MXPA06004021A - Equipment component monitoring and replacement management system - Google Patents

Abstract

A system for managing replacement components for equipment (300, 400) having a plurality of components each with a limited useful life has a computer (40) with a processor (100). The system includes a computer program module for defining a duty profile (220) comprising a plurality of usage cases for the equipment (300, 400), each usage case involving two or more of the plurality of components and specified operating conditions assumed to be experienced by the involved components during the execution of each of the usage cases. There are also a computer program module for determining a theoretical useful life for each component involved in a duty profile (220), the theoretical useful life being based on component useful life data under the specified operating conditions;and sensors (302, 402) for determining and monitoring the occurrence of equipment operation corresponding to a usage case.

Description

SYSTEM FOR ADMINISTRATION OF SUPERVISION AND REPLACEMENT OF COMPONENTS OF EQUIPMENT BACKGROUND OF THE INVENTION The present invention relates to apparatuses and methods for supervising and managing the equipment life cycle. More specifically, the present invention relates to apparatus and methods for forecasting periods of preventive maintenance and component replacement needs. The machinery requires periodic diagnostic maintenance to detect wear of the parts of the machine, forecast faults and locate problems. In modern machinery, such as in marine machines, cranes, automatic transmissions, turbo-axis engines, paper mills, laminators, aircraft engines, helicopter transmissions, and high-speed process machinery, bearing failure, gears and Other equipment often results in costly loss of productivity, severe and costly secondary damage, and potentially life threatening situations. Equipment failures occur, because over time, the gear / bearing assemblies of other stressing parts experience wear and tear, such as weathering elements.

Bearing bearing unsheathed, pitting on gear teeth and damage to bearing guides. To assert security and avoid unscheduled interruptions, typically typical components are replaced at fixed conservative intervals based simply on periods of use. However, wear factors such as load magnitudes, travel distances, time periods under load and travel speeds can strongly influence the wear and damage of the equipment. Consequently, when the wear factors are above normal for a significant period of time, the equipment may fail prematurely. On the other hand, when the wear factors are minimal for a significant period of time, simply relying on periods of use to activate component replacement can increase operating costs. This is because the useful life of the component is wasted, costs are increased due to more frequent maintenance and productivity is decreased due to interruptions for more frequent maintenance. There is a need in the art for a system that more accurately forecasts the periods of preventive maintenance and defines the replacement needs of components. Also, there is a need in the specialty by a method that more accurately forecast periods of preventive maintenance and component replacement needs. BRIEF COMPENDI OF THE INVENTION The present invention, in one embodiment, is a system for administering replacement components for equipment having a plurality of components, each with a limited useful life. The system includes: a computer with at least one processor; a computer program module for defining a service profile comprising a plurality of use cases for the equipment, each use case involving two or more of the plurality of components and operating conditions specified, which is considered to be experienced by the components involved during the execution of each of the use cases; and a computer program module, to determine a theoretical lifetime for each component involved in a service profile, the theoretical service life is based on wear / stress / stress parameters of components that are considered to occur under the specified operating conditions . The systems also include sensors to determine and monitor the occurrence of the operation of the equipment, which corresponds to a use case and make measurements of the current operating conditions experienced in the operation; a memory for storing the measurements of the current operating conditions for the plurality of components; and a computer program module for calculating a theoretical lifetime adjusted for a component after it has undergone one or more operations, a: in response to measurements of current operating conditions, calculating one or more wear / voltage parameters / effort calculated for each operation and accumulate these parameters calculated for this component; and, based on the comparison of the calculated wear / stress / strain parameters of the current operating conditions for cumulative wear / stress / stress parameters, which occur under the operating conditions specified in the determination of a service life theoretical, determine the amount of adjusted theoretical useful life that is consumed in the one or more operations. The present invention, in another embodiment, is a method for managing remote equipment maintenance with replacement components. The method comprises: providing on the remote equipment, a plurality of sensors that detect, operating conditions for each of one or more replacement components; receiving a database that operates condition data detected by the plurality of sensors; compare at least a portion of the detected data with one or more design service profile parameters for the remote equipment; and in response to the comparison stage, identify one or more replacement components that are recommended for replacement, with a suggested future date for replacement. The present invention, in another embodiment, is a computer program stored in computer readable medium, for use in a system for managing replacement components for equipment having a plurality of components, each with a limited shelf life. The program includes software components as described above for the system embodying the invention. Still another embodiment of the present invention provides an automated network-based service, designed to allow customers to interface on-line or off-line with any drilling equipment coupled to the system. Operators-on-site or remote personnel of the site, for example the headquarters of the company; You can use information and knowledge stored between large amounts of data. One part of the concept is to acquire and redirect instrumentation signals from existing equipment, to a centralized database. By also applying corporate knowledge regarding the team, as theoretical models, Diagnostic algorithms, statistics, workload accumulation, etc., a service provider can provide value-added data back to the company that operates the equipment. The system can provide last-minute statistics for a specific machine, or advanced diagnostic algorithms applied through equipment operated by different companies. The system can help point out potential areas for improved performance, as well as assist in forecasting and planning for pre-demand maintenance. There are two main approaches to analyzing equipment condition. One is based on mathematical modeling and advanced engineering, which provide a reference for comparing operational data measured with theoretical data. The second approach, more common is that there is no reliable model or theoretical knowledge for equipment operation and wear. In this case, empirical analysis of trends and patterns in large amounts of data collected, of a large number of equipment units, over time can provide an ever better interpretation of equipment conditions. Any method that is used, models of better conditions will allow a calculation of the use of weighted equipment, that is to say measured use not only by time or repetitions of operations but based on the load or other conditions that affect the useful life of the equipment. Obviously, there is a big difference between 1000 hours of operation with heavy load and 1000 hours of operation without load in fact. Some parts wear out faster with certain operating conditions, ie higher speeds, others with different conditions, for example higher load. It is possible to define a "wear map" for each component of any machine. By combining this wear map with operational data, a figure for the remaining life for wear parts can be estimated. This will form the basis for a Reliability Centered Maintenance (RMC) approach, where from the current condition and the remaining useful life data, "the service and inspection intervals and the requirements can be estimated dynamically. of spare parts This provides longer service and inspection intervals with little or no increase in failure possibilities Reliability and safety can also be improved A typical system according to a further embodiment of the invention may comprise the following elements Main: • Instrumentation (including sensors) ° This can be the existing instrumentation in the equipment and / or new instrumentation • Computer or on-site computer - A physical data acquisition unit located on or near the projection equipment and coupled to the instrumentation, • Server that receives data of a plurality of computers on-site and with the ability to update software on the on-site computer • Communication network, for example Internet The RCM service can be in two modes: (1) Local supervision - performed on-site or within an existing company network; or (2) Performance monitoring, which is provided by one or more groups of servers operated by a service provider. The local monitoring mode is intended to provide raw data and simple statistical data. The performance monitoring mode provides higher level information, more deeply analyzed data, where the accumulated knowledge of the service provider and the competence in the machine have been applied to the raw data. The system is designed to provide a single configuration point for the service and for the equipment involved. In a dedicated network service, service administrators can configure all the elements of the service. The configuration process involves: - selecting equipment to monitor - selecting type of computer on-site for data acquisition - selecting and configuring signals and parameters for the data logger - selecting and configuring calculations, filters and registration frequency for the data logger data - select and configure communication routes select accumulated knowledge to be applied in the central server - define and configure the company, plant and user accounts Based on the power, the administration database in the central server can produce: a file of XML configuration, to automatically configure all aspects of the data logger an XML configuration file, to automatically configure local monitoring an XML configuration file, to configure. automatically the content of supervisor or local monitor automatic configuration and provision of database tables in the performance monitor automatic configuration of the data receiver in the server - a record current handler For each type of equipment or component an empirical service model can be defined. This can be expressed in: algorithms; constants; performance limits, including 2D performance limits; and error codes. To facilitate the incorporation of empirical learning, the service provider regularly scans collected data and correlates it with known incidents, events, inspections and replacements. Various data extraction techniques can be employed. Also to facilitate empirical learning, the product manager will be authorized to explore and able to collect all the equipment for all clients with the same vision and with the same analysis tools. The administrator can: - see parameters over time - see parameters against load see parameters against any other parameter categorized build statistical data from data in ° Alarms ° Operation ° Maintenance ° Any other monitored and accumulated data - explore details surrounding accidents, events or incidents (for example, broken parts) Based on this, you can develop new algorithms and performance limits to implement in the analysis processor of data for the type of equipment. While multiple modalities are described, embodiments of the present invention will still be apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be appreciated, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description will be considered as illustrative in nature and not restrictive. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic block diagram of one embodiment of the system of the present invention.

Figure 2 is a flow diagram showing the stages involved in using the system of Figure 1 to produce a life-cycle analysis report and other maintenance recommendations. Figure 3 is a flow diagram, which shows how the system of Figure 1 is used to manage maintenance data. Figure 4a is a representation of a display screen for an Internet gateway in a computer system using the present invention. Figure 4b is a representation of a display screen for an interactive map employed in a computer system using the present invention. Figure 4c is a representation of a screen display for a maintenance module with expiration or scheduled. Figure 4d is a representation of a display screen for maintenance module and parts manual used in a computer system using the present invention. Figure 4e is a representation of a display screen for a data acquisition module showing operational data and life data and • is used in a computer system that uses the invention. Figure 4f is a representation of a display screen for a spare part module employed in a computer system using the present invention. Figure 5 is a diagram that outlines a simplified component lifetime analysis based on a theoretical useful service profile and considered operating conditions. Figure 6 is a diagram that outlines a simplified component lifetime analysis as in Figure 5, based on a useful performance or effect profile and current operating conditions. Figure 7 is a graphical display comparing current component usage against a theoretical component usage profile. Figure 8 is a graphic display of a component usage profile for a first component. Figure 9 is a graphic display of a component usage profile for a second component. Figure 10 is a graphic display of a component use profile for a third component, which is planned for replacement.

Figure 11 is a schematic block diagram of another embodiment of the system of the present invention. Figure 12 is a data flow diagram showing certain data processing components of the computer-on-site system of Figure 11. Figure 13 is another data flow diagram showing certain data processing components of the system of Figure 11. Figure 14 is an additional data flow diagram, showing certain data processing components of the computer-in-place of the system of Figure 11. Figure 15 is a flow diagram that shows the stages involved in using the system of Figure 11 to collect and analyze data. Figure 16 is a table of typical parameters measured and recorded for a mud pump. Figure 17 shows in the upper part some constants that are used in the parameter calculations and in the lower part a table of typical calculated parameters for a mud pump. Figure 18 shows a table that contains the limit values for some critical parameters.

Figure 19 shows a screen print that contains a table with measurements made for a mud pump. Figure 20 shows a screen print that contains a diagram showing the flow from a mud pump, with the flow plotted against time. Figure 21 is a screen print containing a diagram showing the distribution of discharge pressure in a mud pump against the rotational speed of the pump. Figure 22 shows an example of a typical performance diagram for a mud pump, showing the distribution of pump use. Figure 23 shows a screen print that contains a diagram of the hours of operation of a mud pump. Figure 24 shows a screen print that contains a diagram of the use of a mud pump with minute-by-minute reports. Figure 25 shows a diagram of the torque of two engines A and B, which operate the pump for a period of time starting at 01:00 and showing that at 02:15 a pump failure occurred. Figure 26 shows a table that incorporates a set of bidimensional performance limits.

DETAILED DESCRIPTION A. Equipment Design and Component Lifespan When designing sophisticated equipment, it is often defined with a planned lifetime for the Total Equipment Item. Actually, the design must take into account the lifespan of a variety of components. For components that are critical to service life, there is usually available life data from a manufacturer or other source that has current test data in the service life and / or theoretical projections that are derived from the current life data. Typically, the service life is specified from one or more defined operating conditions, considered. An operation condition can be specified in terms of a regime, such as speed or load, and a length of time to experience this speed or load and / or a distance to maintain the working regime, but may also include other operating conditions, such as environmental factors that may affect the service life, -for example, operating temperature, humidity, corrosives or particles present. The theoretical lifetime for a component under considered operating conditions can then be expressed in terms of hours, days or other extended time interval. Typically, a graph or set of graphs that They show the effect of load, speed or other operating conditions on the lifespan. It will be available (or can be developed from existing data and theoretical or empirical derivative formulas) as a design guide. In some cases, the test may need to be developed to establish the precise life data for a component. Regardless of the source, equipment designers typically have reliable data that shows the relationship between a range of operating conditions and duration or repetitions of these conditions and the useful life of a component that can be selected in the original design. The problem of lifespan is not particularly difficult when a single component that operates in one or a small number of modes is all that is under consideration. But in complex systems that carry out different operations, the useful life is more difficult to determine. One technique known to team designers is to define a performance profile. A performance profile defines certain operations that the team will perform and determines which are the key components involved in each operation and how they will be used in that operation. A performance profile can be described for an expected total life (or design goals) of a piece of equipment. By For example, the following can define a performance profile for an anchor system used on an offshore oil rig: This performance cycle can be defined for a total design life of 25 years with six rig shifts per year and twelve rig trips per year. Alternatively, the performance profile can be described in terms of what functions the equipment performs, and in any given time interval, what proportion of that time interval the equipment will perform each operation or will not operate. For example, for a crane, the following performance profile can be used: Returning to the first performance profile example, with this defined performance profile, the anchor system designer can then determine which key components are involved (winches, motors, gear systems, shafts, bearings, - "wire rope, etc.). ) in each case and what operating conditions are required for each of the key components in each use case Most of the components will be involved in more than one case and can be operated under different operating conditions for different cases. calculation of the performance profile requirements for each component by the considered performance profile and the total design lifetime.The designer can then select components with useful life characteristics that allow that component to be used for the life cycle considered for at least the total design lifetime.In some cases, the available components may not be Use exactly the total design lifetime, and a component can be selected that is determined to have a useful life under the considered performance profile that exceeds the useful life of the total design In other cases a component may not be available or it may be prohibitive in cost if it must satisfy the total design life without replacement. In this case, a component life under the considered performance profile (including the operating conditions considered) can be calculated and the replacement of this component can be planned, at intervals during the total useful life. However, the current operating conditions for the equipment may be more or less severe than the performance profile considered for the original design. For the owner or operator of the equipment, this has several implications. Maintenance on components may be required sooner or later than originally planned. Some components that were not expected to require maintenance during the design life will require maintenance when the performance profile is more severe than the performance profile used in the original design. It is much better to perform this maintenance on a scheduled basis than to have an emergency maintenance session in the middle of a planned productive use of the equipment (which must now be interrupted) or have a equipment failure. The latter may involve injury or damage that cause losses that go beyond the loss of use of the equipment. The above methods to address this situation include simply observing the operation of the equipment and intervening when a failure becomes observable or almost fails. Alternatively in some situations, a sensor may be used to detect when a component of the equipment is near failure, for example because it deforms or requires more than normal operating forces or its characteristics change otherwise. These methods can defer maintenance until required, but can still result in equipment operating at a point of failure or near failure, when an immediate unplanned emergency stop is required. B. Overview of the Present Invention The present invention seeks to reduce or avoid these unplanned interventions and to be determined in a planned base component replacement, even in situations, where the performance profile in current use is quite far from the profile of performance employed in the original design of the total useful life. Figure 1 is a schematic block diagram, which indicates the elements of a data acquisition and management system according to the present invention. This system is intended to administer replacement of components for one or more items of equipment. Figure 1 shows a crane 300 and an anchoring system or winch 400 as examples; Other types of equipment and more than two items of equipment can be administered by the system. As will be apparent from the following description, the system monitors and collects data on operations performed by the team. More specifically, the system monitors and collects data on operations performed by individual components that comprise the total equipment. The system is capable of providing "real time" access to equipment operations and their components. The system allows direct comparison of current operating conditions experienced by the team to the original theoretical performance profiles considered by the team's designers. The system can then analyze the differences between the current and theoretical performance profiles, develop information that adjusts the life expectancies of the original component and schedule compliance maintenance. The system uses the analysis to evaluate the amount of useful life of the component, from that point in time when the operating condition data are collected.

As illustrated in Figure 1, the system includes a communications network 10 and a computer system 40 with an output device 22 (such as a printer) and a maintenance manager terminal 30. The system also includes operator terminals / equipment owner 50, 52, two sensor data links 304 (for the 300 crane) and 404 (for the 400 winch system), each with a corresponding multiple sensor feed 302, 402 (for simplicity, only three feeds are shown for each crane 300 and winch 400, although many more sensors can be placed in the equipment to provide feeds) that are associated with particular components and their operating parameters with the crane 300 and winch 400. The computer 40 includes a processor 100 with a operating system, communication management devices 110, and application software 120. The applications 120 have access to a database 200, including going files for. data of operating conditions 210, performance profiles 220, maintenance information / manuals 230, and order information 240 as well as other data that can be used by the system. The communication management devices 110 communicate with a network of communications 10 (which can be a public data network such as the Internet or a private network) via a communications link 12. The computer 40 interconnects with the "maintenance administrator" terminal 30 and the output device 20 via communications links 22 and 32, respectively. The operator / owner terminals 50, 52 that can use a viewer to access a site in the network supported on the computer 40, are interconnected to the communications network 10 via communication links 24 and 26, respectively. The equipment operator / owner terminals 50, 52 allow the operator / owner to access the "real-time" maintenance and operation history files generated by the system via an Internet portal. The characteristics that an operator / owner can access the Internet portal in addition to described further in section C of this specification. Sensor feeds 302 are located on the crane 300 to monitor operating conditions on key components, such as the slew bearing, container ring bearing, winches, davits, etc. For example, in the context of the crane 300, the sensor feeds 302 may include: a oscillation angle sensor to measure displacement of radial davit; a davit angle sensor (ie an inclinometer) to measure davit lean displacements and davit angles; - and a load sensor to measure the stress in the rear leg structure (knowing the geometry of the crane, the system converts the reading of the load sensor into an equivalent load of the bearing of the turning mechanism or roller circle). Similarly, sensor feeds 402 are located on winch 400 to monitor operating conditions on key components such as the drum, drum cushions, guide assembly, etc. The sensor feeds 302, 402, communicate operating condition data to their respective sensor data links 304, 404. The sensor data links 304, 404 send the operating condition data to the computer 40 via the controller management devices. communications 110 on the computer 40 via the communications network 10. In one embodiment, the sensor data links 304, 404 use PLC 's existing in the equipment and supplementary programming in the PLCs, to collect data from the sensor feeds 302 , 402. These data are formatted using the XML standard or similar, after transmit to or share with a PC or other processor programmed and configured to use TCP / IP or other data transmission protocols, to transmit data via the communication network 10 to the computer 40. In this way, the equipment 300, 400 can * be located remote from, even at great distances away from the computer 40. The applications 120 receive and store the operating condition data from entry into the operating condition data files 210 in the database 200. The operating condition data is then available for analysis, including further processing, so that they can be compared to and used in the component wear patterns defined by the performance profiles 220 as explained in the following discussion directed to Figure 2. Figure 2 is a logical diagram illustrating the processes 1200 executed by the application 120 with respect to the operating condition data and the profiles of ren d. Before the process can be executed, the relevant performance profiles 220 and the original design and any supporting data used to analyze the lifetime of components under various operating conditions, must be loaded. These data are coordinated with and used by applications 120.

As shown in Figure 2, the process 1200 starts with a start / wait state 1202. When the process 1200 is started, it interrogates whether new operating condition data 1204 is present (ie if new operating condition data has been received. of the sensor feeds 302, 402). If the new operating condition data is not present, then the process 1200 determines whether a sensor status check 1206 is required. This check is made to determine whether or not the failure to receive new operating condition data is the result of a sensor that malfunctions. If sensor status verification is required, then process 1200 performs sensor state verification and reports result 1208. The process then returns to start / standby mode 1202. If process 1200 determines that there is new operating condition data present 1204, then the new operating condition data is received and stored 1210 in the system database 200. The process 1200 then determines whether a real-time analysis request is present for the 1212 equipment. If not, then the process 1200 determines whether a scheduled periodic scan 1214 expired. If periodic scan failed, process 1200 returns to the scan mode. start / wait 1202. If the periodic analysis expired (for example, the end of a monitoring period defined for a particular piece of equipment, such as a day, week, month, etc. is present), then the process 1200 has access to the operating condition data for the particular item of equipment and prepares the operational data for comparison and analysis 1216. If the process 1200 determines that a request for real-time analysis is present for the 1212, then the process 1200 advances directly to access the operating condition data for the equipment and prepares the operational data for comparison and analysis 1216. The process 1200 then has access to the performance profile for the equipment and verifies the updates of 1218 maintenance that may have recently occurred and that may affect a performance profile analysis. The process 1200 then performs comparison and analysis of the operating condition data against the performance profile for the 1220 equipment. As described in section D of this specification, the performance profile is part of the initial design process and is employed. to select the original components and develop a theoretical lifetime for each key component under use cases operative considered and operating conditions. The performance profile and its operating conditions considered, and the component life-time data that were considered in the original design, are reviewed during the 1220 comparison and analysis stage, to make adjustments to the component life forecasts and any corresponding maintenance plans, after current operational condition data have been collected. The process 1200 then determines whether critical life results are present for any component 1222 (ie "whether any component has reached or will soon reach (is within a critical range of), the end of its useful life and requires maintenance or replacement. immediately.) If not, process 1200 prepares the useful life results and schedules the planned service 1224. This includes preparing electronic and / or paper reports of operating conditions, service life and short and long-term maintenance plans. Recommended long term and useful life per component A scheduled replacement requires to be signaled when the amount of theoretical consumed life is within a range of replacement of the adjusted theoretical lifetime The process 1200 then determines whether an automatic order is specified. any 1226 components. If no automatic order is specified, process 1200 sends a planned service and requests 228 order notice to the owner / operator of equipment and any parties involved in the maintenance service. This signals the relevant personnel to place the necessary component orders. If automatic order is specified, the process 1200 provides for the components to be obtained and shipped and the maintenance performed in accordance with a program generated by the system 1230. If the process 1200 determines that critical life results for a component 1222 are present , then process 1200 sends a report on an expedited basis (for example email to terminals 50, 52, fax, return messages to links or sensor data links 304, 404) and emergency service program 1232 by contact with the maintenance service personnel and the owner / operator of the equipment. The process 1200 then arranges for the components to be obtained and shipped and for maintenance to be performed according to a program generated by the 1230 system. The process 1200 then updates the maintenance records based on the complete maintenance report 1234. The process 1200 then return to start / wait mode 1202.

Figure 3 illustrates a process 1300 for providing maintenance information to the system. Maintenance can affect the life calculations, when a replacement component is inserted into the analysis. This is because a new component does not have prior operational conditions as part of its history. Also, a new component may or may not have a different theoretical lifetime under the estimated operating conditions. Process 1300 initiates the maintenance record based on equipment configuration 1302. Process 1300 then waits for periodic or special maintenance reports for equipment 1304, for example, powering terminals 50, 52 if maintenance is recorded by the owner / operator or terminal 30 if it is registered by operators of the system of Figure 1. The 1300 process then determines' whether new maintenance record data 1306 is present. If not, then the 1300 process continues to wait for reports of maintenance by the 1304 equipment. If new maintenance record data is present, then the 1300 process stores the data from. maintenance record with the components Referred to in a particular equipment configuration for which maintenance 1308 has been performed. The process 1300 then determines whether the maintenance record data affects any component 1310 lifetime data., then the process again expects maintenance reports for the 1304 team. If the maintenance record data affects any component life data, then the 1300 process updates the component lifetime data and any affected performance profiles for reflect maintenance 1312, including possible changes to the component's lifetime data files. The 1300 process then again expects maintenance reports for the 1304 unit. C. Access Features Through the Internet Portal In one mode, the operator / owner, maintenance personnel or service provider may have the system online with the Internet . By doing so, the person who has access to the system enters an Internet portal (see Figure 4a) that is designed in a modular format that incorporates a standard network-based protocol architecture. The Internet portal provides access to modules that belong to the team associated with the system. The modules are accessed through multiple navigation paths for any of the equipment associated with the system. In one embodiment, the modules include a maintenance module, a parts and maintenance manuals module, a data recording module, a spare parts module, and a computer location map module. In one mode, the operator / owner will be able to access on-line an interactive map of the world or part of the world, as illustrated in Figure 4b. The map will show the owner / operator equipment locations that are under administration by the system. Clicking with the mouse on the desired location or equipment provides the owner / operator, based on the selections made, access to the modules and / or data for each piece of equipment. Alternatively, a custom-created, dynamically created menu bar, based on each owner / operator's equipment list, is displayed through the top. Drop-down menus take the owner / operator directly to the module for each piece of equipment. The system can be customized to - satisfy the operations of each owner / operator using standard network site architecture.

The maintenance module is designed to provide easy access to maintenance records through the network portal. Each person (with Internet access) that registers in the system will have a unique key that provides diverse levels of access. For example, an individual or individuals who complete current equipment maintenance can only access the feed data sheets to record the time and inspection data. Your supervisor will have access to the next level reports illustrating the maintenance history. Each level of access is controlled by the registry key. Each piece of equipment in the customer's inventory has a scheduled maintenance interval that is loaded into the system. The system provides automatic notification of maintenance tasks that have expired and their expiration date. The expired or scheduled maintenance tasks screen illustrated in Figure 4c illustrates the type of data that will be available to the maintenance supervisor that efficiently schedules maintenance assignments. Once the maintenance is complete, the data is uploaded to the system and accessible online by anyone with security access to it. portion of the module. All maintenance records are kept up to date, allowing access in "real time" and preventive maintenance planning. The parts and maintenance manual module provides "real-time" access to the latest up-to-date documents. These manuals are periodically updated in the system and sent to the owner / operator's home office for distribution of the piece of equipment. Online access to manuals, as depicted in Figure 4d, provides maintenance and operators with instant access to update service modifications and security features for equipment that is managed by the system. The data acquisition module provides access to historical information detailing the current load or other operating conditions for each component monitored in the piece of equipment recorded over the component's lifetime. These recorded data are compared with theoretical design considerations (design profiles) and these comparisons are used to forecast preventive maintenance programs for the supervised component. As illustrated in Figure 4e, the data recording module can also use operating condition data to tabulate and sum the total performance of a piece of data. individual equipment that provides information for planning, production programs and maintenance programs. The spare parts module allows access to parts, manuals and drawings. As indicated in Figure 4f, the bill of materials is available online along with the list of appropriate drawings. The component part can be identified online and inventory status, quotes and delivery can be provided. The component can be ordered online. D. Life Calculations of Simplified Actual and Theoretical Simplified Theoretical Components A highly simplified example of the process for calculating the current and theoretical component life for individual components of X equipment (for example a crane, winch, mechanical shovel, etc.) will now be given. etc.). While the wear of components is a function of multiple factors such as strength, torque, speed of displacement, acceleration, deceleration, temperature, corrosion, particles, surface treatment, lubrication, friction, etc., for reasons of understanding, the Component wear in the following example is equal to the work (that is, force or torque multiplied by displacement) performed by the equipment.

In general terms, the process of the invention initially plans maintenance for X equipment, based on considered theoretical performance profiles, which are based on considerable operating conditions. As team X begins its operational life, the operating condition data is collected by the system. The data collected is used to adjust the theoretical performance profiles of the X equipment. The adjusted performance profiles are then used to adjust the maintenance program for the equipment. The adjusted performance profiles are also used to calculate the amount of useful life of equipment exhausted up to that point in time. The adjusted performance profiles are also used to project the remaining expected equipment life. As can be seen in the following example, the current operating conditions can shorten or lengthen the useful life of current components and equipment with respect to the useful life of components and equipment considered original, depending on whether the current operating conditions are more or less arduous than those that were originally considered. As can be seen from the present Figures and discussion, and as will be clearer from the following discussion, the system and process of the present invention allow that The maintenance program and the predicted equipment life are automatically updated based on real-time operation data of the X equipment. The simplified example is as follows. Figure 5 illustrates an exemplary, although highly simplified, performance profile analysis broken down by components for the X equipment (eg a crane, winch, shovel, etc.). As illustrated in Figure 5, team X has components A, B, and C. To calculate a considered performance profile, a team designer first considers a design life of the equipment for the team in question. For example, the design life of the equipment considered for the X equipment is 25 years. The designer then considers the types and numbers of operations (ie, use cases and their repetitions) that the X equipment will undergo during its useful design life of considered equipment. Each use case is considered as a specific type of operation at a specific level of loading and displacement. As indicated in Figure 5, the X team is considered to perform three different use cases (Use Cases 1, 2 and 3) in the course of its useful life design of considered equipment. It is considered that the X equipment does not perform NI operations (for example 100) of "Use Case 1", operations N2 (for example 50) of "Use Case 2", and N3 operations (for example, 125) of "Use Case 3" on life Useful design of the equipment considered 25 years for the X equipment. For the X equipment, the Use Case 1 causes the Component A (for example, the rotary arrow) to turn 10 radians to a torque of 45.36 kgf-m (100 ft. Ibs) and Component B (for example a hydraulic ram) move 1.52 meters (5 feet) against a force of 4.54 kg (10 pounds). Component C (for example, a pulley), does not participate in Use Case 1. In this way, each occurrence of Use Case 1 submits Component A to Cl (453.6 kgf-m (1,000 ft.lbs)) of work, Component B to C2 (22.68 kg (50 ft.lbs)) of work, and Component C to C3 without work. In case of Use 1 is considered to occur NI (100) times in the course of the design life of the estimated equipment of 25 years. For Team X, Use Case 2 causes Component B to move 3.05 meters (10 feet) against a force of 22.68 kg (50 pounds), and Component C • turn 20 radians to a torque of 22.68 kgf-m (50 ft.lbs.). Component A does not participate in the Use Case 2. In this way, each occurrence to Use Case 2 subjects Component B to C5 (226.8 kg-f (500 ft.lbs.) Of work, Component C to C6 (453.6 kg-f (1000 ft.lbs.) of work, and Component A to C4 without work.) Use Case 2 is considered to occur N2 (50) times in the course of 25 years of design life of the considered team., Use Case 3 causes Component A to rotate 15 radians to a torque of 90.7 kgf-m (200 ft.lbs), Component B moves 3.05 meters (10 feet) against a force of 90.7 kg (200 pounds), and Component C rotate 30 radians to a torque of 90.7 kgf-m (200 ft.lbs). In this way, each occurrence of Use Case 3 subjects Component A to C7 (1360.8 kgf-m (3,000 ft.lbs) of work, Component B to C8 (90.7 kgf-m (2,000 ft.lbs) of work and Component C to C9 (2,721.6 kgf-m (6,000 ft.lbs) of work) The Use Case 3 is considered to occur N3 (125) times during the lifetime of the considered equipment design of 25. As shown in Figure 5, the work by use case for each component is multiplies by the number of occurrences of that use case, these values are then added for each component, to reach the Theoretical Component Use Profile of the components, for example, with respect to Component A, the Theoretical Component Use Profile (TCUPA = Theoretical Component Usage Profile), the formula is (NI x Cl) + (N2 x C4) + (N3 x C7) = TCUPA, which results in a value of 215,456.4 kgf-m (475,000 ft.lbs) of work. In this way, under the conditions of the considered performance profile, Component A will need to be able to withstand the amount of wear / stress / strain corresponding to 215,456.4 kgf-m (475,000 ft.lbs) of work in order to have a profile of Component design that is equivalent to the considered design life of 25 years. Similarly, with respect to the Theoretical Component Use Profile considered in Component B (TCUPB), the formula is (NI x C2) + (N2 x C5) + (N3x C8) = TCUPB, which results in the value of 127,006 kgf- m (280,000 ft.lbs) of work. In this way, under the conditions of the considered performance profile, Component B will require to be able to withstand the amount of wear / stress / stress corresponding to 127,006 kgf-m (280,000 ft.lbs) of work, in order to have a profile of component design that is equivalent to the design life of the considered team of 25 years. Finally, with respect to the Use Profile of Component Theory of Component C (TCUPc), the formula is (NI x C3) + (N2 x C6) + (N3 x C9) = TCUPC, which results in a value of 362.874 kgf- m (800,000 ft.lbs) of work. In this way, under the conditions of the considered performance profile, the Component C will require to be able to withstand the amount of wear / stress / strain corresponding to 362,874 kgf-m (800,000 ft.lbs) of work, in order to have a component design profile that is equivalent to the design lifetime of the component. considered team of 25 years. Once the Theoretical Component Use Profiles are generated, they can be used in the selection of current components. A Component Theory Use Profile can also be used to initially schedule maintenance for that component. Sometimes available components will have nominal wear / stress / strain values or characteristics that correspond to the appropriate Theoretical Component Use Profile. In these circumstances, The Useful Life of Theoretical Component Under the Performance Profile will be equal to the useful life of the considered equipment design. This situation is reflected in Figure 5 for Component A. All Nominal Wear / Strain / Stress (WSSR) values (ie, 215,456 kgf-m (475,000 ft.lbs) of current Component A can be used if it is required, over the Useful Life of Selected Design (that is to say the useful life of equipment design considered of 25 years).

Sometimes it will not be possible to find a component that has WSSR or characteristics that correspond to the appropriate Theoretical Component Use Profile. The current selected component may have WSSR or characteristics that are significantly less than or greater than the appropriate Theoretical Component Use Profile. For example, in Figure 5, the current selected component for Component B was able to withstand the amount of wear / stress / strain corresponding to 177,808 kgf-m (392,000 ft.lbs) of work. In this way, the Useful Life of the Theoretical Component of Component B under the considered performance profile will be 35 years. . Also, since WSSR for Component B is 177,808 kgf-m (392,000 ft.lbs), all this capacity is available if required, over the Useful Life of Select Design (that is, the design life of the equipment considered to be 25 years). As a reverse example, in Figure 5, the current component selected for Component C was only able to withstand the amount of wear / stress / strain csponding to 181,437 kgf-m (400,000 ft.lbs) of work. In this way, the Useful Life of the Theoretical Component of Component C under the Considered Performance Profile will be 12.5 years. To meet the requirements of the Useful Life of Selected Design (that is, 25 years), two C Components must be used in succession. In this way, effective WSSR for both Components C is 362,874 kgf-m (800,000 ft.lbs), which is available if required over the Useful Design Select Life. Figure 6 illustrates an exemplary, but highly simplified, current performance profile broken down by component for equipment X over a current period of use. The current period of use for this example will be the first 2 years that the X equipment is in operation. To calculate the current performance profile, we obtain readings of force, torque and displacement of sensors associated with the individual components A, B and C (see Figures 1 and 2). As the X equipment performs an operation (ie case of use), the corresponding readings of force, torque and displacement are recorded. As indicated in Figure 6, Team X has performed NI (10) Case 1 Use operations, over the first two years of Team X's operating life. However, the values of force, torque and displacement for the current operations of Use Case 1, they have been different from those selected from the Considered Performance Profile. For example, Current Case 1 operations have caused Component A (for example, rotary arrow) to rotate 10 radians to a torque of 90.7 kgf-m (200 ft.lbs), and Component B (for example a hydraulic ram) ) move 1.52 meters (5 feet) against a force of 2.27 kg (5 pounds). Component C (for example, a pulley) does not participate in the Use Case 1. In this way, each occurrence of Use Case 1 subjects Component A to Cl (90.7 kgf-m (2,000 ft.lbs) of work, Component B to C2 (3.46 kgf-m (25 ft.lbs) of work and Component C to C3 (without) work. As shown in Figure 6, Team X has performed N2 (5) Case Operations of Use 2 over the first two years of the operational life of the X equipment. However, the values of force, torque and displacement for the current Use Case 2 operations have been different from those selected from the Performance Profile Considered. For example, the current Use Case 2 operations have caused Component B to move 1.52 meters (5 feet) against a force of 11.34 kg (25 pounds) and Component C to turn 20 radians to a torque of 22.8 kgf- m (50 ft.lbs) Component A does not participate in the Use Case 2. In this way, each occurrence of the Use Case 2 som Component B to C5 (56.7 kgf-m (125 ft.lbs)) of work, Component C to C6 (453.6 kgf-m (1000 ft.lbs)) of work, and Component A to C4 without work. As indicated in Figure 6, Team X has performed N3 (12) Use Case 3 operations over the first two years of the operational life of Team X. However, the values of force, torque and displacement for Current Case Use 3 operations have been different from those selected for the Considered Performance Profile. For example, the current Use Case 3 operations have caused Component A to rotate 25 radians to a torque of 181.4 kgf-m (400 ft.lbs), Component B to move 1.52 meters (5 ft) against a strength of 45.4 kg (100 pounds), and Component C rotate 30 radians to a torque of 90.7 kgf-m (200 ft.lbs). In this way, each occurrence of Use Case 3 subjects Component A to C7 (4536 kgf-m (10,000 ft.lbs)) of work, Component B to C8 (226.8 kgf-m (500 ft.lbs) of Work and Component C to C9 (2721.6 kgf-m (6,000 ft.lbs) of work.) As shown in Figure 6, the current work per Use Case for each Component is multiplied by the current number of occurrences of that Case of Use to date (that is, for this example, the current number of occurrences of that Use Case over the first two years that the X equipment is in operation). then they are added for each Component, to arrive at the Use of Current Component for this Component. For example, with respect to the Use for Current component of Component A (ACUA), the formula is (NI x Cl) + (N2 x C4) + (N3 xC7) = ACUA, which results in a value of 63503 kgf-m ( 140,000 ft.lbs) of work. As indicated in Figure 5, the WSSR of the current Component A used in the X equipment was equivalent to the Component A Theoretical Component Use Profile (215456 kgf-m (475,000 ft.lbs)). Dividing the Current Component Use (63,503 kgf-m (140,000 ft.lbs)) by 215,456 kgf-m (475,000 ft.'lbs)) shows that approximately 29.5 percent of the useful life of Component A has been used. This analysis approach is reflected in Figures 4e and 7. Figure 4e is a computer display screen showing the history of 500 lifting of a piece of equipment (eg, a crane) and the remaining life percent of the equipment. a Component (e.g. horizontal swing bearing) of the equipment 510. Figure 7 is a graphic display (like that indicated by 510 in Figure 4e) comparing graphically for each component, the Use of Current Component, versus WSSR for the current component used.

As indicated in Figure 4e, the lift history 500 of the crane is recorded in terms of percent load capacity 505 and swing angle 515. These terms are recorded according to a date stamp 520. This information is used by the process of the invention to adjust in a real-time manner, the Use Profile for the horizontal rotation bearing. As the usage profile is adjusted, the percent of the life of the exhausted horizontal bearing 525 can be displayed as shown in the graphic display 510. To compare the Current Use Regime for Component A with the Theoretical Use that would have occurred according to the Performance Profile considered in the first two years of operation for the X equipment, now reference is made to Figure 8. Figure 8 is a graphic representation of how the Current Component Use compares the Use Profile Considered as it applies to the WSSR for Component A. As indicated in Figure 6, the theoretical amount of the useful life of the component that will have been used in the first two years of operation, is calculated by the following formula: (TCUPA / Selected Design Life) x current years of use = Theoretical Life Employed in Two Years (TLU2y). For Component A, the TLU2y value is 17.236.5 kgf-m (38,000 ft.lbs) and is represented in the Performance Profile curve considered in Figure 8 by a circle. Since the Current Two-Year Component Use is 63,503 kgf-m (140,000 ft.lbs), which is represented in the Performance Profile curve of Figure 8 by a point, it can be understood that Component A wears out at a regime that is significantly higher than that predicted by the Considered Performance Profile. As reflected in Figure 8, the use of Current Component is equivalent to approximately 7.4 years of use to the Considered Performance Profile Regime. In this way, if the current use remains constant over the years, Component A will require replacement in significantly less than 25 years. As indicated in Figure 6, the formula for the Current Component Use of Component B (ACUB) is (NI x C2) + (N2 x C5) + (N3 x C8) = ACUB, which results in a value of 3,118.5 kgf -m (6875 ft.lbs) of work. As indicated in Figure 5, the WSSR of the current Component B used in the X equipment was 177,808 kgf-m (392,000 ft.lbs). This value exceeds the Theoretical Use Component Profile of Component B (127,005 kgf-m (280,000 ft. Lbs)). Consequently, the current WSSR of 177,808 kgf-m (392,000 ft.lbs) is used in the following calculation because this capacity is available, you require over all the useful life of the select design of 25 years. Dividing the Current Component Use 3,118.5 kgf-m (6,875 ft.lbs) by 177,808 kgf-m (392,000 ft.lbs) shows that approximately 1.75 percent of the useful life of Component B has been used. This is reflected in the Figure 7, which compares graphically for each Component the Use of Current Component versus WSSR for the current component used. To compare the Current Use Regime for the Component B with the Theoretical Regime of Use that would have occurred according to the Performance Profile Considered in the first two years of operation for the X equipment, now reference is made to Figure 9. Figure 9 is a graphic representation of how the Use of Current Component is compared to the Usage Profile Considered as it applies to the WSSR for Component B. As indicated in Figure 6, the theoretical amount of component life that would have been used in the first two years of operation as calculated by the following formula: (TCUPB / Selected Design Life) x current years of use = Theoretical Life Employed in Two Years (TLU2y). For Component B, the TLU2y value is 10,160.5 kgf-m (22,400 ft. Lbs) and is represented in the Performance Profile curve considered in Figure 9 like a circle. Since the Current Component Use of two years is 3, 118.5 kgf-m (6,875 ft.lbs), which is represented in the Performance Profile curve of Figure 9 by a point, it can be understood that Component B wears out at a rate that is significantly less than that predicted by the Performance Profile Considered. As reflected in Figure 9, the Current Component Use is equivalent to approximately 0.6 year of use to the Considered Performance Profile Regime. In this way, if the current use remains constant over the years, Component B will last significantly more than 25 years. Also, even if the use of the current component were equivalent to the Usage Profile Considered, as illustrated in Figure 9, Component B would approximately have 50,802 kgf-m (112,000 ft.lbs) of remaining capacity, at the end of the 25-day period. years, because Current Component B had a WSSR of 177,808 kgf-m (392,000 ft.lbs) while the Theoretical Use Profile for Component B only required 127,005 kgf-m (280,000 ft.lbs). As indicated in Figure 6, the formula for the Current Component Use of Component C (ACUC) is (NI x C3) + (N2 x C6) + (N3 x C9) = ACUC, which results in a value of 34.926.6 kgf-m (77,000 ft.lbs) of work. As indicated in Figure 5, the WSSR of Component C Current used in the X equipment was 181,437 kgf-m (400,000 ft.lbs). This value is less than the Theoretical Component Use Profile of Component B (362,874 kgf-m (800,000 ft. Lbs)). Consequently, two Components C must be used in succession to achieve the selected design life of 25 years. Adding the WSSRs of the first and second Component C results in an effective current WSSR of 362,874 kgf-m (800,000 ft.lbs). This effective WSSR is used in the following calculation because this capability is available, if required, over the selected design life of 25 years. Dividing Current Component Use (34,926.6 kgf-m (77,000 ft.lbs)) by 362,874 kgf-m (800,000 ft.lbs) shows that approximately 10 percent of the useful life of the first and second C components has been used. This is reflected in Figure 7, which compares graphically for each Component, the use of Current Component versus WSSR for the Current Component used. To compare the Current Use Speed for Component C with the Velocity or Theoretical Usage Regime that would have occurred according to the Profile of 'Performance Considered in the first two years of operation for equipment X, reference is now made to Figure 10. Figure 10 is a graphic representation of how the Use of Current Component is compared to the Usage Profile Considered as it applies to the WSSR for Component C. As indicated in Figure 6, the theoretical amount of component life that would have been used in the first two years of operation, is calculated by the following formula: (TCUPc / Selected Design Life) x current years of use = Theoretical Life, Employed in Two.

(TLU2y). For Component C, the TLU2y value is 29,029.9 kgf-m (64,000 ft.lbs) and is represented in the Performance Profile curve considered in Figure 10 by a circle. Since the Current Two-Year Component Use is 34,926.6 kgf-m (77,000 ft.lbs), which is plotted on the Performance Profile curve of Figure 10 by a point, it can be understood that Component C wears out at a regime superior to that predicted by the Considered Performance Profile. As reflected in Figure 10, the Current Component Use is equivalent to approximately 2.4 years of use to the Considered Performance Profile Regime. In this way, if the current use remains constant over the years, more than two C Components will be required to last for 25 years. In sum, the analysis of the previous performance profile, which uses theoretical operating conditions or considered and data available in component life under these operating conditions, is used to select components and perform a component replacement and initial theoretical maintenance plan. The plan is placed in the system and as current operating conditions are detected and reported, the performance profile models used for the initial design and the component replacement plan and initial theoretical maintenance are used to update the plan and to recognize conditions that require component maintenance. The update can be performed either in real time as each data set of operating conditions is reported or periodically, after the data has been collected for a specified interval. Figure 11 shows another embodiment of the present invention. It is similar to the modality of Figure 1 in certain aspects but differs in others. So that nothing is missing, the modality of Figure 11 will be fully explained, including features that are similar to the modality of Figure 1. In Figure 11, the area 60 denotes the elements that are arranged on-site, ie on or near the equipment that is being monitored. Area 61 denotes the client computer site, for example the headquarters of the company that uses the equipment. The area 62 denotes the computer site of the service provider. The service provider may be the same company that has supplied the computer system and equipment. In the on-site area 60 is the equipment that is inspected or monitored 63, which in this example is a superior control, in a further example, a slurry pump, but can be any type of equipment that can be supervised. Furthermore, in area 60 there is a computer 64 and two user interfaces 65 and 66. The user interface 65 contains documentation in the equipment 63. This may be technical specifications, manuals, certificates, etc. The user interface 66 provides on-site supervision of the equipment 63 and allows the operator to monitor the performance and status of the associated equipment and sensors both current and historical. Interfaces 65 and 66 are in communication with the on-site computer 64 through a local or on-site area network, denoted by 69. The user interfaces 65 and 66 can be accessed and viewed in any display connected to the network. In the client computer site 61, there is also a documentation user interface 67 and a monitor interface 68. These give access to essentially the same information as the interfaces 65 and 66. Interfaces 67 and 68 are in communication with the on-site computer 64 via a network 70, which may be a corporate network, the Internet or a dedicated link. In the client computer site 61 there is also a user interface 61 for performing supervision which will be explained further below. In the area of service provider 62 is a server 73 (one or more may be present, depending on the need). This server 73 is linked to the on-site computer 64 via the Internet, dedicated link 74 or other communication route. The server 73 collects performance (use) data on the equipment 63 from the on-site computer 64. The server 73 also collects performance data on other similar pieces of equipment that may be present at other sites (not shown). Based on these collected data, the server 73 prepares information aggregated and analyzed in the specific type of equipment. This information is made available to the client through the performance monitoring user interface 71 through a link 75. The link 75 can be the Internet, a dedicated link or another communication route. The communication through the links 70, 74 and 75 can be through cable, any system of wireless communication, satellite or other communication route. If the Internet is used as the link, the only requirement is that the on-site computer, the client site and the service provider site can connect to the Internet. In the equipment 63 various sensors 76 are located. These perform measurements in the equipment 63 and present them to the on-site computer 64. Preferably, the on-site computer 64 is a dedicated computer for the equipment 63 and may be physically connected to team 63, so as to follow the team if the team moves to another site. Consequently, the on-site computer 64 may also be referred to as a computer equipment. The computer 64 is configured to monitor more than one item of equipment, preferably several different types completely. Figures 12 and 13 show a more detailed presentation of the monitoring system according to the embodiment of Figure 11. In Figure 12, some of the elements have been removed in comparison with Figure 13 and vice versa, to facilitate the explanation of some of the aspects Figure 12 shows how a new on-site computer 64 and therefore a new piece of equipment 63 is coupled to the monitoring system and the configuration of the computer on site. The service provider server 73 here is divided into a number of elements 77-85. These will be explained below. On the service provider site there is also a performance monitoring component 86, which is a user interface similar to the supervisor or performance monitor 71 on the client's site. There is also an analytical performance monitoring component 87, which is another user interface that will be explained in more detail below. Finally, there is the graphical user interface database (GUI = Graphic User Interphase) 88. In addition there may be an option as a business-to-business server 89 present in the service provider, which serves as an interface to others computer systems to client. The management database GUI 88 provides access to a database containing detailed information on all equipment that may be connected to the monitoring system, including user interface information. During configuration of a management database component 81 it receives information of the specific type of equipment to be connected. The base administration component 81 then defines how the raw measurements will be treated in such a way that the presentation of the values are convenient for further processing and analysis and for presentation at the user interface. These definitions can be, for example the extension of time between each storage of measurements, smoothing of measurements, etc. The administration database 81 also contains the correspondence between a value detected in equipment and the parameter to which the value belongs. The administration database 81 provides these definitions to a configuration file generator 79, a content server 78 and a local user graphical interface generator 77. The configuration file generator 79 generates a configuration file for the computer on-site 64 and the generator of the local graphic user interface 77 generates a local interface. All this information is fed through the content server and transmitted to the on-site computer 64. Each time an update is made, a new configuration file and / or a new graphical user interface is generated and transferred to the computer. on-site in the manner described above. This provides a single point for on-site computer configuration. The configuration can be done directly between the service provider and the computer on site. The initial configuration contains the following elements: select equipment for supervision select type of computer for data acquisition select and configure signals and parameters for data recording in the on-site computer select and configure calculations, filters and frequency of registration for registration of data in the on-site computer - select and configure communication path edit corporate knowledge to be applied in the central server - define and configure company, plant and user accounts. Based on the feed, the administration database 81 will be the source from which it will be produced: - an XML configuration file, to automatically configure all aspects of data logging on the on-site computer by the configuration server 79 an XML configuration file, to automatically configure the monitoring service local through the interface 66 by the local GUI generator 77 an XML configuration file, to automatically configure the content of the local monitor by the content server 68 configuration and automatic layout of the database tables in the cubes 84 automatic configuration of the handler of the recording stream 80. The transmission of the configuration file and the configuration or layout of the graphical user interface will be conveniently carried out over the Internet, but it is also possible to do so by uploading a CD-ROM or other types of media. data storage. Figure 14 shows an overview of the on-site computer 64. The configuration file, etc., is received through the network interface 601 and transferred through an input / output device 602 and final storage and a configuration database 607. The configuration handler when updating its database 607 updates all configurable conformance parameters (for example, parameters in elements 96, 97, 98 in Figure 14). With reference to Figure 13, the flow of data during the supervision of the equipment will be explained.

In addition to the elements shown in Figure 12, Figure 13 also shows an exit waiting list 92 and an entry waiting list 90 as well as a file transfer protocol server (FTP = file transfer protocol) 91 and a network interface 93. The measurement data of the computer in -site 64 is received through the network interface 93 by the FTP server 91. The data is placed in the waiting list of input 90. The handler of streams of register 80 is configured to obtain data from the waiting list of entry 90 at regular intervals. In the register current handler 80, the data is arranged such that this is presented in an order that will allow temporary storage in the measurement data base 82. The function of the record current handler 80 will be explained in more detail then. A copy of the data transmitted to the measurement database 82 is also stored in the volume store 85. The purpose of this is, first as a backup and second to allow additional processing of data at a later stage, if new methods are developed to perform equipment evaluation calculations. The measurement data is post-processed in the post-processor 83, which involves calculations of certain calculated values (some examples of these are will present below). After these selected measurement data and calculated data will be stored in the database of cubes 84. The dysfunction between measurement data and calculated data is somewhat arbitrary, because the calculations can occur in the equipment or in more central processors. Measurement data come from the on - site computer (equipment) and are referred to as raw, but may be the result of calculations, filtering or other processing that occurs on the on - site computer. This processing can also be done by smart sensors or sensors. Calculated data is what results after the measurement data is received and the particular algorithms are applied that produce the desired calculated data from measurement data, useful to determine how the wear of the components has progressed. The performance monitor 86 and the analytical performance monitor 87 obtain data partially from the measurement database 82 (for lists and tabular reports) and partially from the database of cubes 84 (for trend analysis, historical overview, etc.). .). The purpose of the performance monitor 86 is to perform and present simple analyzes to the people or persons who supervise the team, while the analytical monitor 87 presents more sophisticated analyzes or freeform analysis. Simple analyzes can be presented to an operator that requires quick decisions, while more sophisticated analyzes can be presented to a person who makes more strategic decisions. It is also conceived to use an interface only for both simple and sophisticated analysis. The acquisition of the measurement data will now be explained with reference to Figure 14, which schematically shows the elements and basic components of the on-site computer 64. The signals of the sensors 76 (Figure 11) are coupled to the input interface / output 94. Each of the sensors has its own channel 95 and the measurement data is stored in a temporary storage 97, after adjusting in the scale 96 (to make the value consistent with the specified measurement units). A register module 98 obtains data from temporary storage. The registration module 98 transfers this data via an access buffer 99 to a transfer storage 600. To do this correctly, the registration module 98 has been updated from the configuration manager 604, how to handle the different databases. From transfer storage, the data is transmitted to a network interface 601 via an FTP input / output device 602, with the aid of a transfer handler 603. This data is subsequently received at the network interface 93 at the service provider (FIG.13). If a certain measurement received at 94 needs to be handled differently, the applicable configuration file will be updated and sent to storage with the configuration handler 604 in the manner described above. The configuration handler 604 will inform the registration module 98 how to handle the measurement, such that after the update the server 73 will receive the measurement information as required. The update may for example be to record a certain measurement at shorter or longer intervals. Since the configuration file is stored on-site, the system does not depend on being online so that the measurements are handled in the desired way. A local registry storage 605 also exists. This allows local storage of data in the event of an interruption in the link between the on-site computer 64 and the server 73. In some cases, it may prove difficult to obtain an online connection between the on-site computer 74 and the server 73. In this case, the data can be transferred regularly to a storage medium, for example a detachable memory that can be connected to a computer through a USB port (USB memory). The storage medium can even be shipped to the service provider by ordinary mail or another physical shipment. The on-site computer 64 also comprises an event module 606 that detects faults in the measuring equipment (sensors, sensor wiring, etc.) and measurements that are outside the normal range of the equipment. These events are also transferred to the transfer storage 600 and thus to the server 73. The data handling on the service provider server 73 will be explained more fully in Figure 15. The raw data this is in the list of wait for entry 90 (Figure 13) are represented by the reference number 620. The record stream handler 80 (Figure 13) will analyze syntactically the raw data 620 as denoted by the reference number 621. The syntactic analysis involves particularly identify the individual values in a data stream and assign the correct identification to the values. After this manager of register stream 80 fills "inherited" values, denoted by the reference number 622. In order to reduce the amount of data that has to be transferred from the computer in -place 64 to the server 73, the computer in - site 64 will not send values if a measured value remains unchanged, for example without a measured value remains unchanged, for example if the upper command 63 raises a load, the value of the first measurement of the weight of the load , It will be sent. (This can be done with a filter that causes negligible changes in signals to be classified as unchanged). After this, no additional values will be sent until the weight of the load changes, for example when the load reaches the drilling floor. In 622, the "missing values" are filled, so that the same value is repeated at regular intervals by the time the load was constant. This reduces the data stream and therefore the bandwidth required substantially. After this, the prepared data is transferred to the post-processor • 83, which calculates values based on measured values, denoted by the reference number 623. Examples of calculated values will be given below. Searches in the administration databases determine the storage of values in the measurement database 81 and its post-processing method in the multidimensional information cubes. Post-processor 83 may also identify out-of-limit values, denoted by reference number 54. Out-of-range values may be for example excessive loading, excess operating hours, pressures or out-of-range temperatures, etc., which they indicate problem or excessive consumption of a component's life. After post-processing the measurements, values and identification are supplied in a database consisting of a number of multidimensional "cubes". The multidimensional cubes have managed to increase popularity as a means to store a large amount of data that must be easily accessible. Multidimensional cubes can be viewed as multidimensional arrays where each parameter is cited on one dimension, one dimension for each parameter. This way of storing the data provides the opportunity to quickly display tables and graphs showing the relationship between any of the parameters, even if the amount of data is very large. Data in multidimensional cubes have certain main characteristics: the data is pre-aggregated to obtain high performance in searches and recoveries, or in another way to facilitate extraction of data by tools such as wall networks, - the data is arranged on predefined axes to allow and simplify XY diagrams (for example see the distribution of temperatures over different pressures), the data is optimized for searches through the large number of similar types of equipment. In addition, multidimensional cubes allow storage of all data collected over the entire lifetime for the large number of units of equipment. As a result, this allows a new way to consolidate useful life data as a platform for empirical research and data extraction to be stored back to design processes or service processes. Information regarding how and when the maintenance was executed is stored in the same database and correlated in time. The multidimensional cubes are in this particular example three separate cubes. The first, denoted by the reference number 625, contains all the measurements, including most of the calculated parameters. In second, denoted by the number of reference 626 contains two parameters calculated critical to the monitoring of the useful life, such as hours of operation of heavy load, to supervise the operation of the equipment. The third cube, denoted by the reference number 627, contains the measurements outside the limit. If there are no occurrences of out-of-limit values, this cube is empty. The supervision of the equipment will now be explained in more detail, with reference to the examples of parameters and diagrams. Figure 16 shows a table of typical parameters to be measured and recorded for a piece of equipment, in this example a mud pump, as well as the measurement units that are applied for each parameter. The table shows the various pressures, flow temperatures, hours of operation, fault codes (to be applied), etc. Figure 17 shows in the upper part some constants that are used in the calculation of calculated parameters and in the lower part a table of typical calculated parameters for a mud pump. The first column shows the constant or parameter text, the second column shows the constant or parameter name in the computer system, the third column shows the unit for the parameter constant and the fourth column shows the value of the constant or the formula used to calculate the parameter. In the upper right corner there is a frame that cites definitions of some variables, ie measured parameters that are received as raw data measurement feeds for the calculated wear parameters. One of the most important calculated wear parameters for certain types of equipment are the hours of operation with accumulated weight load, which is cited at the bottom of Figure 17. These are calculated according to the following formula: T_hrw + f * w * delta-t / 3600 where delta-t / 3600 is the time in insurance since the last time record of operation with weight of accumulated load in second divided by seconds per hour. w is a load factor according to the following formula: (2 * p_disch / p_rated)? e * t (2 * S_pump / S_rated), Where p_dish is the current discharge pressure of the measured pump, p_rated is a constant which denotes the nominal pressure, which has a value of 517.1 bar, p_pump the speed of the current pump and s_rated is a constant that denotes the speed of the nominal pump, which has the value 212 pulses per minute. r "is a binary factor that has a value 0 or 1, according to the following formula: if (S_pump < 0.02 * S_rated; 0; 1 Where S_pump is the pump speed, and S_rated is the speed of the nominal pump, as given above, consequently, r is zero if the current pump speed is less than 2% of 212 pulses per minute and one and the current pump speed is equal to or greater than this. of accumulated load weight operation, previously recorded All other calculated factors are also calculated based on measured parameters or constants specified in server 73. Figure 18 shows a table containing the limits for some critical parameters used in the stage 624 in Figure 15. The first column shows the ID number for the limit, the second column shows the parameter limit name, the third column shows the logical operator to be used and the fourth column shows the limit value. If any of these parameters falls outside the established limit, an out-of-limit value will be fed into the out-of-limit cube 627.

For certain types of equipment it is of vital significance to have two-dimensional limit values. This is the case, for example, with a crane. The crane may have a different lifting capacity, depending on the angular position of davit or boom for horizontal as well as vertical connection. In this case, the performance limits will be different depending on the position of the davit. The crane can have a high lifting capacity on a certain sector in the horizontal plane. In another sector in the horizontal plane, it can be prohibitive to use the crane only with the hook empty (only for transit) or with a smaller load. The load limit in the same sector can also depend on the angle of the davit. Consequently, if the davit goes to a sector with an excessive load, an out-of-limit event can be detected, based on the two-dimensional limit values. The operator can obtain a message that tells him how to return within one of the limits where the detected value is within his control or that the operation must cease; for example, he is instructed if he climbs the davit at a steeper angle, he can pass through the sector with this load or it is not possible to pass this sector.

The two-dimensional performance limits can be implemented in the system as a two-dimensional table, such as Figure 26 which is convenient for storing in multidimensional cubes. For some equipment of more than two dimensions can be used to define the design envelope for a safe or appropriate operation. In this way, two-dimensional performance limits can be extended to N-dimensional performance limits. Figure 19 shows a screen print that contains a table with measurements made on a mud pump. The first column 1902 shows the year, the second column 1904 shows the measured parameters, with a description of the limit in some of the parameters (this corresponds to some of the limits shown in Figure 18). The third and fourth columns 1906, 1908 show the number of measurements taken for each of the parameters. Figure 20 shows a screen print as it would appear on a GUI 66, 68 or on server 73 that contains a diagram showing the 2002 flow from a mud pump, with the flow plotted against time. The 2004 time extension in this case is the first 24 days of the month. As is evident from the graph, the pump has been operating every day except one.

Figure 21 shows a screen print containing a diagram showing the distribution of discharge pressure in a mud pump plotted against the rotational speed of the pump. The pressure has been divided into different classes, each covering an area of 50 MPa. This is plotted on the 628 axis. The rotational speed has also been divided into different classes, each one covering an extension of 50 RPM, this is traced on the axis 629. The vertical axis 630 shows the number of hours of operation within each pressure class and revolution speed class. As evident from the graph, the pump has been operating for many hours with moderate pressure and high speed, as denoted by the reference number 631. As shown by bars 632 and 633, the pump has also been operating for some time with high pressure and at moderate speed. However, for a very short time the pump has operated with low speed and high pressure. By using this technique and also including data from a plurality of pumps, it is possible to realize an average utilization profile of the pump type. Figure 22 shows an example of a typical performance diagram for a mud pump, showing the distribution of pump use. As shown in the diagram, the pump (or type of pump, if a plurality 'is It has been supervised) 40% of the time at pressure and moderate pump expenditure is used. With the profile of use as a base, it is possible to predict the wear of critical components in the pump. Some components wear out to a greater extent in high pressure environments and some wear out more in high speed environments. Other components are more susceptible to high temperature and others are again more susceptible to high stress or strain. By evaluating not only the hours of operation but also taking into account the conditions of the equipment in which you have worked, it is possible to predict more precisely when the life span of the critical components is at a specific time. For example, the load can be taken into account, so that for example for a pump, the hours of operation are multiplied by the average flow in which the pump has been supplied. Another example is to track the total time that the temperature at a certain pump site has exceeded a certain limit, the limit, for example, is based on a temperature other than a seal material that is susceptible to damage. Any combination of weighted load parameters can be calculated in the system of the present invention. When the weighted load parameter exceeds a set limit, a warning may be sent to the operator, informing you of the fact that a component is approaching the end of its useful life. Preferably, the warning is sent well in advance of the end of the expected service life, so that there is sufficient time to plan equipment maintenance, including replacement of components. In addition to the warning informing the operator of a maintenance to come, it is also feasible to send an alarm if a parameter exceeds a critical limit, indicating that a failure can occur at any time, or that the equipment has to operate at a reduced performance until that the maintenance has been carried out. The warning and the alarm are sent via the administration database 81 and the content server 78. It can be sent as a message in the user interfaces 66, 68, 86 and 87. Furthermore, it can be sent as a message on any medium to client interfaces. These can be email, SMS, radio-locators, etc. Through the B2B server, the system can also send the information digitally to a client management system. When maintenance has been performed, the parameters that form the basis for the warning or alarm are set to an initial value, such that that can start monitoring the extension of useful life, from the starting point again. It is also possible to perform trend analysis based on experience data. The experience data is the result of an extensive failure analysis. that have occurred in similar equipment previously. If, for example, a certain bearing has failed and resulted in a major decomposition and possibly also damage to other parts of the equipment or other pieces of equipment, the conditions present at the time before the failure can be analyzed. Then it is possible to see if any of the calculated values or values have undergone a change during the time before the failure. The extension of time, certain minutes or a few minutes before the failure is first investigated, but the extension of time within hours or even days or weeks before the failure, will also be taken into account. The results are then compared with results from other similar faults to find if there is something in common among all or at least some of the faults. If this parameter correlation is probably connected to the fault, a procedure can be implemented on the computer that controls the pump based on sensor reading (the on-site computer is not involved in the process, but the lessons learned are implemented in the pump control computer) at regular intervals (the interval depends on how quickly the failure can occur) calculates the correlation between the above factors. If a condition occurs that is similar to the conditions that were present at the time prior to the failure in the previous occurrences, the computer can stop the equipment or, if time permits, carry out a controlled shutdown of the system of which it is part of the pump. . 0 An example of this is illustrated in Figure 25.

This graph shows a trace of the torque of the two engines A and B that operate the pump for a period of time on January 21, 2004, starting at 01:00. At 02:15 a pump failure occurred. The reason that was later found was that suddenly a .bearing. As is evident from the graph, the torque of both engine A and B had a noticeable increase in 02:13, increasing with a large gradient to failure. When the failure occurred, this had harmful consequences to the equipment connected to the pump. This increased torque could not be explained by external factors, such as the increased pump cost or higher viscosity of the pumped fluid. The torque was still within the normal range that the engines were able to supply and the pump was able to receive.

According to the regular out-of-limit measurements, an out-of-limit event would not occur, unless it was too late to avoid critical failure. This example shows an incident only. However, the relationship between the increased torque and the failure is probably enough to implement a check for a similar condition in this type of equipment. The condition for this situation to be considered present may be that if the torque is increased with a steep gradient, for example over 200 Nm / s, for more than 20 seconds and there is no increase in feed or viscosity or other factors that naturally influence Torque will trigger an alarm or the computer that operates the pump will perform a controlled shutdown. A nearby fault can also be indicated by conditions that develop more slowly in a couple of minutes. For example experience may have shown that if a seal has been subjected to a temperature over a certain value or a period of time, this will increase the risk of leakage substantially. However, the leak will not occur until the pressure is above a certain value. If this situation occurs, the computer that operates the equipment will be informed that it operates the equipment in such a way that a pressure limit is not exceeded. At the same time, the operator will receive a message informing him of the situation. If the rate-of-change for a temperature parameter is of importance in predicting a problem, the algorithm module (for example, in post-processor 83) can calculate the rate-change. The performance limit can have "an entry that defines the limit for when this speed-of-change is outside of its normal operating environment." By implementing algorithms that can foresee a failure based on previous experience, the chances of a critical failure can These algorithms can be installed in the management database 81 in a manner very similar to the initial configuration of the on-site computer.Weighted load operation hours can be used as a basis for the total estimated useful life for a Part of wear, and therefore are a typical performance limit.The limit can be adjusted as wide as more extensive experience is achieved.When verifying the cumulative weighted load operating hours against this limit, it is possible to forecast the useful life remaining under conditions and operations similar, proposed inspection intervals, proposed order of spare parts, etc. The theoretical model for this preference descent analysis is managed as tables and records in a database, with a network-based user interface. An internal product champion can be authorized to maintain the model, and can grow incrementally as new knowledge of the equipment is achieved. For example, data extraction can be used to identify patterns of data that can be used to predict failure of different aspects of a single component, based on different operating conditions experienced by different components. Neural networks can be used to identify the patterns and also detect their reoccurrence. In addition to the monitoring of the useful life, trend analysis and out-of-limit supervision, it is also possible to monitor the equipment in real time. Figure 23 shows a screen drain that contains a diagram of the hours of operation of a mud pump. Figure 634 shows the hours of operation as such for each day in the year 2004 until May 13, which is the date of screen emptying. Graph 635 shows the load-weighted operating hours for the same period. It is possible to select a narrower time extension, so that the pump can be monitored minute by minute. This is shown in a graphical display format as in Figure 24, where incidentally, the pump has been at rest. If the pump has been in operation, a graph will show it indicating the percent use of the pump against time. This exhibition can be updated continuously in real time. The embodiment of the invention described in connection with Figures 11 and following may provide one or more of the following benefits: A computer-on-site that functions as a "local" network server. In addition to the sensor data link 304, 404, described in Figure 1, in this embodiment of Figure 11, there is a network server incorporated in the same computer processor or in a processor adjacent to the sensor data link. This will be able to: Present snapshots and trends of values in real time (no calculation, comparison with performance load profiles, etc. have been made to this stage).

Present documents and drawings stored on the server of the local network (if not in contact with the computer network). On-site data can be directly monitored without having to go through the network. Multidimensional cubes, using OLAP and MDX as a storage method, facilitate the search and recovery of large amounts of data needed to implement the service. The general profile and use of multidimensional cubes is well known to a programmer with dexterity. A person with skill in multidimensional cubes will easily understand how to implement the functionality described above in multidimensional cubes. Another service that can be implemented is the publication of news and important security information from the service provider back to the local monitors (operator and company personnel). If there is, for example, a new security bulletin for a specific type of machine will be published, it will be "sent" to the type of machine in the administration database. The head of the publication will be taken to the exit waiting list. The next time the on-site computer connects to the system to provide data (if it is not constantly online), it will also check the exit waiting list, and transfer the header to the on-site computer. On the local on-site monitor, it will appear as a header in a separate window of the user interface. When any user chooses the header, you can confirm that you want the entire article downloaded the next time or immediately. The on-site computer will then reconnect by placing a request through the wait-list entry to the configuration file generator. This process in turn will invoke the content server to send the entire article to the waiting list of output. This will reduce the transfer of data to the amount required by the operator or other personnel in the company. The system can be designed both to propose and report maintenance actions. You can post maintenance actions to the computer on the site in the same way you publish news and bulletins. The source of this information may not be maintenance algorithms that take into consideration weighted use of the machine's current load, that is, it may propose an action for inspection of a bearing every 14 days if the load applied to the machine is dominated by a component of strong speed, or adjust the same interval to 2 months, if the applied load is dominated by pressure components. As for the bulletin, the operator opens a maintenance head. You can also check a box and fill in the status for the action, and send them back to the system. In the following connection, the service report is transmitted to the database where it is correlated with all the other data. Each on-site computer can transport documentation for the machine it supervises. The version as it was built of the documentation can be loaded to the installation. During operation, the service provider can publish new or updated documents through the administration database. Like for news and bulletins, it is possible to send only the header first. Operators can verify or confirm that they want the new documentation loaded in the next re-connection. Although the present invention has been described with reference to preferred embodiments, persons skilled in the art will recognize that changes in form and detail can be made without departing from the spirit and scope of the invention.

Claims (47)

1. CLAIMS 1. A system for administering replacement components for equipment having a plurality of components, each with a limited useful life, characterized in that it comprises: a computer with at least one processor; a computer program module for defining a performance profile comprising a plurality of use cases for the equipment, each use case involving two or more of the plurality of components and specific operating conditions that are considered to be experienced by the components involved during the execution of each of the use cases; a computer program module to determine a theoretical lifetime for each component involved in a performance profile, the theoretical lifetime is based on wear / voltage / stress parameters of components that are considered to occur under the specified operating conditions; sensors to determine and monitor the occurrence of equipment operation that corresponds to a use case and make measurements of the current operating conditions that are experienced in the operation; a memory for storing the measurements of the current operating conditions for the plurality of components; and a computer program module to calculate a theoretical lifetime adjusted for a component after it has experienced one or more operations, to: in response to measurements of current operating conditions, calculate one or more wear / stress / stress parameters calculated for each operation and accumulate these calculated parameters for this component; and based on a comparison of the accumulated wear / stress / stress parameters, calculated from the current operating conditions to accumulated wear / stress / stress parameters that are considered to occur under the operating conditions specified in the determination of a service life Theoretical, determine the quantities of the adjusted theoretical useful life consumed in one or more operations.
2. 2. The system according to claim 1, characterized in that the measurements of the current operating conditions comprise load measurements and the duration of a load.
3. 3. The system according to claim 1, characterized in that the performance profile considers a specific number of operations and the system tracks the number of operations in which a replacement component is involved.
4. 4. The system according to claim 1, characterized in that the sensors are configured to provide measurements of conditions of current operation, to calculate a wear / tension / stress parameter that corresponds to the work done by a component.
5. 5. The system according to claim 1, characterized in that it also comprises a computer program module that responds to the theoretical useful life adjusted to indicate a need for immediate replacement, when the amount of theoretical consumed life is within a critical interval of the adjusted theoretical lifetime.
6. The system according to claim 1, characterized in that it further comprises a computer program module that responds to the theoretical useful life adjusted to signal a need for scheduled replacement when the amount of theoretical consumed life is within a range of replacement of the adjusted theoretical lifetime.
7. The system according to claim 1, characterized in that the equipment is remote from the computer program module to calculate a theoretical useful life adjusted for a component and the sensors are resident in the equipment.
8. 8. The system according to claim 7, characterized in that the sensors resident in the equipment are configured by a module of computer program that operates on a remote computer processor, to produce selected measurements of current operating conditions.
9. 9. The system according to claim 7, characterized in that the sensors resident in the equipment communicate with a computer associated with the equipment.
10. 10. The system according to claim 1, characterized in that it also comprises a supervisor computer module for calculating the theoretical useful life adjusted for a component, in response to a real-time request received by the supervisor computer module or in response to a periodic analysis initiated by the supervisor module.
11. 11. A computer-based method for administering replacement components for equipment having a plurality of components, each with a limited useful life, characterized in that it comprises: controlling a computer program module, to define a performance profile comprising a plurality of use cases for the equipment, each use case involves two or more of the plurality of components and specified operating conditions that are considered to be experienced by the components involved during the execution of each of the use cases; controlling a computer program module to determine a theoretical lifetime for each component involved in a performance profile; the theoretical lifetime is based on wear / stress / strain parameters of components that are considered to occur under specified operating conditions; receive data from sensors to determine and monitor the occurrence of equipment operation corresponding to a use case and to make measurements of current operating conditions experienced in the operation; storing in a memory the measurements of current operating conditions for the plurality of components; and controlling a computer program module to calculate a theoretical lifetime adjusted for a component after it has undergone one or more operations, by: in response to measurements of current operating conditions, calculating one or more wear / stress parameters / voltage calculated for each operation and accumulate these parameters calculated for this component; and based on a comparison of the wear / stress / strain parameters calculated and accumulated from current operating conditions with accumulated wear / stress / strain parameters that are considered to occur under specified operating conditions in the determination of a service life theoretical, determine the amount of theoretical adjusted useful life, which is consumed in the one or more operations.
12. 12. The method according to claim 11, characterized in that the step to perform the measurements of current operating conditions comprises carrying out load measurements and the duration of a load.
13. The method according to claim 11, characterized in that the step of controlling a computer program module to define a performance profile comprises controlling a module that considers a specified number of operations and the step of controlling a program module. of computer to calculate an adjusted theoretical lifetime that comprises tracking the number of operations where a replacement component is involved.
14. The method according to claim 11, characterized in that the step of receiving data from the sensors comprises receiving sensor data configured to provide measurements of current operating conditions to calculate a wear / stress / strain parameter corresponding to the work performed for one component.
15. 15. The method according to claim 11, further comprising controlling a computer program module in response to the adjusted theoretical lifetime to signal an immediate replacement need, when the amount of theoretical lifetime consumed is within a critical range. of the adjusted theoretical lifespan.
16. 16. The method according to claim 11, characterized in that it further comprises controlling a computer program module in response to the adjusted theoretical lifespan, to signal a need for scheduled replacement, when the amount of theoretical lifetime consumed is within of a replacement interval of the adjusted theoretical service life.
17. 17. The method according to claim 11, characterized in that the step of receiving data from the sensors comprises receiving data from sensors resident in remotely located computer of the computer program module, to calculate a theoretical lifetime adjusted for a component.
18. 18. The method according to claim 17, characterized in that it further comprises configuring the sensors resident in the remote equipment by the use of a computer program module that operates on a remote monitoring server of the equipment.
19. 19. The method according to claim 17, characterized in that the step of receiving data from the sensors comprises receiving data from sensors that communicate with a computer associated with the equipment.
20. 20. The method according to claim 11, characterized in that it also comprises controlling a supervising computer module to calculate a theoretical N-life adjusted for a component, in response to a real-time request that is received by the supervising computer module or in response to a periodic analysis initiated by a supervisor module.
21. 21. A method for monitoring the condition of a remote equipment that has at least one wear component, the at least wear component has a service life that depends on the operating conditions experienced by the at least wear component, characterized in that it comprises : define two or more measurements of raw data that vary according to whether the equipment is used under different operating conditions; control a software component, to receive data from sensors that cooperate with the equipment to detect operating conditions and produce the two or more measurements of raw data and to transmit the data sensor to a central monitoring processor; controlling a software component in the central monitoring processor for syntactic analysis of the sensor data in the two or more measurements of raw data for post-processing; controlling the postprocessing software component to calculate from the two or more measurements of raw data, at least one wear parameter calculated for the wear component as a minimum, the value of the wear parameter is weighted by values of the two or more measurements of raw data used in its calculation; controlling a software component to collect a time sequence of the values of the wear parameter calculated at least for the wear component as a minimum and from the time sequence of values by calculating an accumulated wear value on the use of the wear component. wear at least; and controlling a software component to evaluate the accumulated wear value against a maximum wear coefficient for the wear component as a minimum and in response to this provide a warning of life-time operations.
22. 22. The method according to claim 21, characterized in that the step of evaluating the accumulated wear value and providing a Notice of operations, includes providing a notice to the operator, to change the operating conditions of the equipment to conserve the useful life.
23. 23. The method according to claim 21, characterized in that the step of evaluating the accumulated wear value and providing a notice of operations, comprises providing a supervision warning for emergency maintenance.
24. 24. The method according to claim 21, characterized in that the step of evaluating the accumulated wear value and providing a notice of operations, comprises providing a supervision warning for programmed replacement in a time, in response to the accumulated wear value and The remaining useful life.
25. 25. The method according to claim 21, further comprising controlling a software component to collect a time sequence of the values of the wear parameter calculated as a minimum for a sample population of equipment, using this wear component. as a minimum and from this sequence of values and failure data for the wear components in this sample population, determining a wear-failure correspondence between the time sequence of the values of the wear parameter calculated as a minimum and the wear component failure.
26. 26. The method according to claim 25, further comprising controlling a software component in response to this wear-failure correspondence and further in response to a time sequence of the wear parameter values calculated as a minimum for the wear component as a minimum, to calculate the remaining useful life of this wear component.
27. 27. The method according to claim 21, further comprising controlling a software component to collect a time sequence of values of the wear parameter calculated as a minimum and the raw data measurements underlying this wear-out parameter. calculated for a population of equipment sample that attrition component is used as a minimum and from this sequence of values and measurements and failure data for the wear components in this sample population, determine a wear-failure correspondence between the sequence of the values of the attrition parameter calculated as a minimum and the measurements of raw data underlying the parameter of calculated wear and tear component failure incidents.
28. 28. The method according to claim 27, characterized in that it further comprises' controlling a software component in response to this wear-fail correspondence., to apply this wear-fail correspondence as a filter to at least one calculated wear parameter and the raw data measurements underlying the wear parameter calculated by an equipment item corresponding to the equipment sample population to detect a Pre-fault pattern and in response to this detection provide an operation notice for the equipment item.
29. 29. The method according to claim 28, characterized in that the operation warning that is provided is a warning specifying shutdown controlled by the item of equipment in which the pre-fault pattern was detected.
30. 30. The method according to claim 28, characterized in that the operation warning that is provided is a warning specifying an operational limit for the equipment item in which the pre-fault pattern is detected.
31. 31. The method according to claim 21, characterized in that the method also it comprises: defining a limit of bi-dimensional use for the attrition component as a minimum, each dimension comprises a limit for a measurement of raw data or for a calculated wear parameter; and controlling a software component that uses the bi-dimensional use limit, the component responds to raw data measurements and calculated wear parameters to send an out-of-limit warning.
32. 32. The method according to claim 21, characterized in that the method further comprises: defining a limit of N-dimensional use for the wear component as a minimum, each dimension comprises a limit for a raw data measurement or for a parameter of calculated wear; and controlling a software component using the N-dimensional usage limit, the component responds to the raw data measurements and the calculated wear parameters for issuing or sending an out-of-limit warning.
33. The method according to claim 21, characterized in that the method further comprises controlling a software component located in a remote central processor to the equipment being monitored to configure a computer system of the equipment located in the equipment, by defining the minus one of the measurements of raw data to be produced and the frequency of its detection.
34. 34. The method according to claim 33, characterized in that the step of controlling a software component located in a remote central processor of the equipment to be monitored, to configure a computer equipment system, comprising providing data from settings that specify one or more of the following: select wear components for monitoring, select the signals and parameters for a record of the data in the computer system of the equipment, select scale adjustment calculations to be applied to raw data measurements , select filters to be applied to raw data measurements and select a communication path between the computer equipment system and the central monitoring system.
35. 35. The method according to claim 21, characterized in that it further comprises: storing in a user database of component accessible to the central monitoring processor, measurements of raw data and / or calculated wear parameters; store in a fault database with access to the central monitoring processor, fault data for at least one wear component correlated with the component use database; controlling a software component to perform component usage database extraction and the fault database, to derive at least one predictive rule to trigger a warning in advance of the failure of a wear component; and controlling a software component to implement the predictive rule as a minimum as a filter to be applied to real-time streams of raw data measurements received from the sensors.
36. 36. The method according to claim 35, characterized in that it further comprises: storing in a limit database with access to the central monitoring processor, out-of-limit levels for comparison against measurements of raw data and / or parameters of calculated wear; and controlling a software component to implement the out-of-limit levels as a filter to be applied to real-time streams of raw data measurements received from sensors, the filter signals an out-of-limit condition.
37. 37. The method according to claim 35, characterized in that the raw data measurements of the component use database are stored in multidimensional cubes.
38. 38. The method according to claim 35, characterized in that the calculated wear parameters of the component use database are stored in multidimensional cubes.
39. 39. The method according to claim 35, characterized in that the predictive rule as a minimum is fed back into the definitions for the service procedures, which define component replacement programs.
40. 40. The method according to claim 21, characterized in that the wear parameter calculated and accumulated as a minimum, is a load-weighted operating hours parameter.
41. 41. The method according to claim 21, characterized in that the equipment to which the method is applied has two or more wear components that are replacement.
42. 42. The method according to claim 21, characterized in that the equipment to which the method is applied is selected from the group consisting of cranes, winches or winches, upper controls and mud pumps.
43. 43. The method according to claim 21, characterized in that it also comprises storing in a management database with access to the central monitoring processor, the correspondence between raw data measurements and the calculated wear parameters to which the raw data measurements belong.
44. 44. The method according to claim 43, characterized in that it further comprises storing in a management database with access to the central monitoring processor, the post-processing calculation methods applied to the raw data measurements.
45. 45. A data structure used to monitor the condition of remote equipment that has at least one wear component, characterized in that it comprises: definitions of raw data measurements to be taken as minimum wear component operation; Correspondence data between raw data measurements and calculated wear parameters specified for the wear component as a minimum to which the raw data measurements belong; and calculate rules for post-processing of raw data measurements, to produce the calculated wear parameters specified for the wear component as a minimum.
46. 46. The data structure according to claim 45, characterized in that it comprises scale adjustment rules associated with raw data measurements for pre-processing of raw data measurements, before they are sent to a processor for central monitoring.
47. 47. The data structure according to claim 45, characterized in that it also comprises registration rules associated with the raw data measurements, to define the frequency for capturing raw data measurements. SUMMARY OF THE INVENTION A system for administering replacement components for equipment having a plurality of components, each with a limited lifetime, has a computer with a processor. The system includes a computer program module for defining a function profile, comprising a plurality of use cases for the equipment, each use case involving two or more of the plurality of components and specified operating conditions that are assumed to be Experienced by the components involved during the execution of each of the use cases. There is also a computer program module to determine a theoretical lifetime for each component involved in a function profile; the theoretical lifetime is based on component lifetime data under the specified operating conditions; and sensors to determine and monitor the occurrence of operation or operation of equipment corresponding to a use case and to measure the current operating conditions experienced in the operation and the number of such operations. An additional computer program module computes a theoretical lifetime adjusted for a component that has experienced one or more operations, based on a comparison of conditions current conditions of operation that are considered will be experienced in the operation of the use case. w ?. -? - ina.