Abstract: A method, program, and computerized system for creating a data structure of a virtual model of an asset. A computer includes a processor, storage module, user interface module, display module, and software that when executed by the processor implements the following steps. The system receives a designation of an asset type, and presents simplified diagrammatic shapes of an asset based at least in part upon the asset type. The system presents a selection of specification data entry fields, where the selection is based at least in part on the asset type, and receives specifications in regard to the asset type, as guided by the selection of specification data entry fields. The system associates assets one to another into a data structure, and stores a non-transitory copy of the data structure as the virtual model.

Abstract: A machinery health monitoring module processes machine vibration data based on vibration signals and provides the machine vibration data to a distributed control system. A distributed control system operator computer executes a software user interface that filters relevant configuration parameters based on a selected machine measurement type so that only those parameters that are applicable to the selected measurement type appear on the user interface screen. Further, configuration parameters for individual measurement values within the measurement type are made available only when a particular measurement value is selected for acquisition. This greatly simplifies the information that is displayed on the configuration user interface.

Abstract: A computer-executable ratiometric analysis method determines integer components of a rational number ratio or a close approximation of an irrational number ratio. In one embodiment the method uses a ratio of rotational speeds of two rotating assets in a machine or process, generates a new rational number based on the ratio of speeds, and calculates the integer components of the new rational number. The result is the integer ratio relationship between the initial two rational numbers. The method may be used in machinery analysis applications to determine whether a low-order integer ratio relationship exists between two machinery rotating components. Low-order integer ratio relationships in machinery are generally harmful in related machinery rotating components, and detection of such relationships is an important tool in preventing damage to machinery components.

Abstract: A machine monitoring system uses generically defined collection definitions, acquisition definitions, and measurement definitions to define machine data to be collected by machine monitoring devices and other data sources in a unified and device/source independent manner. Configuration software of the machine monitoring system defines data to be collected for a particular machine in such a manner that multiple different types of monitoring devices or data sources can each interpret the data definitions and provide the same type of data back to the software system. Thus, the data to be collected is defined once by the configuration software, and the data definition is interpreted internally by each monitoring device or data source. This greatly simplifies the monitoring system and provides the advantage that new monitoring devices can be added to the system to collect data without impacting the software configuration of the data required.

Abstract: A “periodic signal parameter” (PSP) indicates periodic patterns in an autocorrelated vibration waveform and potential faults in a monitored machine. The PSP is calculated based on statistical measures derived from an autocorrelation waveform and characteristics of an associated vibration waveform. The PSP provides an indication of periodicity and a generalization of potential fault, whereas characteristics of the associated waveform indicate severity. A “periodic information plot” (PIP) is derived from a vibration signal processed using two analysis techniques to produce two X-Y graphs of the signal data that share a common X-axis. The PIP is created by correlating the Y-values on the two graphs based on the corresponding X-value. The amplitudes of Y-values in the PIP is derived from the two source graphs by multiplication, taking a ratio, averaging, or keeping the maximum value.

Abstract: A field programmable gate array (FPGA) in a machine health monitoring (MHM) module includes interface circuitry, vibration data processing circuitry, and tachometer data processing circuitry. The interface circuitry de-multiplexes a synchronous serial data stream comprising multiple multiplexed data channels, each containing machine vibration data or tachometer data, into separate input data streams. The vibration data processing circuitry comprises parallel processing channels for the separate input data streams containing vibration data, each channel including a highpass filter, two stages of integration circuits, a digital tracking bandpass filter, and multiple parallel scalar calculation channels. The tachometer data processing circuitry processes the tachometer data to generate RPM and other values. A cross-point switch in the FPGA distributes tachometer signals between MHM modules in a distributed control system, thereby allowing multiple modules to share tachometer information.

Abstract: A “periodic signal parameter” (PSP) indicates periodic patterns in an autocorrelated vibration waveform and potential faults in a monitored machine. The PSP is calculated based on statistical measures derived from an autocorrelation waveform and characteristics of an associated vibration waveform. The PSP provides an indication of periodicity and a generalization of potential fault, whereas characteristics of the associated waveform indicate severity. A “periodic information plot” (PIP) is derived from a vibration signal processed using two analysis techniques to produce two X-Y graphs of the signal data that share a common X-axis. The PIP is created by correlating the Y-values on the two graphs based on the corresponding X-value. The amplitudes of Y-values in the PIP is derived from the two source graphs by multiplication, taking a ratio, averaging, or keeping the maximum value.

Abstract: A system is described for time synchronizing digitized measurement signals, such as vibration signals. The digitized signals, which are acquired asynchronously by multiple distributed measurement units, indicate the operational condition of a machine or a process. To measure the phase of the digitized signals relative to a pulse tachometer input, the time between the leading edge of the tachometer pulse and the digitized samples is measured. To achieve phase-coherent synchronization across the distributed measurement units, a local synchronization signal is embedded into the data produced by the measurement units. The systems uses the synchronization signal to align the data in post processing, which phase aligns the data and aligns the data in absolute time. The synchronization signal may be encoded with a timestamp to provide additional timing information.

Abstract: A rotating machine valve health monitor. Aspects of the valve monitor include instrumenting each valve of a reciprocating compressor, or other rotating machine, with a sensor capable of detecting at least vibration and instrumenting the crank shaft with a sensor capable of detecting at least rotation. A controller directly monitors the operation and condition of each valve to precisely identify any individual valve exhibiting leakage issues rather than only identifying the region of the leakage. The valve monitor uses a relatively high frequency stress wave analysis technique to provide a good signal-to-noise ratio to identify impact events indicative of leakage. The valve monitor uses circular waveforms of vibration data for individual valves to identify leakage by pattern recognition or visual identification. The valve monitor provides ongoing data collection to give warning of predicted valve failure and scheduling of preventative maintenance for failing valves.

Abstract: A system collects and manages sets of asset data that are indicative of operational performance of physical assets disposed at multiple physical locations in a plant. The system includes a database that associates each set of asset data to (1) a location at which the data was collected, (2) the asset for which the data was collected, and (3) the monitoring device that was used to collect the data. In this way, each location has its own history of all asset data ever collected on all assets disposed at that location, and its own history of all monitoring devices used to collect data at that location. Also, each asset has its own history of all asset data collected on that asset at all locations at which it was disposed and for all monitoring devices. This sort of asset data is referred to herein as multi-referenced data.

Abstract: A vibration data acquisition and analysis module is operable to be inserted directly into a distributed control system (DCS) I/O backplane, so that processed vibration parameters may be scanned directly by the DCS I/O controller. Because the process data and the vibration data are both being scanned by the same DCS I/O controller, there is no need to integrate numerical data, binary relay outputs, and analog overall vibration level outputs from a separate vibration monitoring system into the DCS. The system provides for: (1) directly acquiring vibration data by the DCS for machinery protection and predictive machinery health analysis; (2) direct integration of vibration information on DCS alarm screens; (3) acquisition and display of real time vibration data on operator screens; (4) using vibration data to detect abnormal situations associated with equipment failures; and (5) using vibration data directly in closed-loop control applications.

Abstract: A “store on alert” vibration data acquisition mechanism uses scalar data produced by a vibration monitoring device as a predicate to capturing and storing analytical vibration data in the vibration monitoring device. The scalar data may consist of scalar process variables generated in the vibration monitoring device that are acquired at a fixed interval, such as PeakVue and Overall Vibration. At each interval, these scalar data values are compared to machine performance threshold levels, such as ADVISE, MAINT and FAIL, to determine whether analytical vibration data is to be stored separately inside the vibration monitoring device. Since the analytical vibration data is captured based on a predicate inside the vibration monitoring device (i.e., comparison of the scalar value to the thresholds), the analytical vibration data includes more relevant diagnostic information about a specific machine performance event.

Abstract: A method is described for automatically determining a proper threshold for a tachometer signal in order to produce desired tachometer pulses necessary for analysis of machine vibration data. A tachometer signal is low-pass filtered to exclude high frequency noise and a running derivative of the filtered tachometer waveform is taken to create a derivative waveform. Another waveform is created that includes only positive values from the derivative waveform that correspond to positive values in the low-pass filtered tachometer waveform. In general, a tachometer signal has the greatest derivative value (slope) when a tachometer pulse is present. Based on this observation, a threshold value is determined using both the low-pass filtered tachometer waveform and the positive-value derivative waveform along with statistics from both waveforms.

Abstract: A span of responsibility access control system for use in plant process management and similar applications. The system leverages span-of-responsibility enabled user accounts and corresponding resource properties to assign, verify, and control access to assets and other resources in the plant process management system on a per user basis. Aspects of the system include configuration of properties for each monitored or controlled asset and association of a span of responsibility based on asset properties, such as asset type and location, with a user account. An access control module compares asset properties to the span of responsibility associated with the user account to determine whether the user is entitled to access any given asset, independent of determining permissions to act on such asset.

Abstract: A process plant management system with asset health normalization and aggregation. Aspects of the system include asset monitoring components that sense operating parameters and determine the condition of assets using a number of disparate asset condition assessment methodologies based on those parameters. The system calculates normalized component health scores from the reported asset condition information and evaluates the normalized component health scores to produce an overall asset health score for each asset. The system maintains a hierarchical representation that organizes assets using physical and logical relationships. The system generates virtual health scores for parent objects in the hierarchy from the health scores of the children of each parent object.

Abstract: A method of messaging control is implemented in a plant wide monitoring apparatus. A computer based framework infrastructure communicates with monitoring applications throughout the plant that are implemented on computers, monitors and computer-based applications. Sensors are placed on machinery and monitors receive sensor signals and generate event signals in response to defined physical occurrences, such as when vibration in a machine is exceeding a defined limit or a sensor is failing. A messaging application in the framework infrastructure generates messages corresponding to the event signals. The messages are transmitted to users based on send rules and suppression rules, which are user configurable. The send rules identify messages to be sent or not sent to a particular user based on characteristics of event signals. The suppression rules prevent the transmission of a message based on both the content of a particular event signal plus an external factor, such as a prior event signal.

Abstract: An extensible computing system for integrating asset health data and user control of devices made by different manufacturers, using a computer and program structures including a common platform application structure and a common platform services structure. A services bus communicates device signals in a standardized format from the common platform services structure to a proprietary extension services structure. The proprietary extension services structure converts the device communication signals from the standardized format to a proprietary communication format that is understood by a proprietary device. A data highway bus communicates asset health and reliability data in a standardized data format from the proprietary extension services structure to the common extension services structure. The proprietary services structure converts asset health data from a proprietary data format as received from the proprietary device into the standardized data format.

Abstract: A rotating machine valve health monitor. Aspects of the valve monitor include instrumenting each valve of a reciprocating compressor, or other rotating machine, with a sensor capable of detecting at least vibration and instrumenting the crank shaft with a sensor capable of detecting at least rotation. A controller directly monitors the operation and condition of each valve to precisely identify any individual valve exhibiting leakage issues rather than only identifying the region of the leakage. The valve monitor uses a relatively high frequency stress wave analysis technique to provide a good signal-to-noise ratio to identify impact events indicative of leakage. The valve monitor uses circular waveforms of vibration data for individual valves to identify leakage by pattern recognition or visual identification. The valve monitor provides ongoing data collection to give warning of predicted valve failure and scheduling of preventative maintenance for failing valves.

Abstract: A universal sensor interface for a machine data acquisition system includes a sensor power control circuit that: (1) provides a fast and accurate limiting response to a short-circuit fault, (2) survives and automatically recovers from multiple concurrent continuous short-circuit faults with no interruption to the electrical and thermal integrity of the acquisition system, (3) reduces power consumption/dissipation when in a faulted condition, (4) isolates adverse effects of a faulted channel from uninvolved channels, (5) isolates adverse effects of loose wiring termination “chatter” from uninvolved channels, (6) protects against adverse effects resulting from “hot wiring” of sensors, (7) protects the acquisition system against reasonably anticipated installation wiring errors, and (8) minimizes the availability of spark-inducing energy to the data acquisition system.

Abstract: A vibration data collection system performs an integration or differentiation process on incoming digitized vibration data in real time. The system uses a digital Infinite Impulse Response (IIR) filter running at the input data rate to provide the integration or differentiation function. With this approach, the system reduces hardware complexity and data storage requirements. Also, the system provides the ability to directly integrate or differentiate stored time waveforms without resorting to FFT processing methods.