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Plant maintenance with predictive diagnostics    
United States Patent5311562   
Link to this pagehttp://www.wikipatents.com/5311562.html
Inventor(s)Palusamy; Sam S. (Murrysville, PA); Bauman; Douglas A. (Apollo, PA); Kozlosky; Thomas A. (Oakmont, PA); Bond; Charles B. (Export, PA); Cranford, III; Elwyn L. (Greensburg, PA); Batt; Theodore J. (Penn Hills, PA)
AbstractAn integrated information system is provided for a plant with interactive processes running in functional equipment subsets, such as a nuclear power generation plant. Sensors are operatively coupled to monitor processes and equipment in the plant, collecting sample data for assessing operational conditions and for predicting maintenance requirements based on loading of the equipment. One or more processors access the sample data and compares present conditions to diagnostic specifications, technical specifications and historical data stored in memory and indexed to equipment subsets and functional operating groups. The processor(s) generate prioritized reports to alert users to potential operational and/or maintenance problems. In addition to the prioritized reports, the processor accesses and outputs to the users reports of the diagnostic and technical specifications applicable to the process parameters exhibiting the potential problems. These specifications are provided in successive levels of detail and are cross referenced between related processes and related items of equipment. The information system integrates operations, maintenance, engineering and management interests in a common database of information via network-coupled data terminals.
   














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Drawing from US Patent 5311562
Plant maintenance with predictive diagnostics - US Patent 5311562 Drawing
Plant maintenance with predictive diagnostics
Inventor     Palusamy; Sam S. (Murrysville, PA); Bauman; Douglas A. (Apollo, PA); Kozlosky; Thomas A. (Oakmont, PA); Bond; Charles B. (Export, PA); Cranford, III; Elwyn L. (Greensburg, PA); Batt; Theodore J. (Penn Hills, PA)
Owner/Assignee     Westinghouse Electric Corp. (Pittsburgh, PA)
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Publication Date     May 10, 1994
Application Number     07/983,935
PAIR File History     Application Data   Transaction History
Image File Wrapper   Patent Term   Fees
Litigation
Filing Date     December 1, 1992
US Classification     376/215 60/660 376/216 422/105
Int'l Classification     G21C 007/36
Examiner     Walsh; Donald P.
Assistant Examiner     Voss; Frederick H.
Attorney/Law Firm     Valentine; J. C .
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USPTO Field of Search     376/215 376/216
Patent Tags     plant maintenance predictive diagnostics
   
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ReferenceRelevancyCommentsReferenceRelevancyComments
5009833
Takeuchi
376/217
Apr,1991

[0 after 0 votes]
4961898
Bogard
376/245
Oct,1990

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4935195
Palusamy
376/249
Jun,1990

[0 after 0 votes]
4908775
Palusamy
702/34
Mar,1990

[0 after 0 votes]
4853175
Book, Sr.
376/216
Aug,1989

[0 after 0 votes]
4803039
Impink, Jr.
376/216
Feb,1989

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We claim:

1. An integrated information system for a plant, the plant having a plurality of equipment units operating interactively in functional equipment subsets according to variable operational parameters, said equipment units being controllable for varying the operational parameters, and the operational parameters of at least some of the equipment subsets affecting loading of others of the equipment subsets, the information system comprising:

a plurality of sensors operatively coupled to the equipment units and sensing values of the operational parameters for assessing a condition of the equipment subsets;

sampling means coupled to the sensors, for collecting and generating at least one of sample values of the operational parameters and information including results of numerical operations on the sample values, and a memory means for storage thereof;

an operational control system coupled to at least one of the sampling means and the memory means, the operational control system being attended by an operator for adjusting the operational parameters during plant operation, the operational control system including diagnostic means for assessing plant operation based on the operational parameters and reporting on plant operation to the operator to enable choices for control of the equipment subsets to vary the operational parameters;

a maintenance monitoring system coupled to at least one of the sampling means and the memory means, the maintenance monitoring system being operable for accumulating a usage factor for a plurality of the equipment units and reporting maintenance requirements of the equipment units to maintenance personnel to enable choices for maintenance operations;

data communications means coupling the operational control system and the maintenance monitoring system for bidirectional communications and sharing of data;

wherein the memory means includes a data memory accessible over the data communications means to both said operational control system and said maintenance monitoring system, the data memory including diagnostic specifications for the operational parameters and technical specifications for the equipment subsets;

the diagnostic means assessing said plant operation as a function of the operational parameters and as a function of the usage factor, diagnostic specifications and technical specifications; and,

the maintenance monitoring system reporting on the maintenance requirements of the equipment units as a function of the operational parameters and as a function of the usage factor, diagnostic specifications and technical specifications, and wherein data defining the operational parameters, the usage factor, the diagnostic specifications and the technical specifications are shared commonly between the operational control system and the maintenance monitoring system over the data communications means.

2. The integrated information system according to claim 1, wherein the plant is a nuclear power plant, and further comprising an automatic control system responsive to the operational control system.

3. The integrated information system according to claim 2, wherein the data communication means includes a remote communication capability.

4. The integrated information system according to claim 2, further comprising at least one engineering analysis system coupled over the data communication means, the engineering analysis system also accessing the data defining the operational parameters, the usage factor, the diagnostic specifications and the technical specifications, said data being shared commonly among the operational control system, the maintenance monitoring system and the engineering analysis system.

5. The integrated information system according to claim 4, wherein the sampling means comprises a plurality of data processing units coupled to at least one information bus, and wherein data from the information bus is coupled to the operational control system and the maintenance monitoring system.

6. The integrated information system according to claim 5, wherein a plurality of the sensors measure safety parameters and are coupled to the operational control system over a separate bus, and further comprising a bridge connection for data transfer between the information bus and the separate bus.

7. The integrated information system according to claim 6, wherein the information bus comprises a plurality of data paths accessible to the operational control system and the maintenance monitoring system, said data paths being arranged in a hierarchy, and further comprising a plurality of data analysis units coupled between the data paths for reducing data collected by the sensors.
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BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to the field of plant control and management information systems, and in particular to an integrated plant monitoring and diagnostic system for shared use by the operations, maintenance and engineering departments of a nuclear power plant. The system collects and monitors operating parameter data via sensors, generates prioritized condition reports including present conditions and anticipated impending conditions to be addressed by preventive maintenance or operational changes, and provides users with background technical and historical data that is ranked and cross referenced by related operational systems and related articles of equipment.

2. Prior Art

Various management information systems are known for monitoring and recording process parameters in connection with power generation as well as with industrial processes generally. These systems often are reactive in that they respond to present levels of monitored parameters, or at most respond to present trends to control generation of alarms and the like when a parameter exceeds preset values or threatens to do so. A typical process control system monitors sensed parameters to ensure that they remain within preset limits defined by the programmer of the system. Often the present levels can be displayed graphically to highlight trends.

Another form of management information system is known in connection with scheduling of maintenance procedures. By defining a useful life for each article of equipment among a number of articles which are related or inter-dependent, it is possible to schedule repair, replacement or preventive maintenance operations more efficiently so as to minimize downtime. The idea is to plan replacement or repair of articles of equipment for as late as practicable before an actual failure, preferably using intelligent scheduling procedures to minimize downtime by taking maximum advantage of any downtime. The scheduling system prompts or warns plant personnel to attend to each of the articles which may need attention at or soon after the time at which the maintenance of any particular article becomes critically important.

U.S. Pat. No. 4,908,775--Palusamy et al discloses a cyclic monitoring system which counts down a defined useful life expected for various structures in a nuclear power plant. This system is responsive to operating levels in the plant, and increases the predicted aging rate of plant structures to account for variations in usage including transient loading. A sampling module is provided to detect the current loading of monitored equipment periodically. Transient and steady state operating levels are determined from the sampled data and used to generate a usage factor. Equipment degradation due to fatigue and the like is anticipated by integrating the usage factor over time. Whereas operating levels and transient disturbances are taken into account in assessing the wear on plant equipment, the system can be used to plan maintenance and replacement activities or alternative plant operations, using a more accurate estimation of the useful life of the plant components.

The predictive maintenance system according to Palusamy '775 incorporates both operational data and a defined useful life data indexed to articles of equipment. However, the system is such that it primarily serves only maintenance functions. It would be advantageous to provide a system that benefits operational and engineering departments as well. The present invention is intended to accomplish this by integrating not only information regarding usage and expected useful life, but by further integrating design and technical specifications and historical data into a system that monitors operational levels as well as equipment conditions. This data is provided in a hierarchical data acquisition and processing system providing shared access by the different departments, especially operations, maintenance and engineering. The data is arranged and cross referenced for presentation of meaningful reports for each of the departments.

Nuclear reactors for generation of electric power are heavily instrumented to enable efficient plant operation and to ensure safety. U.S. Pat. No. 4,961,898 Bogard et al discloses a system operable to record and report neutron emission levels in and around the reactor as well as pressure and flow parameters, for accurately assessing the accumulation of stress on the operating structures. U.S. Pat. No. 4,935,195--Palusamy et al similarly attempts to factor corrosion of the coolant flow path structures for assessing the useful life of reactor components.

Typically, monitoring equipment for a nuclear power plant or similar process is associated specifically with a particular structure or operating system of the plant. For example, in Bogard et al the monitoring system is specifically associated with coolant flow structures. In Palusamy '195 the monitoring system is associated with the neutron emissions. For the most part, monitoring systems of this type are dedicated either to safety purposes (e.g., to detect an unsafe condition and to shut down and/or generate alarms automatically), or to operational control (e.g., to control the positions of valves and the like during ongoing plant operation). Routines which accumulate a usage factor for assessing the loading factor on a particular subsystem could use much of the same data which is collected by safety and control instrumentation. However, the prior art fails to provide a fully integrated system that can take full advantage of the available instrumentation.

It would be advantageous to provide such an integrated system which not only monitors various articles of plant equipment, but which also accounts for the interdependence of the subsystems, makes decisions or predictions in view of stored design criteria, and makes all this information available generally to plant personnel. In specifying the subsystems, design criteria and technical specifications were merged under the assumption that the subsystems would operate under certain conditions. Operational conditions such as equipment problems can change the loading level for a given article of equipment or subsystem, and also the loading levels of other articles and subsystems that are related to or interdependent with the given ones. Therefore, the interrelations of the articles or subsystems, their design specifications, their history and their current conditions should all be taken in account when assessing operational conditions and maintenance needs, or when evaluating operations on an engineering level.

It is generally advisable for plant management and/or maintenance personnel to collect any available data regarding the subsystems operating in a plant or in an area of the plant, to coordinate maintenance and repair activities. In this manner, a downtime for work on one or more articles or subsystems can be used for simultaneous work on others. However, a comprehensive calculation and analysis of relevant plant conditions can be lengthy and costly. In a monitoring system where information on operational conditions is only immediately available to the operators (e.g., for safety and/or control purposes), engineers, scientists, maintenance technicians, managers and headquarters staff must collect and analyze much of the same information in planning their activities. Each group tends to collect and analyze data in a manner that is best suited to their own area of concern. Nevertheless, an integrated arrangement is certainly more efficient and useful than one in which the various departments operate substantially independent information systems.

The present invention is intended to integrate diagnostic and predictive instrumentation for a number of interdependent plant systems, for taking advantage of available synergies. Furthermore, safety and control parameters are collected using a data network arrangement that is shared by primary and auxiliary system control and protection groups, plant maintenance groups, plant engineering and management. In order to accomplish this objective, the plant computerized information system is integrated generally with instrument data collection from a variety of sources, and stored design criteria information. The operational parameters are factored together in an integrated diagnostics and monitoring system with technical specifications for condition directed maintenance and aging management. Specific, actionable diagnostic information on equipment condition is developed, including cross referenced selection of background technical data, whereby operations and maintenance decisions can be made more effectively and from a greater base of knowledge.

The diagnostics and maintenance arrangement according to the invention puts control and safety parameter information to use by the engineering and maintenance departments rather than only the operations control personnel. Conversely, the system makes maintenance and engineering information available to operations and safety groups, thus providing various useful lines of communication and data access availability.

SUMMARY OF THE INVENTION

It is an object of the invention to integrate operational parameter data collection, evaluation based on stored design criteria, and plant information reporting, in a comprehensive plant information system useful for planning operational and maintenance decisions.

It is another object of the invention to make pertinent information readily available for use not only by plant operators, but also generally by engineers, scientists, maintenance technicians, managers and headquarters staff.

It is more particularly an object to collect a wide array of information respecting the character and operational conditions of functionally interdependent elements of a nuclear power generation plant, including design criteria applicable to the elements, and to process this information using intelligent monitoring and diagnostic routines that model operation of the plant to anticipate problems and enable efficient planning of operations and maintenance.

It is another object of the invention to define the overall architecture and operation of a plant information system according to these objects, which is best suited to take advantage of technology advancements as well as available data collection devices, processing apparatus, degradation types and diagnostic methodologies.

These and other objects are accomplished by an integrated information system for a plant with interactive processes running in functional equipment subsets, such as a nuclear power generation plant. Sensors are operatively coupled to monitor processes and equipment in the plant, collecting sample data for assessing operational conditions and for predicting maintenance requirements based on loading of the equipment. A processor accesses the sample data and compares present conditions to diagnostic specifications, technical specifications and historical data stored in memory and indexed to equipment subsets and functional operating groups. The processor generates prioritized reports to alert users to potential operational and/or maintenance problems. In addition to the prioritized reports, the processor accesses and outputs to the users reports of the diagnostic and technical specifications applicable to the process parameters exhibiting the potential problems. These specifications are provided in successive levels of detail and are cross referenced between related processes and related items of equipment. The information system integrates operations, maintenance, engineering and management interests in a common database of information via network-coupled data terminals.

BRIEF DESCRIPTION OF THE DRAWINGS

There are shown in the drawings certain exemplary embodiments of the invention as presently preferred. It should be understood that the invention is not limited to the specific examples, and is capable of variations within the scope of the appended claims. In the drawings,

FIG. 1 is a block diagram illustrating generally a plant information system integrating operation, control, protection, engineering and maintenance information according to the invention.

FIG. 2 is a block diagram of the invention showing modular elements of the invention and the data collection and communication links between the elements.

FIG. 3 is a plan view showing a layout for the data processing portions of the system.

FIG. 4 is a schematic illustration of data pathways for monitoring and control functions.

FIG. 5 is a schematic illustration of a networked installation of terminals sharing access to commonly collected and stored information.

FIG. 6 is a tabular display of actionable directives generated by a preferred embodiment in response to detected conditions.

FIG. 7 is a tabular display of exemplary cross referenced technical specifications referring to certain of the directives provided in FIG. 6.

FIG. 8 is a schematic illustration of an exemplary system architecture according to the invention, as applied to a nuclear power generation plant.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The invention is applicable to a variety of industrial processes wherein data respecting process parameters is collected and reported to enable management decision making. A particularly apt application of the invention is to a nuclear power generation plant. A nuclear plant is normally highly instrumented for collecting information needed to operate at peak efficiency, as well as to tightly monitor operation for safety reasons. The signals developed by sensors for flow, temperature, pressure, valve status, nuclear particle flux levels and the like are to some extent coupled into operational circuits which are intended to effect control operations. According to the invention, sensor signals are coupled to a plant instrumentation control and monitoring center 20 that as shown in FIG. 1 is further coupled to a predictive maintenance and diagnostic center 24.

Information required for pertinent diagnostic information according to the invention includes design criteria applicable to the plant. For example, should a certain valve, flow element, heat transfer device or rotating machine be specified as having an estimated useful life when operated at a particular level of demand, pertinent diagnosis of the element requires that the remaining useful life be decremented as a function of the demand level. Accordingly, the predictive maintenance and diagnostic center is coupled to a diagnostic information center which makes such information available. In the embodiment shown in FIG. 1, the information center 20 is shown as a separate location in data communication with the plant-located predictive maintenance and diagnostic center 24. This is an efficient arrangement where the utility company may have a number of plants which share design aspects. However, the particular location of the respective data storage and computing systems can be varied provided the information is available to each of the processors which need the information.

Referring to FIG. 2, plant operational functions, maintenance functions and engineering functions are all integrated to a common network of information stored, collected and otherwise developed according to the invention. Both operational and safety related sensing and information collection are provided, and made available generally to operations, maintenance and engineering stations and/or users. The system can be physically arranged in a control center setup as shown, for example in FIG. 3, or can be accessed from distributed terminals in various areas of the plant or located remotely as in FIG. 4.

As shown in FIG. 2, the system preferably is based on a hierarchical system of data paths, including interconnections that allow data access without interfering with crucial operations. Safety related sensors 32 coupled to the plant operational elements 34 are sampled using a protective data acquisition system 42 and a control data acquisition system 44, which are separate and parallel. A process protection system 46 and operation control system 48 are coupled respectively to the protective and control data acquisition systems 42, 44. These elements are subject to certain inputs from the primary control and protection station(s) coupled to the protection and control systems through an integrated control system forming a kind of bus wherein operational and safety associated parameters are available to both the control and protection systems. However, the control and protection systems have a number of automatic aspects intended to control the plant to achieve process objectives such as efficient complementary setting of valves and the like as well as the capability of automated shutdown without operator intervention in the event of a safety threat.

Sensors 50 which are not directly safety related (but whose data may have implications with respect to operations, safety and control), are coupled to respective data processing units 54, which are coupled to data acquisition means 56 for collecting and reducing the data. The data processing units can collect sample data from one or a plurality of sensors 32, 50, reject data which is impossibly out of limits, and attend to numerical and/or graphical analyses such as average and standard deviation, peak level identification and the like. Data collected from the nonsafety related sensors 50 can be shared over a distributed processing communication path 58 such as the Westinghouse WDPF distributed processing family. In addition, the data processing units 54 are in communication with a number of monitoring systems 62 over the WDPF data pathway 58. Monitoring systems 62 selectively process available data in order to effect specific functions.

Proceeding from left to right over the WDPF 58 in FIG. 2, an interface or bridge element 64 couples the integrated safety/control system data pathway 66 with the WDPF data pathway 58. The bridge 64 permits data to pass between the integrated safety/control pathway 66 and the WDPF 58 in either direction, but is arranged to allow the integrated safety/control system bus 66 to operate regardless of the condition of the WDPF 58. For example, a failure of an element associated with the WDPF such as a power supply, data processing unit or even a line driver or similar element required for operation of the WDPF, cannot affect operation of the integrated safety/control system due to its isolation via the bridge interfacing element 64.

An auxiliary system control unit 68 is also coupled to the WDPF 58, enabling plant operations personnel to monitor data collected over the WDPF and preferably to control operation of the data processing units 54 from plant operations consoles 72. The auxiliary system control unit 68 is coupled to the data processing units 54 (and thus to the non-safety sensors 50) relatively directly through the WDPF 58. The WDPF data pathway is arranged for communication of data from the sensors 50, 32 to plant operations such that individual variables can be examined. However, in addition, the WDPF data is coupled through the intermediate processing systems 62 to a higher level data pathway identified in FIG. 2 as information highway 78. These intermediate processing systems 62 permit the application of higher level long and short term analysis for converting, e.g., a substantially database form of data collected by the data processing units 54 into more sophisticated statistical analyses, trend analyses and correlations that additionally use data stored in the respective intermediate processing systems 62. The modules of the intermediate processing systems 62 report to any and all of the plant operations consoles, plant maintenance personnel and plant engineering personnel. The same information highway 78 can be coupled to additional users via known networking arrangements, telephone line modem pathways and the like.

The intermediate modules 62 represent systems that can be arranged as processing terminals on a data communication network or concurrently operative routines in a larger and more sophisticated data processing system. The function of the intermediate processing units 62 is to select and analyze data available in a relatively less processed form on the WDPF 58, and to provide information which relies on the values and trends identified in the individual process parameters and in selected groups of related parameters. The output of the intermediate modules 62 is reported to users via diagnostic packages 82 tailored to the needs of the operations, maintenance and engineering departments, respectively. A given department such as maintenance or operations normally at least sometimes requires information from different ones of the intermediate modules 62, and the departments thus share the information relating to the process parameters.

A first intermediate processing module, identified in FIG. 2 as the beacon module 84, is arranged to monitor and report present operating parameters. Present operating parameter information affects not only operations decisions, but also is pertinent to maintenance (e.g., whether a subsystem is in use or available for mechanical work, whether a subsystem is being stressed, etc.). The same information is useful to engineering (e.g., to study the overall condition of the plant or interactions between process parameters). An operator diagnostic advisory unit 86 is coupled to the information highway for the primary purpose of collecting and usefully analyzing, storing and reporting upon operations. The operator diagnostic unit 86 can be arranged to run constantly, reporting information respecting diagnostic information and recommending or suggesting operational changes that may affect or alleviate operational problems or potential problems which may occur.

In addition to the beacon intermediate monitoring system 84 and the operations diagnostic unit 86, a corrosion monitoring system 88, a generator monitoring system ("GENAID") 90 and a transient/fatigue cycle monitoring system ("CMS") 92 operate to selectively analyze data collected by the data processing units and made available as process parameter data over the data highway. This information is also potentially useful in connection with operations, maintenance and engineering decisions. The intermediate processing units 62 are devoted to certain aspects of tasks which affect decisions in all these departments, but are organized in a manner that is not limited to one department. Instead, each of the intermediate processing units serves a particular data set. The data needed by the intermediate processing modules 62 may overlap with data needed by others of the intermediate processing modules, and preferably is broken down into the beacon 84 for present operational conditions, corrosion monitoring 88 for long term deterioration due to ambient conditions such as radiation and chemical conditions, generator analysis (GENAID) 90 for thermodynamic and coolant flow analysis, and transient pressure and flow variation monitoring 92, to assess fatigue.

A predictive maintenance and diagnostic unit 102 is also coupled to the information highway 78, for diagnosing and reporting maintenance problems, and a series of engineering diagnostic units 104 are included. The maintenance diagnostic system 102 is preferably organized in a manner that is most meaningful to maintenance personnel, for example referring to individual pieces of plant equipment instead of functional aspects of the process. However, the maintenance diagnostics are preferably arranged to group devices whose operation has an impact on other devices according to functional groupings as well. Preferably, the plant maintenance diagnostic systems are grouped to provide for analysis of categories such as mechanical devices including valves, rotating machines and the like (which may be subject to frictional problems), and pressure/flow conduits (for corrosion/erosion problems).

Similarly, the plant engineering departments use the information available on the information highway 78, as collected by the data processing units 54 and reduced by the intermediate processors 62. A variety of engineering and diagnostic routines 104 are preferably included, for example grouped for residual coolant system diagnosis, transient diagnosis of pressure, flow and/or electrical loading, generator diagnosis and chemical/nuclear diagnosis. These diagnostic processes are related to operational parameters (like the plant operations diagnostics) and also t specific apparatus (like the maintenance diagnostics), and are presented in a format which is tailored to engineering planning as opposed to operations or maintenance procedures.

A major benefit of integrating data collection and reporting according to the invention is that data need not be collected and analyzed redundantly. Nevertheless, the users of the system can retain the benefit of graphic user interfaces with which users may already using (e.g., in connection with analysis of the operation of subsystems having dedicated monitoring systems.). Although the data collection is common to each of the plant departments, specialized mathematical models, xpert "intelligent" analysis and neural networking are readily achieved.

The invention is particularly applicable to operational, maintenance and engineering functions in a nuclear power plant. Such a plant has a variety of apparatus which can be grouped functionally, and which affect one another in the operational and maintenance procedures and decisions undertaken in the plant. A key input to any decision related to life extension of a nuclear plant is the condition of the plant systems and components critical to the safe, reliable and economical operation of that plant. This means not only the current condition, but the condition predicted throughout the remainder of the plant operation. To establish this effectively, at least two things are needed:

Data on critical parameters related to equipment condition; and,

Engineering decision making capability in terms of evaluating available data, namely extraction, saving and use of monitored data to determine current conditions as well as to predict future conditions and make recommendations on actions needed to attain plant objectives.

Certain applications benefit from simply adding raw data to meet the first requirement. However a typical nuclear plant has extensive existing instrumentation providing abundant data. What is more lacking is an optimal means cohesively to use that data for the second requirement, i.e., engineering decision making. The emphasis in the data interface packages developed for nuclear power plants has been an the needs of the operator and his minute-by-minute needs for operations decisions.

The second requirement is met according to the invention by:

Accessing and supplementing the available plant data;

Establishing evaluation objectives (critical components, associated measures of degradation, criteria and limits, etc.); and,

Implementing a capability to evaluate the data and make recommendations.

Of course the system of diagnostics and monitoring must be cost justified. The relative costs of various maintenance approaches (corrective, preventive, predictive) over the plant life are such that a factor of two improvement in cost can be achieved by using a predictive approach to maintenance instead of traditional approaches.

It is an aspect of the invention that the diagnostic and monitoring functions are integrated, for example into a plant process computer and instrumentation system architecture. In this sense, the plant process computer can include one processor or any number of processors in data communication, for example over the network communication paths described. The architecture of the invention relates to the arrangements and interconnections which link inputs to the process, the defined or required characteristics of the process itself, and the resulting outputs from the process. For the case of a nuclear plant diagnostics and monitoring system, the types of data needed include process parameters, control and response data, and preferably accumulated historical data. This information is obtained from plant instrumentation, distributed plant computer systems, additional sensors which may be unrelated to safety and control systems, test and performance data (whether measured, stored from previous measurements or specified for the equipment) and mainframe data storage. Such data may be stored as to any appropriate frequency of measurement, from milliseconds to years, and may be reduced into the form of average and standard deviation over selected periods or may include raw samples.

The type of available data and the required output define the type and frequency of data processing steps needed to convert the available data into meaningful presentations, and to sift through the available data to detect conditions which should generate a diagnostic warning. One or more processors associated with the hierarchy provide the data processing power and data storage capabilities needed to effect timely calculations on a real-time, automated periodic and/or on-demand basis.

The calculations undertaken by the processor(s) are of the type used in monitoring subsystems for the respective plant components; however, according to the invention the calculations are not limited to input based upon current parameter values in an isolated subsystem. Accordingly, diagnostic routines applicable to a subsystem, as undertaken by the integrated diagnostic and monitoring system, are affected by the conditions in related subsystems. The specific calculations can be mathematical algorithms, logical rule based (as in fuzzy logic) or neural network processes involving a multidimensional chain of calculations and decisions. The calculations can also include statistical analyses and database management type processes.

Output data is to be used to alert operators to conditions which may become critical shortly or not for a long time, and preferably also enable general monitoring as to what is going on in the plant. Accordingly, the output is preferably generated in forms including on-screen graphic and tabular data displays, storage of data on disk, tape or hardcopy, as well as audio and/or video signalling. In addition to selection of data from the inputs or from first or second level information generated from the inputs, the output data includes diagnostic information for monitored devices and subsystems, recommendations for action which are selected based on the diagnostic information and plant conditions, and additional backup information about the devices and subsystems (such as their physical characteristics, ratings and the like), from which the operators can discern the basis of the diagnosis and recommendations.

The users of the output generated by the system include most types of plant personnel. General categories of users include the operations support staff, maintenance, engineering and scientific staff, and plant management. Outside of the plant, headquarters engineering and management staff preferably have access to the data, and it is even possible to allow vendors access in order to enable them to assess the conditions under which requested equipment is to operate, or to assess the present conditions applicable to equipment already supplied. Under such conditions the vendors may be aware of an aspect of the equipment that should be made known for diagnostic purposes.

Insofar as users remote from the processor generating the output data may be coupled to the processor, various high speed and low speed data communications links can be employed. Such users may be on-site or off-site, and are coupled in data communication with the processor by hardwire, modem, radio or fiber optic links, as required in view of the data capacity needed.

For output and display, utility personnel need specific diagnoses of critical aspects of plant condition. According to the invention, such critical aspects are ranked and prioritized in a tabular display 110 from which the user can select further information on the diagnosis, the recommended corrected action, and background information on the affected structural elements and/or plant subsystems. The current status of the plant must always be available and easily accessible. A sample of a tabular display of diagnostic considerations in summary form appears in FIG. 5.

In the example shown, there are a number of conditions 114 rated by priorities 116. The list includes conditions which represent reactor status or operational information, and some suggesting a need for maintenance. Based on preprogrammed relationships between components of the plant, operations and maintenance personnel can react as appropriate. FIGS. 6 and 7 are examples of backup information respecting the items mentioned in the diagnostic summary. In the example, a valve identified as 8701A is described as having an incorrect stem packing tightness. Based only on the information on the summary, the implications of incorrect stem packing tightness in the particular valve may be unclear. However, the diagnostics summary 110 is a gateway to additional information describing the valve, and in fact also includes reactor operational information which likewise identifies the valve as an element in need of attention.

Item 2 on the diagnostics summary states that thermal stratification in the residual heat removal (RHR) system exceeds level 1 limits, level 1 being a minimum warning threshold. By selecting item 2, the operator is provided with background information 120 on RHR thermal stratification conditions. The backup information as shown in FIG. 6, includes a longer explanation 124 of the problem, a description 126 of the consequences of inaction, and recommendations 128 for activities which may fix the problem. In the example, the explanation identifies valve 8701A as the likely culprit, suggesting that the valve may be leaking. In conjunction with the diagnostics summary, the user is led immediately to the cause of the problem and can readily assess the severity thereof.

The residual heat removal system is an operating subset of the reactor, and preferably a series of tabular, graphic and text screens can be selected by paging through the respective levels of diagnosis. FIG. 7 illustrates further informational screens 130 under the groupings of RHR Stratification Status, and also Valve Monitoring Status, which are alternative cross referenced paths leading to a resolution of the problem shown in the summary 110. The screens applicable to RHR Stratification include the subject valve, and the screens relating to valve monitoring mention the function of the subject valve. By proceeding through the screens and selecting cross referenced information it is possible to obtain a full picture of the situation.

Preferably, the diagnostic system includes means 132 for the user to acknowledge receipt of the recommendation. In this manner the system ensures that appropriate attention is paid by those people who can act on the recommendation, and one person does not assume that another is taking responsibility for attending to the recommendation. Acknowledgement, as well