System and method for vibration monitoring

The present invention is directed to a system and method of monitoring assets of an enterprise, wherein the assets perform a process and include machines subject to vibration. The system includes a vibration diagnostic software system integrated with a process automation system and a computerized maintenance management system to provide a single window interface for controlling and monitoring a process, for monitoring and analyzing the vibration of the machines associated with the process and for managing the maintenance of the machines. This integration brings vibration data collection, transmission, analysis, historical recording, display and maintenance activities all together in a defined workflow.

BACKGROUND OF THE INVENTION

The present invention is directed toward vibration monitoring and, more particularly, toward a system and method for monitoring the vibration of machinery from the same point that other assets may be monitored or controlled from.

An operating machine, such as a pump or a fan, has a normal or baseline vibration pattern or signature that is characteristic of normal operation of the machine. If the machine is not operating normally, the machine will typically have a vibration signature that differs from the baseline vibration signature. Typically, this difference in vibration signature is unique to the problem with the machine, i.e., the problem causes a telltale change in the vibration signature. Thus, vibration analysis of a machine can detect developing mechanical defects long before they become a threat to the integrity of the machine, thereby providing the necessary lead-time to schedule maintenance to suit the needs of enterprise management. In this manner, vibration monitoring is the cornerstone of predictive maintenance, wherein machines are serviced based on predicted machine problems rather than actual machine failures.

To properly employ predictive maintenance for machines, vibration data is typically collected and analyzed on a scheduled basis during normal use of the machines. Conventional vibration monitoring systems collect and analyze vibration data using portable data collectors that are designed to be transported to the machines to be tested. For a particular machine, a portable data collector is connected to sensors, which are either fixedly or removably attached to the machine. The portable data collector gathers vibration data for the machine from the sensors. After such data is collected, the portable data collector is disconnected from the machine and then transported to a host computer. Vibration data from the portable data collectors is uploaded to the host computer, which runs a data screening and fault diagnostic software program that analyzes the vibration data in order to provide a system operator with advanced diagnoses of the conditions of the machines. Examples of vibration monitoring systems that operate in the foregoing manner are shown in U.S. Pat. Nos. 6,484,109; 4,8234,707 and 4,612,620.

Conventionally, vibration monitoring systems are stand-alone systems that are not tied into other plant systems for the exchange of detailed information. Thus, in a plant that utilizes a vibration monitoring system, along with a process automation system and a computerized maintenance management system (CMMS), the vibration monitoring system typically does not communicate with the process automation system or the CMMS. As a result, an operator at a workstation of the process automation system cannot access detailed information from the vibration monitoring system. In order to access such information, the operator must physically move from the workstation to the host computer of the vibration monitoring system and access the information from the host computer. In addition, in order to perform predictive maintenance, the information from the vibration monitoring must be manually input into the CMMS or written into a directory that can be accessed by the CMMS.

Based on the foregoing, there exists a need in the art for a system and method for monitoring the vibration of machinery from the same point that other assets may be monitored or controlled. The present invention is directed to such a system and method.

SUMMARY OF THE INVENTION

In accordance with the present invention, a system is provided for use in controlling a process of an enterprise and for providing a condition diagnosis of a machine in the enterprise based on vibration data collected from the machine. The system includes at least one computer and a monitor connected to the at least one computer. A diagnostic software system runs on the at least one computer and is operable to provide the condition diagnosis of the machine based on the collected vibration data. A human system interface (HSI) runs on the at least one computer and is communicably connected to the diagnostic software system. The HSI has at least one workspace for display on the monitor. The at least one workplace includes dynamic elements that can be manipulated by an operator to change control parameters for the process and a view for displaying the condition diagnosis of the machine from the diagnostic software system. A notification system runs on the at least one computer and is communicably connected to the diagnostic software system and the HSI. The notification system is operable to generate an electronic notification for transmittal to the HSI and operating personnel when the condition diagnosis of the machine changes.

Also provided in accordance with the present invention is a system and method of monitoring assets of an enterprise, wherein the assets perform a process and include a machine subject to vibration. Vibration data is collected from the machine using a data collector. A diagnostic software system provides a condition diagnosis of the machine based on the collected vibration data. A process automation system receives an operating value of the process from a field device. The operating value is not vibration and is not from a machine that is being monitored for vibration. A human system interface displays the condition diagnosis of the machine and the operating value on a computer monitor.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

It should be noted that in the detailed description that follows, identical components have the same reference numerals, regardless of whether they are shown in different embodiments of the present invention. It should also be noted that in order to clearly and concisely disclose the present invention, the drawings may not necessarily be to scale and certain features of the invention may be shown in somewhat schematic form.

Below is a list of acronyms used in the specification and their respective meanings:“CMMS” shall mean computerized maintenance management system“DCOM” shall mean distributed component object model.“DLL” shall mean dynamic link library.“FDCMS” shall mean field device calibration and management system“HTML” shall mean Hypertext Markup Language.“HTTP” shall mean Hypertext Transfer Protocol.“ODBC” shall mean Open Data Base Connectivity, which is a method of communication to client/server databases. ODBC is part of Microsoft's Windows Open Systems Architecture, which provides a series of application program interfaces to simplify and provide standards for various programming activities.“OPC” shall mean object linking and embedding for process control.

As used herein, the term “asset” shall mean an apparatus that performs work and, thus, has value to an enterprise.

Referring now toFIG. 1there is shown a block diagram of an enterprise10that can benefit from the use of the present invention. The enterprise10includes a plurality of assets12for, inter alia, performing at least one process. The assets12includes at least one machine14that is monitored for vibration, a device16that is not monitored for vibration and a plurality of other assets, such as machines18,20and apparatus22. Machines18,20may also be monitored for vibration. The enterprise10may include a single facility or a plurality of facilities located in one or more geographic locations. The enterprise10may be a heating and cooling plant and the processes may be the heating and cooling of a building. In such a case, the machine14may be a drain pump, the device16may be a heat exchanger, such as a condenser, the machine18may be a chilled water pump, the machine20may be a circulating water pump and the apparatus22may be a boiler. It should be appreciated, however, that the present invention is not limited to use in a heating and cooling plant.

For purposes of monitoring and controlling the assets12, the enterprise10is provided with a vibration monitoring system24, process field devices28, a process automation system30and preferably a computerized maintenance management system (CMMS)32, all of which are interconnected by a network34. The vibration monitoring system24is integrated with the process automation system30and the CMMS32to give enterprise personnel a single window interface for controlling and monitoring the process, for monitoring and analyzing the vibration of the machines associated with the process (such as the machines14,18,20) and for managing the maintenance of said machines. This integration brings vibration data collection, transmission, analysis, historical recording, display and maintenance activities all together in a defined workflow, as will be described more fully in the paragraphs below.

The vibration monitoring system24generally comprises at least one vibration data collector36, a vibration work station38, a diagnostic software system40and a web server42. The vibration monitoring system24monitors and diagnoses the vibration of the machines14,18,20and other machines in the enterprise10.

The vibration data collector36may be fixed in one position and permanently wired to the machines14,18,20or the vibration data collector may be portable and temporarily connectable to the machines14,18,20, as represented by the dashed lines inFIG. 1. The data collector36is adapted for connection to sensors58,60,62that are either fixedly or removably attached to test points on the machines14,18,20, respectively. Typically, data for three axes (axial, radial and tangential) is collected at each test point. The sensors58–62transform periodic, mechanical movement of the machines14,18,20into electrical analog signals, which are transmitted to and received by the data collector36. A variety of such sensors are known in the art, including by way of example, but without limitation, eddy current position sensors and piezoelectric accelerometers. The data collector36samples and digitizes the analog signals from the sensors58–62to yield digital signals, which are then filtered and conditioned to produce digital vibration data, which is stored in the data collector36.

The diagnostic software system40includes a database system64, a diagnostic application program66and a human system interface (HSI)68with a browser. The diagnostic software system40may have substantially the same construction and operation as the system described in U.S. Pat. No. 6,484,109 to Lofall, which is assigned to the assignee of the present invention and is hereby incorporated by reference. A commercially available diagnostic software system that may be utilized is the ExpertALERT™ machine condition assessment software package available from DLI Engineering, a division of ABB Inc. The diagnostic software system40runs on a CPU70of the vibration work station38. Alternately, the diagnostic software system40may run on a CPU118of a workstation110(shown inFIG. 2) in the process automation system30, or on a CPU112of a server computer134(also shown inFIG. 2) in the process automation system30.

The database system64stores vibration information from the data collector(s)36and interfaces with the diagnostic application program66. The database system64includes a database and a database server. The database has one or more tables for storing information, with each table comprising one or more rows or records together with one or more columns or fields. Information can be stored in the database in a variety of different forms, including numbers, graphics files, text files, and HTML pages. The database server includes a database engine for accessing information in the database, adding information to, and removing information from, records in the database and adding records to and removing records from the database. The database engine operates in response to SQL (Structured Query Language) commands received from a client such as the HSI68. Communication between the database engine and a client utilizes ODBC as the transfer protocol.

An operating system80runs on the CPU70of the vibration work station38. The operating system80is a Windows® operating system available from Microsoft Corporation and includes a DCOM service82that runs with the database system64. The vibration data collected by the vibration data collector(s)36may be transferred to the vibration work station38by temporarily connecting the vibration data collector(s)36to the vibration work station38(as indicated by the dashed lines inFIG. 1) and uploading the vibration data to the database system64on the vibration work station34. Alternately, the database system64may also be resident on the data collector(s)36. In such an event, the database system64in the vibration work station is designated the master and the database systems64in the data collector(s)36are designated as subscribers. A database synchronization system may be utilized to take newly obtained information that is uniquely stored in one of the copies of the database and replicates the new data in each of the other copies of the database so that each copy of the database contains the same information, i.e., is identical. The replication can occur over the network34, or a radio frequency network link, or a direct or internet modem connection. An example of a database synchronization system that can be utilized is disclosed in the Lofall patent referenced above (U.S. Pat. No. 6,484,109).

Baseline vibration data for a large number of different types of machine is stored in the database system64. The diagnostic application program66uses this stored data to analyze the vibrations of the machines14,18,20and other machines. More specifically, for a machine, which is of a particular type (such as a certain type of pump), the diagnostic application program66uses stored diagnostic rules to compare vibration data collected from the machine to baseline vibration data for the type of the machine (e.g. certain type of pump). Based on this comparison, the diagnostic application program66selects an appropriate condition diagnosis from a collection or library of condition diagnoses and generates a diagnosis report. The diagnosis report contains information about any diagnosed fault and provides a recommendation for remedying any such diagnosed fault. For each type of machine, the stored baseline vibration data is obtained from empirical data collected from a large number of identical, properly operating machines. The collected vibration data and the baseline vibration data may be in the form of spectrums and/or cepstrums. A cepstrum can be defined as a spectrum of a spectrum.

The web server42is resident on the vibration work station38and is a service of the operating system80. The web server42generates web or HTML pages using information obtained from the database system64and communicates with clients on the network34via HTTP. The HTML pages generated by the web server42include diagnosis reports; fault severity trends; alarm and event lists; machine view diagrams with harmonic markers; and single axis, triaxial, and double-triax spectral and waveform displays. The HTML pages generated by the web server42can be accessed by a browser on a remote client84.

Process Field Devices.

The process field devices28include monitoring devices (such as sensors and transmitters) and control devices (such as valves and drives) for monitoring and controlling the process. In the case where the enterprise10is a heating and cooling plant, the process field devices28include, by way of example, flow transmitters and control valves for respectively measuring and controlling the supply of fuel to burners for the boiler22, flow transmitters and control valves for respectively measuring and controlling the supply of feedwater to the boiler22, and flow and temperature transmitters for monitoring the characteristics of hot and cold fluids flowing through hot and cold legs of the heat exchanger16. The process field devices28communicate operating values of the process to the process automation system30over a field network106, which may utilize shielded twisted pair wires, coaxial cables, fiber optic cables, or wireless communication channels.

Process Automation System.

Referring now toFIG. 2, the process automation system30is preferably a distributed control system, such as a System 800xA distributed control system, which is commercially available from the assignee of the present invention, ABB Inc. The process automation system30generally includes at least one control work station110and one or more controllers114. Input signals from the field devices28are communicated over the field network106to the network34by 4–20 mA signaling and/or by one or more of the conventional control protocols, such as the HART® protocol, the Foundation™ Fieldbus protocol, or the Profibus protocol. For any of the field devices28communicating via the Foundation™ Fieldbus protocol, the field network106comprises HSE/H1 linking devices, which connect the field devices28to a high speed Ethernet subnet, which is connected to the network34through an FF HSE communication interface of the controller(s)114or through an FF OPC server (not shown). For any field devices28communicating via the Profibus protocol, the field network106comprises DP/PA linking devices, which connect the field devices28to a Profibus-DP line, which is connected to the network34through a Profibus communication interface of the controller(s)114or through a Profibus OPC server (not shown). For any field devices28communicating via 4–20 mA signaling and/or the HART® protocol, the field network106typically comprises shielded twisted pair wires, which connect the field devices28to an I/O subsystem116, which includes one or more I/O modules with one or more associated module termination units, as is shown inFIG. 2. The I/O subsystem116is connected by a module bus to the controller(s)114, which is/are connected to the network34.

The network34interconnects the control work station110, the controller(s)114, the vibration work station38and optionally the vibration data collector(s)36. The network34includes a pair of redundant Ethernet cables over which information is communicated using the Manufacturing Message Specification (MMS) communication protocol and a reduced OSI stack with the TCP/IP protocol in the transport/network layer. Together, the network34and the field network106help form a communication link over which information may be transmitted between the field devices28and clients.

The controller(s)114contain(s) control programs for controlling the process of the enterprise10and sub-processes thereof. The control programs utilize operating values from the field devices28, which are received by the controller(s)114from the I/O subsystem116. By way of example, the control programs may include a digital burner control logic scheme and an analog feedwater control logic scheme for the boiler22(in the case where the enterprise10is a heating and cooling plant). The control programs are written in one or more of the five IEC 61131-3 standard languages: Ladder Diagram, Structured Text, Function Block Diagram, Instruction List and Sequential Function Chart. Outputs from the control programs are transmitted to the control devices of the process field devices28over the field network106.

The control work station110is a personal computer (PC) with a central processing unit (CPU)118and a monitor120for providing visual displays to an operator. The CPU118has an operating system running thereon, which is a Windows® operating system available from Microsoft Corporation. A human system interface (HSI)124and an asset optimization system138with asset monitors140run on the operating system of the control work station110. An OPC server126may also run on the control work station110, or may instead run on the server computer134.

The OPC server126is based on Microsoft's OLE (now Active X), COM, and DCOM technologies. The OPC server126makes information from the controller(s)114available to any OPC client connected to the network34, such as the HSI124. As set forth above, an FF OPC server and/or a Profibus server may also be provided to connect the field devices28to the network34without having to be connected to the controller(s)114. The FF OPC server and the Profibus server are also based on Microsoft's OLE (now Active X), COM, and DCOM technologies that make information available to any OPC client on the network34.

The HSI124has a client/server architecture and may have communication based on OPC. A suitable human system interface that may be utilized for the HSI124is Process Portal™, which is commercially available from the assignee of the present invention, ABB Inc. The HSI124has a server130and a plurality of client workspaces, which will be more fully described below. The server130may be resident on the control workstation110, or may instead run on the server computer134. The server130includes an aspect directory148(shown inFIG. 9) containing all aspect objects and their aspects, as well as an aspect framework (AFW) server150(also shown inFIG. 9). The AFW server150is operable to wrap together HTML pages (aspects) for an object (e.g. the machine14) in a web-compliant AFW file that can be launched from an object tree in the HSI124. The AFW server150periodically (e.g. every 10 seconds) sends requests for data to the DCOM service82of the vibration workstation38.

The server130implements a method of organizing information using aspect objects (or simply “objects”) and aspects associated with the aspect objects. An aspect object represents a physical object (such as an asset12) or a virtual object (such as a function) and acts as a holder or container for information (such as run time data) concerning the object. Information concerning an object is contained in its aspects. An aspect is an assembly of information describing certain properties of an aspect object, such as functional properties, physical construction properties and location properties. Information in an aspect is presented in a view, which may be a list, a table, a diagram, a drawing, or a graphic. An aspect may have more than one view. An aspect object methodology that may be utilized is set forth in U.S. Pat. No. 6,694,513 to Andersson et al., which is assigned to a sister company of the assignee of the present invention and is hereby incorporated by reference.

The aspect object methodology of the process automation system30utilizes at least three types of object hierarchies or structures: functional, locational and control. The functional structure shows where a particular object fits into a functional context. For example, the functional structure would show which control loops are associated with the feedwater control valves of the boiler22(in the case where the application10is a heating and cooling plant) and which field devices28are associated with each control loop. The locational structure shows where an object fits into the physical (geographical context). For example, the locational structure would show exactly where in the enterprise10the feedwater control valves are located. The control structure shows where a software function or hardware device can be found in the process automation system30or the vibration monitoring system24. For example, the control structure would show which analog/digital output signals control the feedwater control valves, which output boards carry the output signals and how these signals connect to the control program controlling the feedwater control valves.

As set forth above, the HSI124has a plurality of workplaces that may be utilized. Each workplace comprises a collection of user-interactive functions (such as tool bars, faceplates, windows, pull-down menus, buttons, scroll bars, iconic images, wizards, etc.) that are combined for a particular use, such as controlling the process, maintaining assets12in the enterprise10, or configuring a model of the enterprise10. Enterprise personnel may select a particular workplace from a workplace login page of the HSI124. Two of the workplaces that may be selected are an operator workplace156and a plant explorer workplace158.

Referring now toFIG. 3, the operator workplace156is configured for process operators responsible for controlling the process. The operator workplace156includes an upper application bar162, a central display area164and a lower status bar166. The application bar162includes an alarm band that provides a summary display for selected alarm lists, as well as links to the alarm lists, and an alarm line that shows three of the latest alarms. The status bar166includes an operator message line showing the latest operator message from the process automation system30, a button for accessing a list of the operator messages, and a current user tool for showing the identity of the current user. The display area164is the area from which the process is controlled. The display area164is used to show aspects, such as graphic displays, faceplates, alarm display and/or trend displays. For example, inFIG. 3, both a graphic display170and a faceplate172are shown. The graphic displays (such as graphic display170) and the faceplates (such as faceplate172) utilize Microsoft ActiveX Controls and include both static and dynamic elements. Dynamic actuation elements in the graphic displays and faceplates (such as buttons174) are interconnected with the control programs in the controller(s)114and may be manipulated by an operator to: initiate state changes (e.g. block alarms or switch from manual to auto mode); change process values, limits and set-points; and acknowledge alarms. In addition to containing dynamic actuation elements, the graphic displays and the faceplates typically display operating values of the process.

Referring now toFIG. 4, the plant explorer workplace158is used to explore and build hierarchically structured models of the enterprise10. The plant explorer workplace158includes an application bar178and a plurality of frames or areas, including an aspect object area180, an aspect list area182and a preview area184. The application bar178includes a fixed display area, a tool collection and shortcuts. The aspect object area180is where the object browser displays a list or tree186of objects for a selected object structure (functional, locational or control), with each root object at a top level and its child objects at a lower or leaf level. An object can be accessed by right clicking on the object in an object tree186, which opens a context menu containing a number of actions that can be performed. The aspect list area182displays all aspects of a currently selected object in an object tree186. The preview area184displays the aspect currently selected in the aspect list area182.

Integration of the Vibration Monitoring System with the Process Automation System

As will be discussed in more detail below, the vibration monitoring system24is integrated at four levels into the process automation system30:Object Tree Integration: Objects representing machines (such as machines14,18,20) that are monitored by the vibration monitoring system24can be displayed in an object tree186(such as an asset condition tree) in the plant explorer workplace158and in a thin client tree, which mimics an asset condition tree in the plant explorer workplace158. The machine objects can be manually entered into a system baseline for the process automation system30, or can be uploaded from the diagnostic software system40and merged with other objects in the system baseline. The machine objects can be instantiated in whatever object structure (functional, locational, or control) is desired for appropriately monitoring the machines in the context of the operation of the process and/or management of the enterprise10.View Integration: Selected views from the diagnostic software system40are rendered as aspects in the plant explorer workplace158.Thin Client Integration: Selected views from the diagnostic software system40are thin client compatible for viewing from an asset condition tree. As will be described further below, an asset condition tree displays icons, each of which indicates a fault report for a change in status of a machine.Notification Integration: The asset optimization system138determines whether a notification needs to be sent to the CMMS32for generating a work order and/or to a system messaging service238to notify enterprise personnel that action needs to be taken.
Object Tree Integration

Referring now toFIGS. 4–7B, windows or views of the plant explorer workplace158are shown. An object188for all of the vibration-monitored machines of the enterprise10is provided in an object structure of the plant explorer workplace158and is referred to as the “plant object”. Aspects for the plant object188are provided and include a plant properties aspect190, a server configuration aspect192and an alarm and event list aspect194. The plant properties aspect190stores a numerical identification and a name (such as “XYZ plant”) for the collection of vibration-monitored machines (e.g. machines14,18,20) of the enterprise10, while the server configuration aspect192provides a view192a(shown inFIG. 5) that contains information for connecting the process automation system30to the database system64and the web server42of the vibration monitoring system24.

All of the vibration-monitored machines of the enterprise10are provided with objects that may be child objects of the plant object188and will hereinafter referred to as “machine objects”. For example, the machines14,18,20are provided with machine objects198,200,202, respectively. An aspect for machine properties, an aspect for a vibration asset monitor (which will be more fully described below) and an aspect for a vibration monitoring view are provided for each of the machine objects. For example, machine properties aspects203,204,205are provided for machine objects198,200,202, respectively; vibration asset monitor aspects206,207,208are provided for machine objects198,200,202, respectively; and vibration monitoring view aspects209,210,211are provided for machine objects198,200,202, respectively.

Referring now toFIG. 6, for a particular machine object (such as the machine object200), the machine properties aspect (such as machine properties aspect204) provides a view (such as view204a) that includes the identification and name of the corresponding machine (e.g. machine18), the area of the enterprise10where the machine is located, and status, fault and repair recommendations for the machine.

Although the machine objects are shown inFIGS. 4–7B(as well asFIGS. 11–15) as being arranged in an object tree186in a locational object structure, separate from objects for other assets12, it should be appreciated that the machine objects may also be arranged in control and/or functional object structures with objects for other assets12of the enterprise.

The device16, the apparatus22and other assets12of the enterprise10are also provided with objects. For example, the device16is provided with an object242(shown inFIG. 10), having aspects, such as a heat exchanger asset monitor246. The objects for the device16, the apparatus22and other assets12may be arranged in object trees186in locational, control and/or functional object structures separate from, or combined with, the machine objects.

With particular reference now toFIG. 8andFIG. 5, machine objects (such as machine objects198,200,202) may be created using an upload operation, which is initiated by actuating an upload button212of the server configuration aspect192. When the upload button212is actuated, the server configuration aspect192transmits configuration data (e.g. the name of the database server, the name of the database, user credentials, plant name) to the AFW server150and requests database data from the AFW server150. Using the configuration information, a database data collector DLL214of the AFW server150assembles an SQL query and transmits the SQL query over the network34to the database server of the database system64using ODBC DCOM. In response to the SQL query, the database server retrieves data from the database and transmits the data back to the database data collector DLL214, which then forwards the data to the server configuration aspect192. Using the returned data, the server configuration aspect192creates the child objects in the aspect directory148and populates them with aspects. If a machine object already exists as a child object, the server configuration aspect192will not overwrite the existing machine object. Instead, the server configuration aspect192will only update information of the machine object, such as its name, identification number and status information.

A machine object uploaded from the database system64or manually entered into the system baseline may be merged with any other object by selecting a “join object with” function from a context menu for the machine object. When the “join object with” function is selected, an object browser appears and provides a list of objects from which an object to be joined may be selected. Once the object to be joined is selected, the machine object and the selected object are merged into a single object having all of the aspects of the machine object and the selected object, with the object icon being taken from the selected object. An example of the merger of a machine object with another object is the merger of machine object200for the machine18and the object242(shown inFIG. 10) for the device16, which may be desirable in the event the machine18is associated with the device16, such as may occur when the enterprise10is a heating and cooling plant and the machine18is a chilled water pump and the device16is a heat exchanger. With such a merger, the resulting object has all the aspects of the machine object200and the object242. In this manner, vibration information about a vibration-monitored machine (machine18) and non-vibration information about a device (device16) that is not monitored for vibration are accessible from a single object.

The process automation system30obtains updated data from the database system64over the network34through an automatic update operation, which utilizes an update trigger (not shown) in the database system64that monitors the status of the vibration-monitored machines (such as the machines14,18,20). When the status of one of the machines14,18,20or other vibration-monitored machines changes, the update trigger transmits the identity of the changed machine and the new status information of the machine to the DCOM service82through a handler DLL216. The DCOM service82then forwards this information to the AFW server150. When the AFW server150receives the new status information from the DCOM service82, the AFW server150updates the data for the changed machine stored in the aspect directory148. The updated data for the changed machine in the aspect directory148is then picked up by the aspects for the machine, such as the vibration asset monitor.

The status of each vibration-monitored machine, as represented in the machine object therefor, is updated when the upload operation or the automatic update operation is performed. The status of each vibration-monitored machine is displayed in the object tree186in the aspect object area180via an icon associated with the machine object for the machine. For example, machines objects198,200,202have icons218,220,222(shown inFIG. 4). The icon for each machine object will have a particular color for a particular status condition. For example, if the machine is in good condition, the icon will be green, whereas if the machine has extremely serious faults, the icon will be red.

View Integration

Referring now toFIGS. 7A,7B, the vibration monitoring view aspect (such as the vibration monitoring view aspect209) uses information from the machine properties aspect (like machine identification) and information from the server configuration aspect (like host name, virtual directory name and customer identification) to generate a Uniform Resource Locator (URL), which is sent to the web server42of the vibration monitoring system24. Based on this URL, the web server42creates an HTML page, which the vibration monitoring view aspect receives and displays as a view (such as view209a). The view (and, thus, the HTML page) contains the current status of the machine (e.g. “extreme”), a condition diagnosis of the machine made by the diagnostic software system40(e.g. “extreme motor bearing wear”), a recommendation generated by the diagnostic software system40(e.g. “replace motor bearing”) and severity trends for different analyses. The vibration monitoring view aspect is implemented in Microsoft Visual Basic.

Asset Optimization Features

Asset Monitors. Referring now toFIG. 9, the thin client integration and notification integration are accomplished using the asset optimization system138. The asset optimization system138integrates asset monitoring and decision support applications with the HSI124, as well as the CMMS32and typically a field device calibration and management system (FDCMS)226. A strategic maintenance management software package sold under the tradename MAXIMO® by MRO Software, Inc. has been found suitable for use as the CMMS32, while a device management software package sold under the tradename DMS by Meriam Process Technologies has been found suitable for use as the FDCMS226. The asset optimization system138has the asset monitors140, which include vibration asset monitors142,144,146, an asset monitor230for the device16and other asset monitors, which may monitor other physical components of the process and/or process field devices28and information technology assets of the process automation system30. In an exemplary embodiment of the present invention, all of the vibration-monitored machines have asset monitors. The asset optimization system138also includes an asset monitoring server232and a software development kit (SDK)234, which may be based on Visual Basic® from Microsoft Corporation, which can be used to create custom asset monitors. The asset optimization system138may have an architecture substantially in accordance with the AO architecture described in U.S. patent application Ser. No. 09/770,167 (Publication Number US2002/0103828A1), which is assigned to the assignee of the present invention and is hereby incorporated by reference.

The asset monitoring server232interacts with the OPC server126and/or the FF OPC server and/or the Profibus server to receive operating values from the process field devices28over the network34. In addition, the asset monitoring server232receives information (such as vibration data, fault diagnoses and suggested remedial action) from the diagnostic software system40over the network34, via the AFW server150.

The asset monitors140may be written in Visual Basic® using the SDK234and their parameters may be defined using Excel. Standard asset monitors140can be configured to perform Boolean checks, quality checks, runtime accumulation checks, high, low, high/low limit checks, XY profile deviation checks and flow delta checks. The parameters of the asset monitors140, such as conditions and subconditions, may be defined using Excel™, which is a spreadsheet program from Microsoft Corporation. Custom asset monitors140can be written in Visual Basic, Visual C++, or other programs. Outputs of the asset monitors140must be in an asset condition document format. A condition of an asset monitor140can be a variable (such as vibration) of an asset being monitored (such as the machine14), while a subcondition can be the quality or status of the condition, such as “normal” or “extreme”. An asset monitor140can be configured such that if a subcondition is met (such as “extreme”), the asset monitor140creates an asset condition document236, which is an XML file containing all information necessary to describe an asset condition. The asset condition document236is transmitted to the HSI124and may also be reformatted and sent to the system messaging service238for delivery to plant operating personnel via email and/or pager. The system messaging service238permits plant operating personnel to subscribe to a plurality of asset monitors140for which the plant operating personnel desire to receive status change information.

The vibration asset monitors142,144,146are provided as aspects (206,207,208) to the machine objects198,200,202, which, as set forth above, are child objects to the plant object188in the plant explorer workplace158. Each vibration asset monitor142,144,146has a condition of “vibration” and five sub-conditions, namely “not tested/OK”, “slight”, “moderate”, “serious” and “extreme”. Each vibration asset monitor aspect (such as vibration asset monitor aspect206) provides a detailed view of the condition and the subconditions of the associated asset monitor (such as asset monitor142). The status of the subconditions is provided by text, as well by color, with the color being selected based on the nature of the status.

Referring now toFIG. 10, the asset monitor230for the device16is provided as an aspect246to the object242for the device16. In the case where the enterprise10is a heating and cooling plant and the device16is a heat exchanger, the asset monitor230for the device16may have the same construction and function as the heat exchanger asset monitor disclosed in applicant's co-pending patent application (Ser. No. 10/896,732) entitled A SYSTEM AND METHOD FOR MONITORING THE PERFORMANCE OF A HEAT EXCHANGER, which is hereby incorporated by reference. With such a construction, the asset monitor230provides a measure of the performance (referred to as “E”) of the device16without using any information concerning the physical construction of the device16. The measure of performance, E, is calculated using only differential temperatures. The asset monitor aspect246provides a detailed view246A of the condition and the subconditions of the asset monitor230. Once again, the status of the subconditions is provided by text, as well by color, with the color being selected based on the nature of the status. In the event the object242and the machine object200are merged together, as contemplated above, the resulting object has both the aspect246for the asset monitor230for the device16and the aspect207for the asset monitor144for the machine object200.

Asset Reporter and Viewer (Including Thin Client)

Referring back toFIG. 4, an asset reporter aspect248is provided for the plant object188in the plant explorer workplace158. In addition, an asset reporter aspect is provided for each of the machine objects. For example, asset reporter aspects250,252,254are provided for machine objects198,200,202, respectively. An asset reporter aspect (not shown) is also provided for the object242in the control object structure of the plant explorer workplace158. An asset reporter provides a list of all asset monitors for an associated object, along with the statuses of the asset monitors.

An asset viewer aspect260is provided for the plant object188. The asset viewer aspect260displays the machine objects in an asset condition tree262(shown inFIG. 11). The asset viewer aspect260is accessible in the aspect object area180of the plant explorer workplace158, as well as in the operator workplace156. The asset viewer aspect260is also accessible as a web-enabled view on a remote client that is not part of the process automation system30, i.e., the asset viewer aspect260is accessible on a thin client. A thin client, such as the remote client84inFIG. 2, accesses the asset viewer aspect260through a web server on the machine hosting the asset monitoring server232. A thin client view264of the asset condition tree262is shown inFIG. 11. The statuses of the machine objects (and thus the machines) are displayed in the asset condition tree262via icons associated with the machine objects, respectively, with the form of the icons being based on the nature of the statuses. For example, the machine objects198,200, are provided with icons266,268, respectively. When a machine object is in a normal condition, the icon will be a check mark, whereas if the machine object is in an extremely severe non-normal condition (such as machine objects198,200), the icon (such as icons266,268) will be a red circle with a cross through it. Each icon represents the composite severity of its associated machine object and its children. The icons may be preset, or may be configurable by enterprise personnel.

The thin client view264of the asset condition tree262is the same as the views of the asset condition tree262in the operator and plant explorer workplaces156,158, except the thin client view264is not dynamically updated when the status of a machine changes. Instead, the thin client view264must be updated through a manual refresh.

The statuses of the objects and the subconditions thereof that are displayed in the asset condition tree262and the asset reporters are determined by the asset condition documents236issued by the asset monitors140. When an asset monitor140issues an asset condition document236for a change in status (i.e., a new subcondition is met), the icon displayed in the asset condition tree262and the color of the subcondition in the corresponding asset reporter are changed. In addition, if the change in status is from normal or OK to an abnormal condition, an alarm and an electronic fault report269are automatically created.

Notification (A&E). As set forth above, an alarm and event list aspect194is provided for the plant object188, as shown inFIG. 4. An alarm and event list aspect is also provided for each of the machine objects. For example, alarm and event list aspects274,276,278are provided for the machine objects198,200,202, respectively. For the plant object188, the alarm and event list aspect194provides a view194athat shows all alarms and events generated by all of the machine objects, whereas for a particular machine object, the alarm and event list aspect shows all alarms and events generated by that particular machine object. The alarm and event list aspect shows the severity and time of occurrence of the alarms and events.

Notification (CMMS). A fault report submitter aspect is provided for each machine object for a machine having an asset monitor. For example, fault report submitter aspects280,282,284are respectively provided for machine objects198,200,202, which are respectively provided for machines14,18,20, which respectively have vibration asset monitors142,144,146. A fault report submitter aspect may be accessed from the aspect list area182, or from the asset condition tree262or an asset reporter by right clicking on the relevant icon in the asset condition tree262or the subcondition in the asset reporter, as the case may be, which produces a pop-up context menu that provides access to the fault report submitter aspect. Each fault report submitter aspect has a fault report viewer that shows all fault reports for an associated asset monitor. For example, fault report submitter aspect282has a fault report reviewer282athat shows the fault report269that has been issued by the asset monitor144, as is shown inFIG. 12. Right-clicking anywhere in a fault report row produces a context menu with the option to dismiss or submit the fault report269. If the fault report269is to be submitted, a submit fault report view is launched. For example, a submit fault report view282bfor the fault reporter aspect282is shown inFIG. 13. The submit fault report view includes a description of the work that should be performed (work order) and a submit button (e.g. submit button282c). The WO description contains the fault diagnosis and recommended remedial action produced by the diagnostic software system40. When a user clicks the submit button (e.g.282c) in the submit fault report view (e.g.282b), the fault report269, containing the information from the submit fault report view (e.g.282b), is submitted to the CMMS32and the FDCMS226.

Referring now toFIGS. 2 and 9, the CMMS32runs on a CPU286of a computer288that is connected to the process automation system30by network34. The CMMS32generates, issues and tracks job plans, work orders290and preventive maintenance schedules for the assets12of the enterprise10. A work order290from the CMMS32is electronic and contains comprehensive and detailed information for work that needs to be performed on an asset12. Such information includes a description of the work that needs to done and a plan and a schedule for performing the work. Such information also typically includes the amount, type and cost of labor, material and equipment required to perform the work. A work order290may also reference or include information from failure analysis and safety-related documents. A work order290is transmitted to maintenance personnel who will perform the work order290to remedy the fault of the concerned machine.

When the CMMS32receives a fault report269from the process automation system30for a vibration-monitored machine, the CMMS32creates a work order290for the machine. An aspect for active work orders290is provided for each machine object. For example, an active work order aspect292is provided for the machine object200, as shown inFIG. 14. The active work orders aspect for a machine object shows all of the work orders that are open or active for the machine to which the machine object corresponds. For example, the active work order aspect292has a view292athat shows at least three work orders (namely,4833,4829and4828) that are open for the machine18. A work order column (e.g.292b) of each active work order aspect (e.g. aspect292) contains links to the CMMS32. Clicking on a link for a particular work order opens a portal that contains a CMMS view of the work order290.

URLs are created for all of the asset monitor aspects (e.g.206,207,208), vibration monitoring view aspects (e.g.209,210,211), asset reporter aspects (e.g.248,250,252,254,256), fault report submitter aspects (e.g.280,282,284) and active work order aspects (e.g.292), thereby permitting a thin client such as the remote client84to access said aspects. The foregoing aspects can be accessed from the thin client view264of the asset condition tree262by right clicking on the plant object188or a machine object, as the case may be, which causes a context menu to be displayed. The context menu lists the aspects that are available for access through the web browser of the thin client. A desired aspect is accessed by clicking on the aspect in the context menu.

Integrating the vibration monitoring system24with the process automation system30, as described above, extends vibration monitoring of the machines14,18,20and other machines of the enterprise10to include visibility to process operators (who are responsible for controlling the process) in a single window and to provide proper notifications to plant personnel. The work order generation triggers the appropriate personnel into repair action prior to a costly failure. Besides avoiding the costly shutdown, the owner of the enterprise10also realizes a benefit from the proper deployment of resources. Maintenance and repair personnel can be placed in other jobs or plant locations instead of hanging out and waiting for failures. In addition, the audit history in the electronic work order system can be used to analyze the frequency and costs of repairs for scheduling and ordering processes. Moreover, the electronic recording of the maintenance information can also provide information for expediting production and allow comparisons to data from other areas for the plants or from other lines.

While the invention has been shown and described with respect to particular embodiments thereof, those embodiments are for the purpose of illustration rather than limitation, and other variations and modifications of the specific embodiments herein described will be apparent to those skilled in the art, all within the intended spirit and scope of the invention. Accordingly, the invention is not to be limited in scope and effect to the specific embodiments herein described, nor in any other way that is inconsistent with the extent to which the progress in the art has been advanced by the invention.