the lot is searched and notified.
The private diagnosis unit 31 of the integrated management server 30 transmits the cause of the device having an abnormality and the coping method (first coping method) to the transmission / reception unit 23 of the machine 20 and, at the same time, the lot defect diagnosis unit of the diagnostic server 40 of the manufacturer. 43, the serial number of the device, the failure phenomenon, and cause data are transmitted.

The lot defect diagnosis unit 43 receives this data and accumulates the received device manufacturing number, lot number, failure phenomenon, and cause data in the lot defect analysis database 44.
The lot number is stored in accordance with the lot number numbering rule defined for each device in the product database 45 managed by the manufacturer by determining the manufacturing period, the manufacturing line, etc. from the manufacturing number.
Each time trouble occurrence data is accumulated in the lot defect analysis database 44, the number of occurrences is counted for each device, failure phenomenon, lot number, and if this number exceeds a predetermined threshold, the trouble continues in that lot. Is determined to have occurred.

When the lot defect diagnosis unit 43 determines the defect of the device lot, the lot defect diagnosis unit 43 searches the product database 45 for all the production numbers of the devices manufactured in the lot and transmits them to the private diagnosis unit 31 of the integrated management server 30.
The private diagnosis unit 31 of the integrated management server 30 searches the machine database 20 using the equipment from the equipment database 32 using the received equipment serial number as a key, and requires inspection to the inspection terminal 22 of the target machine 20. Notify
In addition, the lot defect analysis database 44 can be additionally registered from the responsible terminal 46 so that the lot defect analysis of the equipment can be performed in consideration of the lot information of the failure found in other than the system shown in the present invention.

Next, the operation of the plant equipment maintenance management system 100 will be described with reference to FIG. FIG. 3 is a flowchart showing the operation of the plant equipment maintenance management system 100.
The private diagnosis unit 31 of the integrated management server 30 is always waiting to receive inquiry data transmitted from the transmission / reception unit 23 of the machine place 20.
When the inquiry data is received (step S501), a search is made as to whether or not the event has been registered in the failure database 33 for a device in which an event relating to some process malfunction or condition change has occurred (step S502).

When registered (step S502 / YES), the cause and the treatment method registered in the failure database 33 are transmitted as diagnosis results (step S503) to the inspection terminal 22 via the transmission / reception unit 23 (step S504). ).
If not registered (NO in step S502), the private diagnosis unit 31 searches the device database 32 from the device information in the inquiry data to identify the manufacturer of the device, and makes an inquiry to the information processing unit 41 of the manufacturer. (Step S505).

When receiving the inquiry data, the information processing section 41 of the manufacturer's diagnostic server 40 searches whether or not the device and the event that has occurred are registered in the inspection database 42 (step S506).
If registered (step S506 / YES), the integrated management server 30 is notified of the inspection target parts and inspection items for the cause investigation (step S508). The private diagnosis unit 31 of the integrated management server 30 registers the notification received from the manufacturer's diagnosis server 40 in the failure database 33 (step S509), and transmits the same contents to the inspection terminal 22 via the transmission / reception unit 23 (step S509). S504).

If not registered (NO in step S506), the information processing unit 41 notifies the terminal 46 of the person in charge of the manufacturer, and at the same time, prompts the user to input the inspection target part and inspection item for the cause investigation from the screen (step S506). S507). The parts to be inspected and the inspection items input while looking at the screen of the person in charge terminal 46 are stored in the inspection database 42.
In response, the integrated management server 30 is notified of the inspection target parts and inspection items for the cause investigation (step S508).
The private diagnosis unit 31 of the integrated management server 30 registers the notification received from the manufacturer's diagnosis server 40 in the failure database 33 (step S509), and transmits the same contents to the inspection terminal 22 via the transmission / reception unit 23 (step S509). S504).

The lot defect diagnosis unit 43 of the manufacturer's diagnosis server 40 receives the manufacturing number, failure phenomenon, and cause data of the device in which the failure occurred from the private diagnosis unit 31 of the integrated management server 30, and stores it in the manufacturing number and product database 45. The lot number is extracted and stored in the lot defect analysis database 44 together with the lot number extracted by judging the production period, production line, etc. from the lot number numbering rule determined for each device (step S510).
At the same time, the number of occurrences is counted for each device, failure phenomenon, and lot number, and it is determined that the lot is defective when the number exceeds the threshold (step S511).
If it is determined as a defective lot (step S511 / YES), the product serial number of the device manufactured in the defective lot is retrieved from the product database 45 and notified to the private diagnosis unit 31 of the integrated management server 30. The private diagnosis unit 31 grasps the equipment manufactured in the defective lot and the machine place 20 using the equipment from the equipment database 32, and notifies the inspection terminal 22 of the machine place 20 (step S512).

  According to the device maintenance management system 100 according to the present embodiment, when a lot defect is detected in a device, the device manufactured in that lot can be immediately notified to the machine in use, and failure treatment can be horizontally deployed. For example, if the motor is the cause of the abnormal noise generated in the water and sewage pump, the motor serial number, while accumulating the lot information indicating the motor manufacturing period and production line along with the failure phenomenon, The failure phenomenon and the number of failures for each lot are counted, and when failures are concentrated in that lot, it can be diagnosed as a lot defect and reported to each machine.

In addition, since a process state associated with the operation and a coping method for an event indicating a failure or a sign of the failure are retrieved and transmitted to the inspection terminal, an effect of promoting the avoidance of a failure in the plant operation can be obtained.
In addition, because it deals simultaneously with events related to process failures associated with operation and events related to equipment failures or abnormalities that show signs of it, knowing how to deal with faulty equipment makes it easy to identify the direct cause of faults occurring in the process. As a result, it is possible to estimate and confirm, and it is possible to obtain an extraordinary effect of more efficiently accelerating the avoidance of plant operation problems, which has not been possible with a device maintenance management system.

Embodiment 2. FIG.
Hereinafter, the second embodiment of the plant equipment maintenance management system 200 according to the present invention will be described with reference to the drawings, focusing on the differences from the first embodiment.
In the first embodiment, when the integrated management server 30 and the diagnostic server 40 of each manufacturer cooperate with each other in response to the inquiry of the device event that has occurred in the plant monitoring device 21 of the machine place 20, the failure database 33 is registered. Answers the cause and treatment method, and if not registered, the manufacturer's diagnostic server notifies the inspection terminal 22 of the parts to be inspected and the inspection items for the cause investigation.
Furthermore, the manufacturer's lot defect diagnosis unit 43 analyzes the lot information of the defective device while accumulating the failure information in the lot defect analysis database 44, searches for the device manufactured in the lot, The case of notifying the aircraft 20 was described.

In this embodiment, in addition to the analysis of equipment lot defects, the relationship between the environmental conditions such as temperature and humidity in the area where the plant facilities are located and the equipment and phenomenon in which the failure has occurred is investigated. Analysis and the device and environmental conditions are notified to the inspection terminal 22 as warning information together with the phenomenon.
For example, when failure frequently occurs in a specific device under an environmental condition where the temperature exceeds 30 degrees, this information is notified as a warning.

FIG. 4 is a block diagram showing a detailed configuration of the plant equipment maintenance management system 200 according to Embodiment 2 of the present invention.
The integrated management server 230 in this embodiment includes a failure condition analysis unit 235.
Environmental condition data such as temperature and humidity is added to the inquiry data transmitted from the plant monitoring device 21 to the private diagnosis unit 231. ((1) in FIG. 4)
Then, when the private diagnosis unit 231 notifies the inspection terminal 22 of the diagnosis result, the failure condition analysis database 234 provided in the integrated management server 230 includes the target device name, the failure phenomenon, and the environment at the time of occurrence of the abnormality. The conditions are sequentially recorded ((2) in FIG. 4).

  When the private diagnosis unit 231 notifies the inspection terminal 22 of the diagnosis result, the failure condition analysis unit 235 selects from among the environmental conditions stored in the failure condition analysis database 234 and the device or phenomenon in which the failure has occurred. For the devices and phenomena that are considered to be malfunctioning, the number of malfunctions classified according to the current environmental conditions is automatically counted ((3) in Fig. 4). If the number exceeds the threshold, the device Information indicating that the reliability under the current environmental conditions is low is transmitted as warning information to the inspection terminal 22 and displayed on the inspection terminal 22 ((4) in FIG. 4).

Although the environmental conditions indicate items such as temperature and humidity, all the environmental condition data transmitted from the plant equipment via the plant monitoring device 21 can be automatically analyzed.
In the second embodiment, in the countermeasure against the failure of the plant operation, an effect leading to the recurrence prevention can be obtained because the root cause leading to the failure phenomenon occurring in the device can be analyzed from the viewpoint of the environmental condition.

Embodiment 3 FIG.
Hereinafter, the third embodiment of the present invention will be described with reference to the drawings, focusing on the differences from the second embodiment.
In the second embodiment, the number of past failures that occurred under the same conditions as the current environmental conditions is automatically calculated from the environmental conditions accumulated in the failure condition analysis database 234 and the devices and phenomena that have failed under those environmental conditions. The case where it totals and it displays on the inspection terminal 22 as warning information when the occurrence number exceeded a threshold value was described.

  In the present embodiment, before the number of failure occurrences of each device registered in the failure condition analysis database 234 reaches the threshold value, the user gives an instruction from the inspection terminal 22 to determine the relationship between the failure occurring in the device and the environmental condition. Make it possible to refer to the graph shown.

FIG. 5 is a block diagram showing a detailed configuration of a plant equipment maintenance management system 300 according to Embodiment 2 of the present invention.
When a device to be analyzed from the inspection terminal 22 and an environmental condition such as temperature and humidity are designated and an inquiry is made to the failure condition analysis unit 335 via the transmission / reception unit 23 ((1) in FIG. 5), the failure condition analysis unit 335 Creates a graph showing the relationship between the specified environmental condition, the device, and the phenomenon of failure from the data accumulated in the failure condition analysis database 334 ((2) in FIG. 5), and sends it to the inspection terminal 22 ( The graph can be referred to at the inspection terminal 22 in FIG. An example of a graph displayed on the inspection terminal 22 is shown in FIG. In the graph of FIG. 6, it is possible to recognize a tendency that the probability that the phenomenon A occurs in the device X under an environmental condition where the temperature exceeds 30 degrees.

In the third embodiment, since the trend of the relationship between the failure phenomenon that occurred in the device and the environmental condition in the past before the occurrence of the failure can be grasped by the graph, there is a correlation between the environmental condition and the failure phenomenon. Occurrence of failure can be prevented in advance because it is possible to take preventive and maintenance measures such as replacement and inspection for the equipment that is seen.
Thereby, the effect which can operate a stable plant is acquired.

100, 200, 300 Equipment maintenance management system, 20 machines,
21 plant monitoring device, 22 inspection terminal, 23 transmitter / receiver,
30, 230 Integrated management server, 231 Private diagnostic department,
234 Database for failure condition analysis, 31 Private diagnostic department,
32 Equipment database, 33 Failure database,
334 failure condition analysis database, 235, 335 failure condition analysis unit,
40 diagnosis server, 41 information processing unit, 42 inspection database,
43 Lot defect diagnosis department, 44 Lot defect analysis database,
45 product database, 46 charge terminal, 50 communication network.

Claims (6)

A plant monitoring device for transmitting inquiry data for inquiring about events of equipment constituting the plant;
Because the inquiry data is compared and referred to in advance in the failure registration data registered in advance for the failure that has occurred in the process of the plant, the failure that has occurred in the equipment or the event relating to the abnormality or the first countermeasure that was the countermeasure. In the inspection database registered in advance for the second diagnostic method that was a countermeasure and the event related to the failure or abnormality of the device having the same specifications as the device and the private diagnostic unit for diagnosing the malfunction of the process or the failure or abnormality of the device, An integrated management server comprising means capable of accessing a diagnostic server having an information processing unit for diagnosing a failure or an abnormality of the equipment of the same specification by comparing and referring to the inquiry data;
In a plant equipment maintenance management system comprising an inspection terminal for displaying the first or second countermeasure,
The diagnostic server receives the event, the name of the device, and the serial number of the device from the integrated management server, and the product based on the event, the name of the device, the serial number of the device, and the serial number If the lot number of the device acquired from the database is registered in the database for lot defect analysis and the number of registrations related to the device related to the same lot exceeds a predetermined threshold, it is determined that the device is a lot defect. A plant equipment maintenance management system comprising a lot defect diagnosis unit that notifies the inspection terminal of the plant that uses the equipment via the integrated management server. The plant maintenance management system according to claim 1, wherein the lot defect analysis database can be additionally registered arbitrarily. The inquiry data includes environmental conditions at the time of the event occurrence,
The integrated management server includes a failure condition analysis database that stores and stores the event, the name of the device that caused the event, and the name of the component of the device together with the environmental condition;
From the failure condition analysis database, the failure of the device generated under a predetermined environmental condition is totaled to predict the failure of the device and the component under a specific environmental condition, and the device and the component are used. The plant equipment maintenance management system according to claim 1, further comprising a failure condition analysis unit that warns the prediction of the occurrence of the failure in the plant. The plant equipment maintenance according to claim 3, wherein the failure prediction warning is performed when the number of occurrences of the failure under a predetermined environmental condition exceeds a threshold for the same equipment and the same part. Management system. The plant environmental maintenance system according to claim 3 or 4, wherein the environmental condition includes one or more of temperature and humidity. The said failure condition analysis part has the graph display means which displays the relationship between the said failure which generate | occur | produced in the said apparatus and the said components, and the said environmental condition corresponding to the said failure on the said inspection terminal. The plant equipment maintenance management system according to any one of the above.

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