Title of Invention

SYSTEM AND METHODS FOR MANAGING REPLACEABLE COMPONENT FOR EQUIPMENT OR REMOTE EQUIPMENTS

Abstract A system for managing replaceable components for equipment (300, 400) having a plurality of components, each with a limited useful life. It has a computer with at least one processor (100); a module (120) for defining a duty profile (220) comprising a plurality of usage cases for the equipment, and for determining a theoretical useful life for each component. The theoretical useful life is based on component wear/stress/strain parameters under the operating conditions. Sensors (302, 402) are provided for determining, monitoring and making measurements of actual operation conditions. A memory (210) stores the measurements of actual operating conditions. A module (120) computes an adjusted theoretical useful life for a component. A method for managing replaceable components and a method for managing such components at remote locations are also disclosed.
Full Text BACKGROUND OF THE INVENTION
[001] The present invention relates to system and methods for managing replaceable
components for equipment by monitoring and managing the lifecycle of the equipment
or the remote equipment. More specifically, the present invention relates to apparatus
and methods for predicting preventive maintenance periods and component
replacement needs.
[002] Machinery requires periodic diagnostic maintenance to detect machine part
wear, predict failure, and locate problems. In modern machinery, such as marine
machines, cranes, automatic transmissions, turboshaft engines, paper mills, rolling
mills, aircraft engines, helicopter transmissions, and high-speed process machinery,
failure of bearings, gears and other equipment frequently result in costly productivity
loss, severe and expensive secondary damage, and potentially life threatening
situations. Equipment failures occur because, over time, gear/bearing assemblies and
other parts that are stressed experience wear and damage, such as spalled bearing
rolling elements, pitting on gear teeth, and bearing race damage.
[003] To ensure safety and avoid unscheduled interruptions, critical components are
typically replaced at conservative fixed intervals based simply on periods of use.
However, wear factors such as load magnitude, displacement distances, time periods
under load, and speeds of displacement may heavily influence equipment wear and
damage. Consequently, when the wear factors are above normal for a significant period
of time, the equipment can prematurely fail. On the other hand, when the wear factors
are minimal for a significant period of time, simply relying on periods of use to trigger
component replacement can increase the costs of operation. This is because useful
component life is wasted, costs are increased due to more frequent maintenance, and
productivity is decreased due to more frequent maintenance shutdowns.
[004] There is a need in the art for a system that will more accurately predict
preventive maintenance periods and define component replacement needs. Also,there is
a need in the art for a method that will more accurately predict preventive maintenance
periods and component replacement needs.

BRIEF SUMMARY OF THE INVENTION
[005] The present invention, in one embodiment, is a system for managing
replaceable components for equipment having a plurality of components, each with a limited
useful life. The system comprises: a computer with at least one processor; a computer
program module for defining a duty profile comprising a plurality of usage cases for the
equipment, each usage case involving two or more of the plurality of components and
specified operating conditions assumed to be experienced by the involved components during
the execution of each of the usage cases; and a computer program module for determining a
theoretical useful life for each component involved in a duty profile, said theoretical useful
life being based on component wear/stress/strain parameters assumed to occur under the
specified operating conditions. The systems further comprises sensors for determining and
monitoring the occurrence of equipment operation corresponding to a usage case and making
measurements of actual operating conditions experienced in the operation; a memory for
storing the measurements of actual operating conditions for the plurality of components; and
a computer program module for computing an adjusted theoretical useful life for a
component after it has experienced one or more operations, by: responsive to the
measurements of actual operating conditions, calculating one or more calculated
wear/stress/strain parameters for each operation and accumulating these calculated
parameters for such component; and, based on a comparison of the accumulated, calculated
wear/stress/strain parameters from actual operating conditions to accumulated
wear/stress/strain parameters assumed to occur under the specified operating conditions in the
determination of a theoretical useful life, determining the amount of the adjusted theoretical
useful life consumed in the one or more operations.
[006] The present invention, in another embodiment, is a method for managing
maintenance of remote equipment with replaceable components. The method comprises:
providing on said remote equipment a plurality of sensors that sense operating conditions for
each of one or more replaceable components; receiving at a database operating condition data
sensed by said plurality of sensors; comparing at least a portion of the sensed data to one or
more design duty profile parameters for the remote equipment; and in response to the step of
comparing, identifying one or more replaceable components that are recommended for
replacement, with a suggested future date for replacement.
[007] The present invention, in another embodiment, is a computer program stored
on computer readable media for use in a system for managing replacement components for

equipment having a plurality of components each with a limited useful life. The program
includes software components as described above for the system embodying the invention.
[008] Yet another embodiment of the present invention provides an automated web-
based service designed to let clients interface online or offline with any drilling equipment
coupled to the system. On-site operators or personnel remote from the site, e.g., the f
headquarter of the company; can utilize information and knowledge stored among huge
amounts of data. A part of the concept is to acquire and redirect existing equipment
instrumentation signals into a centralized database. By also applying corporate knowledge
about the equipment, like theoretical models, diagnostic algorithms, statistics, work load-
accumulation, etc, a service provider can provide value added data back to the company
operating the equipment. The system may deliver last hour statistics from one specific
machine, or advanced diagnostic algorithms applied across equipment operated by different
companies. The system may help pinpointing potential areas for improved performance as ;
well as assisting in predicting and planning on-demand maintenance.
[009] There are two main approaches to equipment condition analysis. One is based
on advanced engineering and mathematical modeling, which provide a reference for
comparing measured operational data with theoretical data. The second, more common
approach is that there is no known reliable model or theoretical knowledge for operation and
wear on the equipment. In that case, empirical analysis of trends and patterns in large
amounts of collected data, from a large number of equipment units, may over time provide
better and better interpretation of equipment conditions.
[010] Whatever method is used, better condition models will enable calculation of
weighted equipment use, i.e., use measured not just by time or repetitions of the operations
but based on load or other conditions that effect equipment life. Obviously, there is a huge
difference between 1000 running hours with heavy load and 1000 running hours without load
at all. Some parts wear faster with certain operating conditions, e.g. higher speeds, others
with different conditions, e.g., higher load. It is possible to define a "wear-map" for each
component of any machine. By combining this wear-map with operational data, a figure for
remaining lifetime can be estimated for wear parts. This will form the basis for a Reliability
Centered Maintenance (RCM) approach, where from current condition and remaining
lifetime data, one can dynamically estimate service and inspection intervals and spare part
requirements. This provides for longer service and inspection intervals with little or no
increase in chances of failure. Reliability and safety can also be improved.

[011] A typical system according to a further embodiment of the invention may
comprise the following main elements:
• Instrumentation (including sensors)
o This may be existing instrumentation on the equipment and/or new
instrumentation
• On-site computer - A physical data acquisition unit located on or near the
monitored equipment and coupled to the instrumentation,
• Server receiving data from a plurality of on-site computers and with capability
to upgrade software in the on-site computer
• Communication network, e.g., the Internet
[012] The RCM service may be in two modes: (1) Local monitoring - made on-site
or within an existing company network; or (2) Performance monitoring - provided by one or
a group of servers operated by a service provider. The local monitoring mode is intended for
provision of raw data and simple statistics. The performance monitoring mode provides
higher-level information, more deeply analyzed data, where the service provider's
accumulated knowledge and machine competence has been applied to the raw data.
[013] The system is designed to provide a single point of configuration for the
service and for the equipment involved. In a dedicated web service, service administrators
can configure, all the elements of the service. The configuration process involves:
selecting equipment to monitor
selecting on-site computer type for data acquisition
selecting and configuring signals and parameters for the data logger
selecting and configuring calculations, filters and logging frequency for the data
logger
selecting and configuring communication routes
- selecting accumulated knowledge to be applied at the central server
- defining and setting up company, plant and user accounts
[014] Based on the input, the management database in the central server may
produce:
- an XML configuration file to automatically set up all aspects of the data logger
an XML configuration file to automatically set up the local monitoring
- an XML configuration file to automatically set up the local monitor content
- automatic configuration and set up of database tables in the performance monitor

- automatic configuration of the data receiver in the server - a logstream handler
[015] For each type of equipment or component there may be defined a empirical
service model. This may be expressed in: algorithms; constants; performance limits,
including 2D performance limits; and error codes. To facilitate incorporating empirical
learning, the service provider regularly explores data collected and correlates it with known
incidents, events, inspections and replacements. Various data-mining techniques can be used.
[016] Also to facilitate empirical learning, the product manager will be authorized to
explore and able to gather all equipments for all clients with the same view and with the same
analysis tools. The manager can:
- view parameters over time
view parameters versus load
view parameters versus any other categorized parameter
- build statistics from data on
o Alarms
o Operation
o Maintenance
o Any other monitored and accumulated data
explore details surrounding accidents, events or incidents (e.g., broken parts)
Based on this, he can develop new algorithms and performance limits to implement in the
data analysis processor for the equipment type.
[017] While multiple embodiments are disclosed, still other embodiments of the
present invention will become apparent to those skilled in the art from the following detailed
description, which shows and describes illustrative embodiments of the invention. As will be
realized, the invention is capable of modifications in various obvious aspects, all without
departing from the spirit and scope of the present invention. Accordingly, the drawings and
detailed description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE/DRAWINGS
[018] FIG. 1 is a schematic block diagram of one embodiment of the system of the
present invention.
[019] FIG. 2 is a flow chart showing the steps involved in using the system of FIG. I
to produce a useful life analysis report and other maintenance recommendations.
[020] FIG. 3 is flow chart showing how the system of FIG. 1 is used to handle
maintenance data.

[021] FIG. 4a is a representation of a screen display for an internet entry portal into a
computer system using the subject invention.
[022] FIG. 4b is a representation of a screen display for an interactive map used in a
computer system using the subject invention.
[023] FIG. 4c is a representation of a screen display for an over-due or scheduled
maintenance module.
[024] FIG. 4d is a representation of a screen display for a maintenance and parts
manual module used in a computer system using the subject invention.
[025] FIG. 4e is a representation of a screen display for a data acquisition module
that shows operating data and useful life data and is used in a computer system using the
subject invention.
[026] FIG. 4f is a representation of a screen display for a spare parts module used in
a computer system using the subject invention.
[027] FIG. 5 is a chart outlining a simplified component useful life analysis based on
a theoretical duty profile and assumed operating conditions.
[028] FIG. 6 is a chart outlining a simplified component useful life analysis as in
FIG. 5 based on an actual duty profile and actual operating conditions.
[029] FIG. 7 is a graphical display comparing actual component usage versus a
theoretical component usage profile.
[030] FIG. 8 is a graphical display of a component usage profile for a first
component.
[031] FIG. 9 is a graphical display of a component usage profile for a second
component.
[032] FIG. 10 is a graphical display of a component usage profile for a third
component, which is planned for replacement.
[033] FIG. 11 is a schematic block diagram of another embodiment of the system of
the present invention.
[034] FIG. 12 is a data flow diagram showing certain data processing components of
the on-site-computer of the system of FIG. 11.
[035] FIG. 13 is a another data flow diagram showing certain data processing
components of the system of FIG. 11.
[036] FIG. 14 is a further data flow diagram showing certain data processing
components of the on-site-computer of the system of FIG. 11.

[037] FIG. 15 is a flow chart showing the steps involved in using the system of FIG.
11 to collect and analyze data.
[038] FIG. 16 is table of typical parameters measured and logged for a mud pump.
[039] FIG. 17 shows in the upper part some constants that are used in the
calculations of calculated parameters and in the lower part a table of typical calculated
parameters for a mud pump.
[040] FIG. 18 shows a table containing the limit values for some critical parameters.
[041] FIG. 19 shows a screen print containing a table with measurements made for a
mud pump.
[042] FIG. 20 shows a screen print containing a chart showing the flow from a mud
pump, with the flow plotted against time.
[043] FIG. 21 is a screen print containing a chart showing the discharge pressure
distribution in a mud pump against the rotational speed of the pump.
[044] FIG. 22 shows an example of a typical performance chart for a mud pump,
showing the distribution of the pump utilization.
[045] FIG. 23 shows a screen print containing a chart of the running hours of a mud
pump.
[046] FIG. 24 shows a screen print containing a chart of the use of a mud pump with
reports minute-by-minute.
[047] FIG. 25 shows a plot of the torque of two motors A and B running the pump
for a period of time starting at 01:00 and showing that at 02:15 a failure of the pump
occurred.
[048] FIG. 26 shows a table that embodies a set of 2-dimensional performance
limits.
DETAILED DESCRIPTION
A. Equipment Design And Component Useful Life
[049] When sophisticated equipment is designed, it is frequently defined with a
planned useful life for the overall item of equipment. In reality, the design must take into
consideration the useful life of a variety of components. For components that are critical to
useful life, there is usually useful life data available from a manufacturer or other source that
has actual test data on useful life and/or theoretical projections that are derived from actual
useful life data. Typically, the useful life is specified for one or more defined, assumed
operating conditions. An operating condition may be specified in terms of a rate, such as
speed or load, and a time duration for experiencing that speed or load and/or a distance for

maintaining the rate of work, but may also include other operating conditions, such as
environmental factors that may affect useful life, e.g., operating temperature, humidity,
corrosives or particulates present. The theoretical useful life for a component under the
assumed operating conditions may then be expressed in terms of hours, days or other
extended time interval. Typically a graph or set of graphs showing the effect of load, speed
or other operating conditions on useful life will be available (or may be developed from
existing data and theoretical or empirically derived formulas) as a design guide. In some
instances, testing may need to be performed to establish accurate useful life data for a
component. Whatever the source, equipment designers typically have reliable data that
shows the relationship between a range of operating conditions and duration or repetitions of
these conditions and the useful life of a component that that may be selected in the original
design.
[050] The useful life problem is not particularly difficult when a single component
operating in one or a small number of modes is all that is under consideration. But in
complex systems that carry out different operations, the useful life is more difficult to
determine. One technique known by equipment designers is to define a duty profile. A duty
profile defines certain operations that the equipment will perform and determines which are
the key components that are involved in each operation and how they will be used in that
operation. A duty profile may be described for an expected (or design goal) overall useful
life of a piece of equipment. For example, the following might define a duty profile for a
mooring system used on an offshore oil platform:

Case No. Operation
1 Raise 4000 ft of chain plus 10 metric tons anchor from sea bottom
2 Payout 4000 ft of chain with anchor on work boat
3 Inhaul 4000 ft of chain with anchor on work boat
4 Payout 8000 ft of wire rope with anchor on work boat
5 Inhaul 8000 ft of chain with anchor on work boat
6 Anchor setting on chain (300 ft + 100 ft)
7 Anchor setting on wire rope (500 ft + 100 ft)
8 200 ft rig excursion on chain

9 400 ft rig excursion on wire rope
[051] This duty cycle might be defined for an overall design life of 25 years with six
rig moves per year and twelve rig excursions per year.
[052] Alternatively, the duty profile might be described in terms of what functions
equipment performs and, in any given time interval, what proportion of that time interval the
equipment will be performing each operation or no operation. E.g., for a crane, the following
duty profile might be used:

[053] Returning to the first duty profile example, with such a duty profile defined
the mooring system designer can then determine what key components (winches, motors,
gear systems, shafts, bearings, wire rope, etc) are involved in each case and what operating
conditions are required for each of the key components in each usage case. Most components
will be involved in more than one case and may be operated at different operating conditions
for different cases. This permits the computation of the duty profile requirements for each
component for the assumed duty profile and the overall design life. The designer can then
choose components with useful life characteristics that permit that component to be used for
the assumed duty cycle for at least the overall design life. In some cases, the available
components may not exactly fit the overall design life, and a component may be selected that

is determined to have a useful life under the assumed duty profile that exceeds the overall
design life. In other cases a component may not be available or may be cost prohibitive if it
must meet the overall design life without replacement. In this case, a component useful life
under the assumed duty profile (including assumed operating conditions) may be calculated
and replacement of such component at intervals during the overall useful life can be planned.
[054] However, the actual operating conditions for the equipment may be more or
less severe than the duty profile assumed for the original design. For the owner or operator of
the equipment, this has several implications. Maintenance on components may be required
sooner or later than originally planned. Some components that were not expected to require
maintenance during the design life will require maintenance where the duty profile is more
severe that the duty profile used in the original design. It is much better to perform such
maintenance on a scheduled basis than it is to have an emergency maintenance session in the
midst of planned productive use of the equipment (which must now be interrupted) or to have
an equipment failure. The latter may involve injury or damage causing losses that go far
beyond loss of use of the equipment.
[055] Past methods of addressing this situation include simply observing equipment
operation and intervening when a near-failure or failure becomes observable. Alternatively,
in some situations a sensor may be used to detect when an equipment component is near
failure, e.g., because it deforms or requires greater than normal operating forces or its
characteristics otherwise change. Such methods may defer maintenance until needed, but
they may also result in equipment being operated to a point of failure or near-failure, where
immediate, unplanned emergency stoppage is required.
B. Overview Of Present Invention
[056] The present invention attempts to reduce or avoid such unplanned
interventions and to perform on a planned basis component replacement, even in situations
where the duty profile in actual use is quite far from the duty profile used in the original
design of the overall useful life.
[057] FIG. 1 is a schematic block diagram indicating the elements of a data
acquisition and management system in accordance with the present invention. This system is
intended to manage component replacement for one or more items of equipment. FIG. 1
shows a crane 300 and a winch or mooring system 400 as examples; other types of equipment
and more than two items of equipment may be managed by the system.
[058] As will become apparent from the following discussion, the system monitors
and collects data from operations performed by the equipment. More specifically, the system

monitors and collects data from the operations performed by individual components that
comprise the overall equipment. The system is able to provide "real-time" access to
operations of the equipment and its components. The system allows direct comparison of
actual operating conditions experienced by the equipment to the original theoretical duty
profiles considered by the designers of the equipment. The system can then analyze the
differences between the actual and theoretical duty profiles, develop information adjusting
the original component useful life projections and schedule maintenance accordingly. The
system uses the analysis to ascertain the amount of component useful life exhausted as of that
point in time when operating condition data is collected.
[059] As shown in FIG. 1, the system includes a communication network 10 and a
computer system 40 with an output device 22 (such as a printer) and a maintenance manager
terminal 30. The system further includes equipment operator/owner terminals 50, 52, two
sensor data links 304 (for crane 300) and 404 (for winch system 400), each with
corresponding multiple sensor inputs 302, 402 (for simplicity, only three inputs are shown for
each of crane 300 and winch 400, although many more sensors could be placed on the
equipment to provide inputs) that are associated with particular components and their
operating parameters within crane 300 and winch 400.
[060] The computer 40 includes a processor 100 with an operating system,
communications management devices 110, and applications software 120. The applications
120 have access to a database 200 including files for operating conditions data 210, duty
profiles 220, manuals/maintenance information 230, and ordering information 240, as well as
other data that may be used by the system.
[061] The communications management devices 110 communicate with a
communication network 10 (which may be a public data network such as the Internet or a
private network) via a communication link 12. The computer 40 is interconnected to the
maintenance manager terminal 30 and the output device 20 via communication links 22 and
32, respectively. The operator/owner terminals 50, 52, which may use a browser to access a
web site supported on computer 40, are interconnected to the communication network 10 via
communication links 24 and 26, respectively. The equipment operator/owner terminals 50,
52 allow the operator/owner to access via an Internet portal the "real-time" equipment
operation and maintenance history files generated by the system. The features that an
operator/owner may access at the Internet portal are further described in section C of this
specification.

[062] Sensor inputs 302 are located on the crane 300 to monitor operating conditions
in key components such as the slewing bearing, container ring bearing, winches, boom, etc.
For example, in the context of the crane 300, the sensor inputs 302 might include: a swing
angle sensor for measuring radial boom displacement; a boom angle sensor (i.e., an
inclinometer) to measure boom incline displacements and boom angles; and a load sensor for
measuring the strain in the backleg structure (knowing the crane geometry, the system
converts the reading from the load sensor into an equivalent loading of the roller circle or
slewing bearing). Similarly, sensor inputs 402 are located on the winch 400 to monitor
operating conditions in key components such as the drum, drum bearings, levelwind, etc.
[063] The sensor inputs 302, 402 communicate operating condition data to their
respective sensor data links 304, 404. The sensor data links 304, 404 forward the operating
condition data to the to the computer 40 via the communications management devices 110 in
the computer 40 via the communication network 10. In one embodiment, the sensor data
links 304, 404 use existing PLC's on the equipment and supplemental programming on the
PLC's to gather data from the sensor inputs 302, 402. This data is formatted using XML or a
similar standard then transmitted to or shared with a PC or other processor programmed and
configured to use TCP/IP or other data transmission protocols to transmit data via the
communication network 10 to computer 40. Thus, the equipment 300, 400 may be located
remote from, even great distances away from, the computer 40. The applications 120 receive
and store the incoming operating condition data in the operating conditions data files 210 in
the database 200. The operating conditions data is then available for analysis, including
further processing so that it may be compared to and utilized in the component wear models
defined by the duty profiles 220, as explained in the following discussion directed to FIG. 2.
[064] FIG. 2 is a logic diagram illustrating the processes 1200 executed by the
applications 120 with respect to the operating condition data and the duty profiles. Before the
process can be executed, the relevant duty profiles 220 from the original design and any
supporting data used to analyze component useful life under various operating conditions
must be loaded. This data is coordinated with and used by the applications 120. As shown in
FIG. 2, the process 1200 begins with a start/wait state 1202. When the process 1200 is
initiated, it inquires whether new operating condition data is present 1204 (i.e., whether new
operating condition data has been received from the sensor inputs 302, 402). If the new
operating condition data is not present, then the process 1200 determines whether a sensor
status check is needed 1206. This check is performed to determine whether or not the failure
to receive new operating condition data is the result of a malfunctioning sensor. If a sensor

status check is needed, then the process 1200 performs the sensor status check, and reports the
result 1208. The process then returns to the start/wait mode 1202.
[065] If the process 1200 determines that there is new operating condition data
present 1204, then the new operating condition data is received and stored 1210 in the
system's database 200. The process 1200 then determines whether a real-time analysis
request is present for the equipment 1212. If not, then the process 1200 determines whether a
scheduled, periodic analysis is due 1214. If no periodic analysis is due, then the process 1200
returns to the start/wait mode 1202. If the periodic analysis is due (for example, the end of a
defined monitoring period for a particular piece of equipment, such as a day, week, month
etc., is present), then the process 1200 accesses the operating condition data for the particular
item of equipment and prepares the operating data for comparison and analysis 1216.
[066] If the process 1200 determines that a real-time analysis request is present for
the equipment 1212, then the process 1200 proceeds directly to access the operating condition
data for the equipment and prepares operating data for comparison and analysis 1216. The
process 1200 then accesses the duty profile for the equipment and checks for maintenance
updates 1218 that may have recently occurred and that may affect a duty profile analysis.
The process 1200 then performs comparison and analysis of the operating condition data
against the duty profile for the equipment 1220.
[067] As described in section D of this specification, the duty profile is part of the
initial design process and is used to select the original components and to develop a
theoretical useful life for each key component under assumed operating usage cases and
operating conditions. The duty profile and its assumed operating conditions, and the
component useful life data that were assumptions in the original design, are revisited during
comparison and analysis step 1220 to make adjustments to component useful life predictions
and any corresponding maintenance plans, after some actual operating condition data has
been gathered.
[068] The process 1200 then determines whether critical useful life results are
present for any component 1222 (i.e., whether any component has reached, or will soon reach
(is within a critical range of), the end of its useful life and require maintenance or
replacement immediately). If not, the process 1200 prepares useful life results and schedules
planned service 1224. This includes preparing electronic and/or paper reports on operating
conditions, useful life and recommended long and short term maintenance plans by
component. A scheduled replacement need may be signaled when the amount of the
theoretical useful life consumed is within a replacement range of the adjusted theoretical

useful life. The process 1200 then determines whether auto order of any components is
specified 1226. If auto order is not specified, the process 1200 sends a planned service and
request for order notice 1228 to the equipment owner/operator and any parties involved in
maintenance service. This prompts relevant personnel to place necessary component orders.
If the auto order is specified, the process 1200 arranges for components to be obtained and
shipped and for maintenance to be performed per a system-generated schedule 1230.
[069] If the process 1200 determines that critical useful life results are present for a
component 1222, then the process 1200 issues a report on an expedited basis (e.g., e-mail to
terminals 50, 52; fax; messages back to sensor data links 304, 404) and schedules emergency
service 1232 by contacts with maintenance service personnel and the equipment
owner/operator. The process 1200 then arranges for components to be obtained and shipped
and for maintenance to be performed per a system-generated schedule 1230. The process
1200 then updates the maintenance log records based on the report of completed maintenance
1234. The process 1200 then returns to the start/wait mode 1202.
[070] FIG. 3 illustrates a process 1300 for entering maintenance information into the
system. Maintenance can affect useful life computations when a replacement component is
inserted into the analysis. This is because a new component has no past operating conditions
as part of its history. Also, a new component may or may not have a different theoretical
useful life under the assumed operating conditions.
[071] The process 1300 initializes the maintenance log based on equipment
configuration 1302. The process 1300 then awaits periodic or special maintenance reports for
equipment 1304, e.g., input from terminals 50, 52 if maintenance is logged by the
owner/operator or from terminal 30 if logged by operators of the system of FIG. 1.
[072] The process 1300 next determines whether new maintenance log data is
present 1306. If not, then the process 1300 continues to await maintenance reports for the
equipment 1304. If new maintenance log data is present, then the process 1300 stores the
maintenance log data with the referenced components in a particular equipment configuration
for which maintenance has been performed 1308.
[073] The process 1300 then determines if maintenance log data affects any
component useful life data 1310. If no, then the process again awaits maintenance reports for
the equipment 1304. If the maintenance log data does affect any component useful life data,
then the process 1300 updates the component useful life data and any affected duty profiles to
reflect the maintenance 1312, including possible changes in component useful life data files.
The process 1300 then again awaits maintenance reports for the equipment 1304.

C. Features Accessible Via The Internet Portal
[074] In one embodiment, the operator/owner, maintenance personnel, or service
provider may access the system on-line via the Internet. In doing so, the person accessing the
system enters an Internet portal (see FIG. 4a) that is designed in a modular format
incorporating standard web-based protocol architecture. The internet portal provides access
to modules pertaining to the equipment associated with the system. The modules are
accessible via multiple navigation paths for any of the equipment associated with the system.
In one embodiment, the modules include a maintenance module, a maintenance and parts
manuals module, a data log module, a spare parts module, and an equipment location map
module.
[075] In one embodiment, the operator/owner will be able to access on-line an
interactive map of the world or part of the world, as illustrated in FIG. 4b. The map will
show the locations of the owner/operator's equipment that are under management by the
system. Clicking on the desired location or equipment provides the owner/operator, based on
the selections made, access to the modules and/or data for each piece of equipment.
Alternatively, a customized, dynamically-created bar menu, based on each owner/operator's
equipment list, is displayed across the top. Drop down menus bring the owner/operator
directly to the modules for each piece of equipment. The system can be customized to meet
each owner/operator's operations utilizing standard web site architecture.
[076] The maintenance module is designed to provide easy access to maintenance
records via the web portal. Each person (with Internet access) signing onto the system will
have a unique password that will provide for varying levels of access. For example, an
individual or individuals completing the actual maintenance of the equipment could have
access only to the input data sheets for recording the inspection time and data. Their
supervisor would have access to the next level reports illustrating maintenance history. Each
level of access is controlled by the log-on password.
[077] Each piece of equipment in the customer's inventory has a scheduled
maintenance interval that is loaded into the system. The system provides for automatic
notification of maintenance tasks that are due and their due date. The over-due or scheduled
maintenance task screen shown in FIG. 4c illustrates the type of data that would be available
for maintenance supervisor to efficiently schedule his maintenance assignments.
[078] Once the maintenance is completed, the data is loaded into the system and is
accessible on-line by any person with security access to this portion of the module. All

maintenance records are kept up to date, allowing for "real-time" access and planning of
preventive maintenance.
[079] The maintenance and parts manual module provides "real-time" access to the
latest updated documents. These manuals are updated periodically on the system and sent to
a owner/operator's home office for distribution to the piece of equipment. The online access
to manuals, as portrayed in FIG. 4d, provides the maintenance and operators instant access to
updates to service modifications and safety features for the equipment under management by
the system.
[080] The data acquisition module provides access to historical information detailing
the actual loading or other operating conditions for each monitored component in the piece of
equipment recorded over the life of the component. This recorded data is compared with
theoretical design considerations (design profiles) and these comparisons are used to predict
preventive maintenance schedules for the monitored component. As illustrated in FIG. 4e,
the data log module can also use operating condition data to tabulate and sum the total
throughput of an individual piece of equipment providing information for planning,
production schedules, and maintenance schedules.
[081] The spare parts module provides for access to parts manuals and drawings. As
indicated in FIG. 4f, the bill of material is available on-line along with the appropriate
drawing listing. The component part can be identified on-line and inventory status,
quotations and deliveries can be provided. The component can be ordered on-line.
D. Simplified Exemplary Theoretical And Actual Component Useful Life Calculations
[082] A highly simplified example of the process of calculating the theoretical and
actual component useful life for individual components of equipment X (e.g., a crane, winch,
loader, etc.) will now be given. While component wear is a function of multiple factors such
as force, torque, displacement speed, acceleration, deceleration, temperature, corrosion,
particles, surface treatment, lubrication, friction, etc., for the sake of understandability,
component wear in the following example, is equated with the work (i.e., force or torque
multiplied by displacement) done by the equipment.
[083] In general terms, the process of the invention initially plans maintenance for
equipment X based on assumed theoretical duty profiles, which are based on assumed
operating conditions. As equipment X begins its operational life, operating condition data is
collected by the system. The collected data is utilized to adjust the theoretical duty profiles

of equipment X. The adjusted duty profiles are then used to adjust the maintenance schedule
for the equipment. The adjusted duty profiles are also used to calculate the amount of
equipment life exhausted up to that point in time. The adjusted duty profiles are also utilized
to project the remaining expected equipment life.
[084] As can be appreciated from the following example, actual operating conditions
can shorten or lengthen the actual equipment and component useful life relative to the
original assumed equipment and component useful life depending on whether the actual
operating conditions are more or less harsh than originally assumed. As can be appreciated
from the preceding FIGS, and discussion, and as will become more clear from the following
discussion, the system and process of the subject invention allows the predicted equipment
life and maintenance schedule to be automatically updated based on equipment X's real-time
operational data. The simplified example is as follows.
[085] FIG. 5 illustrates an exemplary, but highly simplified, Assumed Duty Profile
analysis broken down by component for equipment X (e.g., a crane, windlass, loader, etc.).
As shown in FIG. 5, equipment X has components A, B and C.
[086] In calculating an assumed duty profile, an equipment designer first assumes an
equipment design life for the equipment in question. For this example, the assumed
equipment design life for equipment X is 25 years. The designer then assumes the types and
numbers of operations (i.e., usage cases and their repetitions) equipment X will be subjected
to during its assumed equipment design life. Each usage case is assumed to be a specific type
of operation at a specific level of loading and displacement.
[087] As indicated in FIG. 5, equipment X is assumed to perform three different
usage cases (Usage Cases 1, 2 and 3) over the course of its assumed equipment design life. It
is assumed that equipment X will perform Nl (e.g., 100) "Usage Case 1" operations, N2
(e.g., 50) "Usage Case 2" operations, and N3 (e.g., 125) "Usage Case 3" operations over the
25 year assumed equipment design life for equipment X.
[088] For equipment X, Usage Case 1 causes Component A (e.g., rotating shaft) to
rotate 10 radians at a torque of 100 ft.lbs., and Component B (e.g. a hydraulic ram) to
displace 5 ft against a force of 10 lbs. Component C (e.g., a sheave) does not participate in
Usage Case 1. Thus, each occurrence of Usage Case 1 subjects Component A to CI (1,000)
ft.lbs. of work, Component B to C2 (50) ft.lbs. of work, and Component C to C3 (no) ft.lbs.
of work. Usage Case 1 is assumed to occur Nl (100) times over the course of the 25 year
assumed equipment design life.

[089] For equipment X, Usage Case 2 causes Component B to displace 10 ft against
a force of 50 lbs, and Component C to rotate 20 radians at a torque of 50 ft.lbs. Component
A does not participate in Usage Case 2. Thus, each occurrence of Usage Case 2 subjects
Component B to C5 (500) ft.lbs. of work, Component C to C6 (1000) ft.lbs. of work, and
Component A to C4 (no) ft.lbs. of work. Usage Case 2 is assumed to occur N2 (50) times
over the course of the 25 year assumed equipment design life.
[090] For equipment X, Usage Case 3 causes Component A to rotate 15 radians at a
torque of 200 ft.lbs., Component B to displace 10 ft against a force of 200 lbs, and
Component C to rotate 30 radians at a torque of 200 ft.lbs. Thus, each occurrence of Usage
Case 3 subjects Component A to C7 (3,000) ft.lbs. of work, Component B to C8 (2,000)
ft.lbs. of work, and Component C to C9 (6,000) ft.lbs. of work. Usage Case 3 is assumed to
occur N3 (125) times over the course of the 25 year assumed equipment design life.
[091] As shown in FIG. 5, the ft.lbs. of work per usage case for each component is
multiplied by the number of occurrences of that usage case. These values are then added for
each component to arrive at the component's Theoretical Component Usage Profile. For
example, with respect to Component A's Theoretical Component Usage Profile (TCUPA), the
formula is (Nl x CI) + (N2 x C4) + (N3 x C7) = TCUPA, which results in value of 475,000
ft.lbs. of work. Thus, under the conditions of the assumed duty profile, Component A would
need to be able to withstand the amount of wear/stress/strain corresponding to 475,000 ft.lbs.
of work in order to have a component design profile that is equivalent to the assumed
equipment design life of 25 years. Similarly, with respect to Component B's assumed
Theoretical Component Usage Profile (TCUPB), the formula is (Nl x C2) + (N2 x C5) + (N3
x C8) = TCUPB, which results in value of 280,000 ft.lbs. of work. Thus, under the conditions
of the assumed duty profile, Component B would need to be able to withstand the amount of
wear/stress/strain corresponding to 280,000 ft.lbs. of work in order to have a component
design profile that is equivalent to the assumed equipment design life of 25 years. Finally,
with respect to Component C's Theoretical Component Usage Profile (TCUPc), the formula
is (Nl x C3) + (N2 x C6) + (N3 x C9) = TCUPC, which results in value of 800,000 ft.lbs. of
work. Thus, under the conditions of the assumed duty profile, Component C would need to
be able to withstand the amount of wear/stress/strain corresponding to 800,000 ft.lbs. of work
in order to have a component design profile that is equivalent to the assumed equipment
design life of 25 years.

[092] Once the Theoretical Component Usage Profiles are generated, they may be
utilized in the selection of actual components. A component's Theoretical Component Usage
Profile may also be utilized to initially schedule maintenance for that component.
[093] Sometimes available components will have Wear/Stress/Strain Ratings or
characteristics that will correspond to the appropriate Theoretical Component Usage Profile.
In those circumstances, the Theoretical Component Life Under the Duty Profile will equal the
assumed equipment design life. This situation is reflected in FIG. 5 for Component A. The
entire Wear/Stress/Strain Ratings (WSSR) (i.e., 475,000 ft.Ibs. of work) of the actual
Component A may be utilized, if needed, over the Selected Design Life (i.e., the 25 year
assumed equipment design life).
[094] Sometimes it will not be possible to find a component that has the WSSR or
characteristics that correspond to the appropriate Theoretical Component Usage Profile. The
actual component selected may have WSSR or characteristics that are significantly less than
or greater than the appropriate Theoretical Component Usage Profile. For example, in FIG.
5, the actual component selected for Component B was able to withstand the amount of
wear/stress/strain corresponding to 392,000 ft.Ibs. of work. Thus, Component B's
Theoretical Component Life Under the Assumed Duty Profile would be 35 years. Also, since
the WSSR for Component B is 392,000 ft.Ibs., this entire capacity is available, if needed,
over the Selected Design Lifetime (i.e., the 25 year assumed equipment design life).
[095] As a converse example, in FIG. 5, the actual component selected for
Component C was only able to withstand the amount of wear/stress/strain corresponding to
400,000 ft.Ibs. of work. Thus, Component C's Theoretical Component Life Under the
Assumed Duty Profile would be 12.5 years. To meet the requirements of the Selected Design
Life (i.e., 25 years), two Component C's must be utilized in succession. Thus, the effective
WSSR for the two Component C's is 800,000 ft.Ibs., which is available, if needed, over the
Selected Design Life.
[096] FIG. 6 illustrates an exemplary, but highly simplified, Actual Duty Profile
broken down by component for equipment X over an actual period of use. The actual period
of use for this example will be the first 2 years equipment X is in operation.
[097] In calculating an actual duty profile, force, torque and displacement readings
are obtained from sensors associated with the individual components A, B and C (see FIGS. 1
and 2). As equipment X performs an operation (i.e., usage case), the corresponding force,
torque and displacement readings are recorded.

[098] As indicated in FIG. 6, equipment X has performed Nl (10) Usage Case 1
operations over the first two years of equipment X's operational life. However, the force,
torque and displacement values for the actual Usage Case 1 operations have been different
from those selected for the Assumed Duty Profile. For example, actual Usage Case 1
operations have caused Component A (e.g., rotating shaft) to rotate 10 radians at a torque of
200 ft.lbs., and Component B (e.g. a hydraulic ram) to displace 5 ft against a force of 5 lbs.
Component C (e.g., a sheave) did not participate in Usage Case 1. Thus, each occurrence of
Usage Case 1 subjects Component A to CI (2,000) ft.lbs. of work, Component B to C2 (25)
ft.lbs. of work, and Component C to C3 (no) ft.lbs. of work.
[099] As shown in FIG. 6, equipment X has performed N2 (5) Usage Case 2
operations over the first two years of equipment X's operational life. However, the force,
torque and displacement values for the actual Usage Case 2 operations have been different
from those selected for the Assumed Duty Profile. For example, actual Usage Case 2
operations have caused Component B to displace 5 ft against a force of 25 lbs, and
Component C to rotate 20 radians at a torque of 50 ft.lbs. Component A did not participate in
Usage Case 2. Thus, each occurrence of Usage Case 2 subjects Component B to C5 (125)
ft.lbs. of work, Component C to C6 (1000) ft.lbs. of work, and Component A to C4 (no)
ft.lbs. of work.
[0100] As indicated in FIG. 6, equipment X has performed N3 (12) Usage Case 3
operations over the first two years of equipment X's operational life. However, the force,
torque and displacement values for the actual Usage Case 3 operations have been different
from those selected for the Assumed Duty Profile. For example, actual Usage Case 3
operations have caused Component A to rotate 25 radians at a torque of 400 ft.lbs.,
Component B to displace 5 ft against a force of 100 lbs, and Component C to rotate 30
radians at a torque of 200 ft.lbs. Thus, each occurrence of Usage Case 3 subjects Component
A to CI (10,000) ft.lbs. of work, Component B to C8 (500) ft.lbs. of work, and Component C
to C9 (6,000) ft.lbs. of work.
[0101] As shown in FIG. 6, the actual ft.lbs. of work per usage case for each
component is multiplied by the actual number of occurrences of that usage case to date (i.e.,
for this example, the actual number of occurrences of that usage case over the first two years
equipment X is in operation). These values are then added for each component to arrive at
the component's Actual Component Usage. For example, with respect to Component A's
Actual Component Usage (ACUA), the formula is (Nl x CI) + (N2 x C4) + (N3 x C7) =
ACUA, which results in value of 140,000 ft.lbs. of work.

[0102] As indicated in FIG. 5, the WSSR of the actual Component A utilized in
equipment X was equivalent to Component A's Theoretical Component Usage Profile
(475,000 ft.lbs). Dividing the Actual Component Usage (140,000) by 475,000 shows that
approximately 29.5 percent of Component A's useful life has been utilized. This analysis
approach is reflected in FIGS. 4e and 7.
[0103] FIG. 4e is a computer screen display that shows the lift history 500 of a piece
of equipment (e.g., a crane) and the remaining percent life of a component (e.g., slew
bearing) of the equipment 510. FIG. 7 is a graphical display (like that indicated by 510 in
FIG. 4e) that graphically compares for each component the Actual Component Usage versus
the WSSR for the actual component utilized.
[0104] As indicated in FIG. 4e, the lifting history 500 of the crane is recorded in
terms of percent load capacity 505 and swing angle 515. These terms are recorded according
to a time stamp 520. This information is utilized by the process of the invention to adjust in a
real-time manner the usage profile for the slewing bearing. As the usage profile is adjusted,
the percent of slewing bearing life exhausted 525 may be displayed as shown in graphical
display 510.
[0105] To compare the Actual Rate of Usage for Component A to the Theoretical
Rate of Usage that should have occurred per the Assumed Duty Profile in the first two years
of operation for equipment X, reference is now made to FIG. 8. FIG. 8 is a graphical
representation of how the Actual Component Usage compares to the Assumed Usage Profile
as applied to the WSSR for Component A.
[0106] As indicated in FIG. 6, the theoretical amount of component life that should
have been utilized in the first two years of operation is calculated by the following formula:
(TCUPA / Selected Design Life) x actual years of use = Theoretical Life Used in Two Years
(TLU2y). For Component A, the TLU2y value is 38,000 ft.lbs and is represented on the
Assumed Duty Profile curve of FIG. 8 by a circle. Since the two year Actual Component
Usage is 140,000 ft.lbs., which is represented on the Duty Profile curve of FIG. 8 by a dot, it
can be understood that Component A is being worn at a rate that is significantly higher than
predicted by the Assumed Duty Profile. As reflected in FIG. 8, the Actual Component Usage
is equivalent to approximately 7.4 years of use at the Assumed Duty Profile rate. Thus, if the
actual usage remains constant over the years, Component A will require replacement in
significantly less than 25 years.
[0107] As indicated in FIG. 6, the formula for Component B's Actual Component
Usage (ACUB) is (Nl x C2) + (N2 x C5) + (N3 x C8) = ACUB, which results in value of

6875 ft.lbs. of work. As indicated in FIG. 5, the WSSR of the actual Component B utilized in
equipment X was 392,000 ft.lbs. This value exceeds Component B's Theoretical Component
Usage Profile (280,000 ft.lbs). Consequently, the actual WSSR of 392,000 is utilized in the
following computation because this capacity is available, if needed, over the selected design
life of 25 years.
[0108] Dividing the Actual Component Usage (6875 ) by 392,000 shows that
approximately 1.75 percent of Component B's useful life has been utilized. This is reflected
in FIG. 7, which graphically compares for each component the Actual Component Usage
versus the WSSR for the actual component utilized.
[0109] To compare the Actual Rate of Usage for Component B to the Theoretical
Rate of Usage that should have occurred per the Assumed Duty Profile in the first two years
of operation for equipment X, reference is now made to FIG. 9. FIG. 9 is a graphical
representation of how the Actual Component Usage compares to the Assumed Usage Profile
as applied to the WSSR for Component B.
[0110] As indicated in FIG. 6, the theoretical amount of component life that should
have been utilized in the first two years of operation is calculated by the following formula:
(TCUPB / Selected Design Life) x actual years of use = Theoretical Life Used in Two Years
(TLU2y). For Component B, the TLU2y value is 22,400 ft.lbs and is represented on the
Assumed Duty Profile curve of FIG. 9 by a circle. Since the two year Actual Component
Usage is 6875 ft.lbs., which is represented on the Duty Profile curve of FIG. 9 by a dot, it can
be understood that Component B is being worn at a rate that is significantly lower than
predicted by the Assumed Duty Profile. As reflected in FIG. 9, the Actual Component Usage
is equivalent to approximately 0.6 years of use at the Assumed Duty Profile rate. Thus, if the
actual usage remains constant over the years, Component B will last significantly longer than
25 years. Also, even if the Actual Component Usage were equivalent to the Assumed Usage
Profile, as illustrated in FIG. 9, Component B would have approximately 112,000 ft.lbs. of
capacity left at the end of the 25 year period because the actual Component B had a WSSR of
392,000 ft.lbs. while the theoretical usage profile for Component B only required 280,000
ft.lbs.
[0111] As indicated in FIG. 6, the formula for Component C's Actual Component
Usage (ACUC) is (Nl x C3) + (N2 x C6) + (N3 x C9) = ACUC, which results in value of
77,000 ft.lbs. of work. As indicated in FIG. 5, the WSSR of the actual Component C utilized
in equipment X was 400,000 ft.lbs. This value is less than Component B's Theoretical
Component Usage Profile (800,000 ft.lbs). Consequently, two Component C's must be

utilized in succession to reach the selected design life of 25 years. Adding the WSSR's of the
first and second Component C's results in an effective actual WSSR of 800,000. This
effective WSSR is utilized in the following computation because this capacity is available, if
needed, over the selected design life of 25 years.
[0112] Dividing the Actual Component Usage (77,000) by 800,000 shows that
approximately 10 percent of the first and second Component Cs' useful life has been utilized.
This is reflected in FIG. 7, which graphically compares for each component the Actual
Component Usage versus the WSSR for the actual component utilized.
[0113] To compare the Actual Rate of Usage for Component C to the Theoretical
Rate of Usage that should have occurred per the Assumed Duty Profile in the first two years
of operation for equipment X, reference is now made to FIG. 10. FIG. 10 is a graphical
representation of how the Actual Component Usage compares to the Assumed Usage Profile
as applied to the WSSR for Component C.
[0114] As indicated in FIG. 6, the theoretical amount of component life that should
have been utilized in the first two years of operation is calculated by the following formula:
(TCUPC / Selected Design Life) x actual years of use = Theoretical Life Used in Two Years
(TLU2y). For Component C, the TLU2y value is 64,000 ft.lbs and is represented on the
Assumed Duty Profile curve of FIG. 10 by a circle. Since the two year Actual Component
Usage is 77,000 ft.lbs., which is represented on the Duty Profile curve of FIG. 10 by a dot, it
can be understood that Component C is being worn at a rate that is higher than predicted by
the Assumed Duty Profile. As reflected in FIG. 10, the Actual Component Usage is
equivalent to approximately 2.4 years of use at the Assumed Duty Profile rate. Thus, if the
actual usage remains constant over the years, it will require more than two Component C's to
last 25 years.
[0115] In sum, the preceding duty profile analysis, which uses assumed or theoretical
operating conditions and available data on component useful life under these operating
conditions, is used to select components and make an initial theoretical maintenance and
component replacement plan. The plan is placed on the system and as actual operating
conditions are sensed and reported, the duty profile models used for the initial design and the
initial theoretical maintenance and component replacement plan are used to update the plan
and to recognize conditions that require component maintenance. The updating can be done
either in real time as each set of operating conditions data is reported or periodically after
data has been collected for a specified interval.

[0116] FIG. 11 shows another embodiment of the present invention. It is similar to
the embodiment of FIG. 1 in some aspects, but differs in other. For the sake of completeness
the embodiment of FIG. 11 will be fully explained, even the features that are similar to the
embodiment of FIG. 1.
[0117] In FIG. 11 the area 60 denotes the elements that are situated on-site, i.e., on or
close to the equipment being monitored. The area 61 denotes the client computer site, e.g.,
headquarters of the company using the equipment. The area 62 denotes the computer site of
the service provider. The service provider may be the same company that has supplied the
computer system and the equipment.
[0118] At the on-site area 60 is found the monitored equipment 63 that in this
example is a top-drive and in a further example below a mud-pump, but may be any type of
equipment feasible for monitoring. Moreover, in area 60 are found a computer 64 and two
user interfaces 65 and 66. The user interface 65 contains documentation on the equipment 63.
This may be technical specifications, manuals, certificates, etc. The user interface 66 provides
on-site monitoring of the equipment 63, and allows the operator to monitor the performance
and state of the equipment and associated sensors both current and historic. The interfaces 65
and 66 are in communication with the on-site computer 64 via an on-site or local area
network, denoted by 69. The user interfaces 65 and 66 can be accessed and viewed on any
browser connected to the network.
[0119] At the client computer site 61 there is also a documentation user interface 67
and a monitor interface 68. These give access to essentially the same information as the
interfaces 65 and 66. The interfaces 67 and 68 are in communication with the on-site
computer 64 via a network 70, which may be a corporate network, the Internet or a dedicated
link.
[0120] At the client computer site 61 there is also a user interface 71 for performance
monitoring that will be explained further in the following.
[0121] At the service provider area 62 is a server 73 (one or more may be present,
depending on need). This server 73 is linked to the on-site computer 64 via the Internet,
dedicated link 74 or other communication path. The server 73 collects performance (usage)
data on the equipment 63 from the on-site computer 64. The server 73 also collects
performance data on other pieces of similar equipment that may be present on other sites (not
shown). On the basis of these collected data, the server 73 prepares aggregated and analyzed
information on the specific type of equipment. This information is made available to the

client through the performance monitor user interface 71 through a link 75. The link 75 may
be the Internet, a dedicated link or other communication path.
[0122] The communication through the links 70, 74 and 75 may be through cable, any
wireless communication system, via satellite or other communication path. If the Internet is
used as a link, the only requirement is that the on-site computer, the client site and the service
provider site are connectable to the Internet.
[0123] On the equipment 63 are situated various sensors 76. These perform
measurements on the equipment 63 and present these to the on-site computer 64. Preferably
the on-site computer 64 is a dedicated computer for the equipment 63 and may be physically
attached to the equipment 63, so that it will follow the equipment if the equipment is moved
to another site. Consequently, the on-site computer 64 may also be called an equipment
computer. Computer 64 is configured to monitor more than one item of equipment,
preferably several completely different types.
[0124] FIGS 12 and 13 show a more detailed presentation of the monitoring system
according to the embodiment of FIG. 11. In FIG. 12 some of the elements have been removed
in comparison with FIG. 13 and vice versa, to facilitate the explanation of some of the
aspects.
[0125] FIG. 12 shows how a new on-site computer 64, and hence a new piece of
equipment 63, is coupled to the monitoring system and the set up of the on-site computer.
The service provider server 73 is here divided into a number of elements 77-85. These will be
explained in the following.
[0126] At the service provider site is also a performance monitor component 86,
which is a user interface similar to the performance monitor 71 at the client site. There is also
an analytical performance monitor component 87, which is another user interface that will be
explained in more detail later. Finally, there is the database management GUI (graphic user
interface) 88. In addition there may as an option be a business-to-business server 89 present
at the service provider, serving as an interface to other client computer systems.
[0127] The management database GUI 88 provides access to a database that contains
detailed information on all the equipment that may be connected to the monitoring system,
including user interface information. During set-up a management database component 81
receives information on the specific type of equipment that is to be connected. The
management database component 81 then defines how the raw measurements will be treated
so that the presentation of the values is convenient for further processing and analysis and for
presentation on the user interface. These definitions may be, e.g., the time span between each

storage of measurements, smoothing of measurements, etc. The management database 81 also
contains the correspondence between a value sensed on equipment and the parameter to
which the value belongs.
[0128] The management database 81 provides these definitions to a configuration file
generator 79, a content server 78 and a local graphic user interface generator 77. The
configuration file generator 79 generates a configuration file for the on-site computer 64 and
the local graphic user interface generator 77 generates a local interface. All this information
is fed through the content server and transmitted to the on-site computer 64.
[0129] Every time an update is made a new configuration file and/or a new graphic
user interface is generated and transferred to the on-site computer in the above described
way. This provides a single point for configuration of the on-site computer. The configuration
can be made directly between the service provider and the on-site computer. The initial
configuration contains the following elements:
-selecting equipment to monitor
-selecting computer type for data acquisition
-select and configure signals and parameters for the data logger in the on-site
computer
-select and configure calculations, filters and logging frequency for the data logger in
the on-site computer
-select and configure communication route
-edit corporate knowledge to be applied on the central server
-define and set up company, plant and user accounts
[0130] Based on the input, the management database 81 will be the source from
which to produce:
-an XML configuration file to automatically set up all aspects of the data logger in the
on-site computer by the configuration server 79
-an XML configuration file to automatically set up the local monitor service via the
interface 66 by the local GUI generator 77
-an XML configuration file to automatically set up the local monitor content by the
content server 78
-automatic configuration and set up of database tables in the cubes 84
automatic configuration of the logstream handler 80

[0131] The transmittal of the configuration file and the graphic user interface setup
will conveniently be done via the Internet, but it is also possible to do it by shipment of a CD-
ROM or other type of data storage medium.
[0132] FIG. 14 shows a general overview of the on-site computer 64. The
configuration file etc. is received through a network interface 601 and transferred through an
input/output device 602 and final storage in a configuration database 607. The configuration
handler will upon updating of its database 607 update all configurable parameters accordingly
(for example parameters in elements 96, 97, 98 in FIG. 14).
[0133] Referring to FIG. 13, the data flow during the monitoring of the equipment
will be explained. In addition to the elements shown in FIG. 12, FIG. 13 also shows an
outbound queue 92 and an inbound queue 90 as well as an FTP (file transfer protocol) server
91 and a network interface 93.
[0134] The measurement data from the on-site computer 64 is received through the
network interface 93 by the FTP server 91. The data is put in the inbound queue 90. The
logstream handler 80 is configured to get data from the inbound queue 90 at regular intervals.
In the logstream handler 80 the data are arranged so that these are presented in an order that
will enable temporary storage in the measurement database 82. The function of the logstream
handler 80 will be explained in more detail below.
[0135] A copy of the data transmitted to the measurement database 82 is also stored
in the bulk storage 85. The purpose of this is, firstly, for backup and, secondly, to enable
additional processing of data at a later stage if new methods for making equipment evaluation
calculations are developed.
[0136] The measurement data is post processed in the postprocessor 83, involving
calculation of certain calculated values (some examples of these will be presented below).
After this selected measurement data and calculated data will be stored in the cubes database
84. The distinction between measurement data and calculated data is somewhat arbitrary,
because calculations can occur at the equipment or at more central processors. Measurement
data comes from the on-site (equipment) computer and is denominated raw, but it may be the
result of calculations, filtering or other processing that occurs at the on-site computer. Such
processing may also be done by intelligent sensors or controllers. Calculated data is what
results after the measurement data are received and the particular algorithms are applied that
produce from measurement data the desired calculated data useful in determining how
component wear has progressed.

[0137] The performance monitor 86 and the analytical performance monitor 87 get
data partly from the measurement database 82 (for tabular lists and reports) and partly from
the cubes database 84 (for trend analyses, historic overview, etc.). The purpose of the
performance monitor 86 is to make and present simple analyses to the person or persons
monitoring the equipment, while the analytical monitor 87 presents more sophisticated
analyses or freeform analyses. The simple analyses may be presented to an operator who
needs to make quick decisions, while the more sophisticated analyses may be presented to a
person who is making more strategic decisions. It is also conceivable to use one interface
only for both simple and sophisticated analyses.
[0138] The acquiring of the measurement data will now be explained referring to
FIG. 14, which show schematically the basic elements and components of the on-site
computer 64.
[0139] The signals from sensors 76 (FIG. 11) are coupled to the input/output interface
94. Each of the sensors has its own channel 95 and the measurement data is stored in a
temporary storage 97 after scaling 96 (to make the value consistent with the specified
measurement units).
[0140] A logger module 98 gets the data from the temporary storage. The logger
module 98 transfers these data via an access buffer 99 to a transfer storage 600. To perform
this correctly, the logger module 98 has been updated from the configuration handler 604 on
how to handle the different pieces of data. From the transfer storage 600 the data is
transmitted to a network interface 601 via an FTP input/output device 602 by the aid of a
transfer handler 603. This data is subsequently received at the network interface 93 at the
service provider (FIG. 13).
[0141] If a certain measurement received at 94 needs to be handled in a different way,
the applicable configuration file will be updated and sent to storage with the configuration
handler 604 in the way described above. The configuration handler 604 will then tell the
logger module 98 how to handle the measurement, so that after the update the server 73 will
receive the measurement information as requested. The update may, for instance, be to log a
certain measurement at longer or shorter intervals. Since the configuration file is stored on-
site, the system is not dependent on being online for the measurements to be handled in the
desired way.
[0142] A local log storage 605 also exists. This enables local storage of data in the
event of a break in the link between the on-site computer 64 and the server 73. In some cases
it may prove difficult to obtain an online connection between the on-site computer 64 and the

server 73. In this case the data may be transferred regularly to a storage medium, e.g., a
removable memory that can be connected to the computer via a USB port (USB memory).
The storage medium may even be shipped to the service provider by ordinary mail or other
physical delivery.
[0143] The on-site computer 64 also comprises an event module 606 that detects
malfunctions in the measurement equipment (sensors, sensor wiring, etc.) and measurements
that are out of the normal range of the equipment. These events are also transferred to the
transfer storage 600 and hence to the server 73.
[0144] The handling of data in the service provider server 73 will be explained further
referring to FIG. 15. The raw data that is in the inbound queue 90 (FIG. 13) is represented by
reference number 620. The logstream handler 80 (FIG. 13) will parse the raw data 620, as
denoted by reference number 621. The parsing particularly involves identifying the individual
values in a data stream and assigning the correct identification to the values. After this the
logstream handler 80 fills in "inherited" values, denoted by reference number 622. In order to
reduce the amount of data that has to be transferred from the on-site computer 64 to the
server 73, the on-site computer 64 will not send values if a measured value remains
unchanged, e.g., if the top-drive 63 is lifting a load, the value of the first measurement of the
load weight will be sent. (This can be effected with a filter that causes negligible changes in
signals to be classified as unchanged.) After this no further values will be sent until the load
weight changes, e.g., when the load reaches the drill floor. In 622 the "missing values" are
filled in, so that the same value is repeated at regular intervals for the time the load was
constant. This reduces the stream of data and hence the required bandwidth substantially.
[0145] After this the prepared data is transferred to the post processor 83, which
calculates values based on the measured values, denoted by reference number 623. Examples
of calculated values will be given below. Lookups in the management database determine the
storage of values in the measurement database 81 and their post processing method into the
multi-dimensional information cubes.
[0146] The post processor 83 may also identify out of limit values, denoted by
reference number 624. The out of limit values may. for example, be excess load, excess
running hours, out of range pressures or temperatures, etc., which signal problems or
excessive consumption of useful life of a component. After the post processing the measures,
values and identification are entered into a database consisting of a number of
multidimensional "cubes." Multidimensional cubes have gained increased popularity as a
means for storing large amount of data that has to be readily accessible. The

multidimensional cubes can be seen as multidimensional matrixes in which each parameter is
listed along one dimension, one dimension for each parameter. This way of storing the data
provides the opportunity to quickly display tables and graphs showing the relationship
between any of the parameters, even if the amount of data is very large.
[0147] Data in the multidimensional cubes has some main characteristics:
-the data is pre-aggregated to obtain high performance in searches and retrievals, or
otherwise to facilitate data-mining by tools such as neural networks
-the data is arranged along predefined axes to enable and simplify X-Y charts (e.g.,
view distribution of temperatures over different pressures)
-the data is optimized for searches across large number of similar type of equipment
[0148] In addition, the multidimensional cubes enable storage of all data collected
over the full lifetime for large number of equipment units.
[0149] As a result, this enables a new way of consolidating lifetime data as a platform
for empirical investigation and data mining to be fed back into the design process or service
procedures. Information about how and when maintenance was executed is stored in the same
database, and correlated in time.
[0150] The multidimensional cubes are in this particular example three separate
cubes. The first, denoted by reference number 625, contains all measurements, including
most of the calculated parameters. The second, denoted by reference number 626 contains the
calculated parameters critical to the lifetime surveillance, like the load weighted running
hours, for monitoring the operation of the equipment. The third cube, denoted by reference
number 627, contains the out of limit measures. If there have been no occurrences of out of
limit values, this cube is empty.
[0151] The monitoring of the equipment will now be explained in more detail,
referring to examples of parameters and charts.
[0152] FIG. 16 shows a table of typical parameters to be measured and logged for a
piece of equipment, in this example a mud pump, as well as the measurement units applicable
for each parameter. The table shows various pressures, temperatures, flows, running hours,
fault codes (if applicable), etc.
[0153] FIG. 17 shows in the upper part some constants that are used in the
calculations of calculated parameters and in the lower part a table of typical calculated
parameters for a mud pump. The first column shows the constant or parameter text, the
second column shows the constant or parameter name in the computer system, the third

column shows the unit for the constant or parameter and the fourth column shows for the
value of the constants or the formula used to calculate the parameter. In the upper right hand
corner is a frame listing definitions of some of the variables, i.e., measured parameters
received as raw data measurement inputs for the calculated wear parameters.
[0154] One of the more important calculated wear parameters for certain types of
equipment is the accumulated, load weighted running hours, which is listed at the bottom of
FIG. 17. This is calculated according to the following formula:
[0155] T_hrw+f*w*delta-t/3600
[0156] where delta-t/3600 is the time in seconds since the last logging of accumulated
load weighted running hours in seconds divided by seconds per hour.
[0157] w is a load factor according to the following formula:
[0158] (2*p_disch/p_rated)Ae * (2*S_pump/S_rated),
[0159] where pdisch is the current discharge pressure from the pump
measured, prated is a constant denoting rated pressure, which has the value 517.1 bar,
Spump is the current pump speed and Srated is a constant denoting rated pump speed,
(which has the value 212 strokes per minute.
[0160]- :f ( r is a binary factor that has the value zero or one, according to the following
formula:
[0161] If(S_pump [0162] where Spump is the pump speed and Srated is the rated pump speed,
as given above. Consequenfiy, r is zero if the current pump speed is less than 2% of 212
strokes per minute and one if the current pump speed is equal to or greater than this.
[0163] Thrw is the previously logged accumulated load weighted running hours.
[0164] All the other calculated factors are also calculated based on measured
parameters or constants specified at the server 73.
[0165] FIG. 18 shows a table containing the limits for some critical parameters used
at step 624 of FIG. 15. The first column shows the ID number for the limit, the second
column shows the parameter limit name, the third column shows the logical operator to be
used and the fourth column shows the limit value. If any of these parameters fall outside the
limit set, an out of limit value will be entered into the out of limit cube 627.
[0166] For certain types of equipment it is of vital significance to have 2-dimensional
limit values. This is the case with, e.g., a crane. The crane may have different lifting capacity
depending on the angular position of the boom in both the horizontal and the vertical plane.
In this case the performance limits will be different depending on the boom position. The

crane may have a high lifting capacity over a certain sector in the horizontal plane. In another
sector in the horizontal plane, it may be prohibited to use the crane only with empty hook (for
transit only) or with a smaller load. The load limit in the same sector may also depend on the
boom angle. Consequently, if the boom passes into a sector with an excess load, an out of
limit event can be detected based on the 2-dimensional limit values. The operator may get a
message telling him how to return within one of the limits where the sensed value is within
his control or that the operation must cease; e.g., instructed that if he raises the boom to a
steeper angle, he may pass through the sector with this load, or that it is not possible to pass
this sector.
[0167] The 2-dimensional performance limits can be implemented in the system as a
2-dimensional table, such as FIG. 26, which is convenient to store in multidimensional cubes.
For some equipment more than 2-dimensions might be used to define the design envelope for
safe or appropriate operation. Thus, the 2-dimensional performance limits can be extended to
N-dimensional performance limits.
[0168] FIG. 19 shows a screen print containing a table with measurements made on a
mud pump. The first column 1902 shows the year, the second column 1904 shows the
parameters measured, with a limit description on some of the parameters (this corresponds to
some of the limits shown in FIG. 18). Third and fourth columns 1906, 1908 show the number
of measurements taken for each of the parameters.
[0169] FIG. 20 shows a screen print as it might appear at a GUI at 66, 68 or at server
73 containing a chart showing the flow 2002 from a mud pump, with the flow plotted against
time. The time span 2004 is in this case the first 24 days of a month. As is evident from the
graph, the pump has been running all days except for one.
[0170] FIG. 21 shows a screen print containing a chart showing the discharge
pressure distribution in a mud pump graphed against the rotational speed of the pump. The
pressure has been divided into different classes, each covering a span of 50 MPa. This is
plotted along the axis 628. The rotational speed has also been divided into different classes,
each covering a span of 50 RPM, and plotted along the axis 629. The vertical axis 630 show
the number of running hours within each pressure class and revolution speed class. As is
evident from the graph the pump has been running for many hours with a moderate pressure
and high speed, as denoted by reference number 631. As shown by bars 632 and 633, the
pump has also been running for some time with high pressure at a moderate speed. However,
for very little time has the pump been running with low speed and high pressure.

[0171] By using this technique and also including data from a plurality of pumps, it is
possible to make an average utilization profile of the type of pump. FIG. 22 shows an
example of a typical performance chart for a mud pump, showing the distribution of the
pump utilization. As the chart shows, the pump (or pump type, if a plurality of pumps has
been monitored) is used 40% of the time at moderate pressure and pump rate. With the
utilization profile as a basis it is possible to predict wear of critical components in the pump.
Some components wear to a greater extent in high pressure environments and some wear
more in high speed environments. Other components are more susceptible to high
temperature and others again are more susceptible to high stress. By evaluating not only the
running hours but also taking into account the conditions the equipment has been running in,
it is possible to predict more accurately where in the lifespan of the critical components one is
at a specific time. For instance, the load may be taken into account so that, e.g., for a pump
the running hours is multiplied by the average flow the pump has delivered. Another example
is to keep track of the total time the temperature at a certain place in the pump has been in
excess of a certain limit, the limit, e.g., being based on a temperature above which a sealing
material is susceptible to damage. Any combination of load weighted parameters may be
calculated in the system of the present invention. When the load weighted parameter exceeds
a set limit a warning may be sent to the operator, informing him of the fact that a component
is approaching the end of its life span. Preferably, the warning is sent out well before the
expected life span has come to an end, so that there is sufficient time for planning
maintenance of the equipment, including component replacement.
[0172] In addition to the warning informing the operator of an upcoming
maintenance, it is also feasible to send out an alarm if a parameter exceeds a critical limit,
indicating that a failure may occur at any time, or that the equipment has to be run at a
reduced performance until maintenance has been performed.
[0173] The warning and the alarm is sent out via the management database 81 and the
content server 78. It can be posted as a message on the user interfaces 66, 68, 86 and 87. In
addition, it can be messaged over any media to client interfaces. This can be e-mail, SMS,
pagers, etc. Via the B2B server, the system can also send the information digitally to a client
management system.
[0174] When maintenance has been performed, the parameters forming the basis for
the warning or the alarm are set to an initial value, so that the monitoring of the life span can
start from fresh again.

[0175] It is also possible to perform trend analyses based on experience data. The
experience data is a result of an extensive analysis of failures that has occurred in similar
equipment previously. If, e.g., a certain bearing has failed and resulted in a major breakdown
and possibly also damages on other parts of the equipment or other pieces of equipment, the
conditions present at the time before the failure may be analyzed. It is then possible to see if
any values or calculated values have undergone a change during the time before the failure.
The time span some minutes before the failure is first investigated but the time span within
hours or even days or weeks before the failure will also be taken into account.
[0176] The results are then compared with results from other similar failures to find
out if there is something in common between all or at least some of the failures.
[0177] If this correlation of parameters is likely to be connected with the failure, a
procedure may be implemented in the computer controlling the pump that based on sensor
reading (the on-site computer is not involved in the process, but the lessons learned are
implemented into the pump control computer) at regular intervals (the interval depending on
how quickly the failure may occur) calculates the correlation between the above factors. If a
condition occurs that is similar to the conditions that were present at the time before failure in
the previous occurrences, the computer may stop the equipment or, if time allows, perform a
controlled shut down of the system that the pump is a part of.
[0178] An example of this is shown in FIG. 25. This graph shows a plot of the torque
of the two motors A and B running the pump for a period of time on January 21, 2004
starting at 01:00. At 02:15 a failure of the pump occurred. The reason, found out later, was
that a bearing suddenly failed. As is evident from the graph, the torque of both motor A and
B had a remarkable increase from 02:13, increasing with a large gradient until the failure.
When the failure occurred this had detrimental consequences to the equipment connected to
the pump. This increased torque could not be explained by any outside factors, like increased
pump rate or higher viscosity of the pumped fluid. The torque was still within the normal
range that the motors were capable of delivering and the pump was able to receive.
According to the regular out of limit measurements, an out-of-limit event would not occur, at
least not until it was too late to prevent the critical failure.
[0179] This example shows one incident only. Nevertheless, the relation between the
increased torque and the failure may be likely enough to implement a check for a similar
condition in this type of equipment. The condition for such a situation to be considered
present may be that if the torque increases with a steep gradient, e.g. above 200 Nm/s, for
more than 20 seconds and there is no increase in input or viscosity or other factors that will

naturally influence the torque, an alarm will go off or the computer operating the pump will
perform a controlled shut down.
[0180] An upcoming failure may also be indicated by conditions that develop more
slowly than within a couple of minutes. For instance experience may have shown that if a
sealing has been subject to a temperature above a certain value or a period of time, this will
increase the risk of leakage substantially. However, the leakage will not occur until the
pressure is above a certain value. If such a situation occurs the computer operating the
equipment will be told to operate the equipment so that a pressure limit is not exceeded. At
the same time the operator will receive a message informing him of the situation.
[0181] If the rate-of-change for a temperature parameter is of importance to predict a
problem, the algorithm module (e.g., at post-processor 83) may calculate the rate-of-change.
The performance limit may have an entry defining the limit for when this rate-of-change is
outside its normal operating environment.
[0182] By implementing algorithms that can foresee a failure based on previous
experience, the chances of a critical failure can be substantially reduced. These algorithms
can be installed in the management database 81 much the same way as the initial set-up of the
on-site computer.
[0183] Load weighted running hours can be used as a basis for total estimated
lifetime for a wear part, and is hence a typical performance limit. The limit can be adjusted as
broader and broader experience is gained. By checking the load weighted running hour
accumulator against this limit, it is possible to predict remaining lifetime under similar
conditions and operation, propose inspection intervals, propose ordering of spare parts, etc.
[0184] The theoretical model for this trend analysis is preferably managed as tables
and records in a database, with a web-based user interface. An internal product champion can
be authorized to maintain the model, and it can grow incrementally as new knowledge about
the equipment is gained. For example, data mining cam be used to identify data patterns that
may be used to predict failure of different aspects of a single component, based on different
operating conditions experienced by different components. Neural networks may be used to
identify the patterns and also to detect their re-occurrence.
[0185] In addition to the lifespan monitoring, trend analysis and an out of limit
surveillance, it is also possible to monitor the equipment in real time. FIG. 23 shows a screen
dump containing a chart of the running hours of a mud pump. The graph 634 shows the
running hours as such for each day in the year 2004 until 13th May, which is the date of the
screen dump. The graph 635 shows the load weighted running hours for the same period. It is

[0193] The system may be designed to both propose and report maintenance actions.
It can publish maintenance actions to the on-site computer in the same way as it publishes
news and bulletins. The source of this information can be maintenance algorithms which take
actual load weighted use of the machine into consideration, i.e., it can propose an action for
inspection of a bearing every 14 days if the load applied to the machine is dominated by a
heavy speed component, or adjust the same interval to 2 months if the applied load is
dominated by pressure components.
[0194] Just like for the bulletin, the operator opens a maintenance header. He can also
check a box and fill in status for the action, and post it back to the system. At next
connection, the service report is transmitted into the database, where it is correlated to all
other data.
[0195] Each on-site computer can carry the documentation for the machine it is
monitoring. The as-built version of the documentation can be uploaded at installation.
During operation, the service provider can publish new or updated documents through the
management database.
[0196] Just like for the news and bulletins, it is possible to post headings only first.
Operators can check or confirm that they want the new documentation uploaded at the next
reconnect.
[0197] Although the present invention has been described with reference to preferred
embodiments, persons skilled in the art will recognize that changes may be made in form and
detail without departing from the spirit and scope of the invention.

WE CLAIM:
1. A system for managing replaceable components for equipment (300, 400)
having a plurality of components, each with a limited useful life, comprising:
a computer apparatus with at least one processor (100);
means for (120) defining a duty profile (220) comprising a plurality
of data sets relating to use of the equipment, each usage data set
involving two or more of the plurality of components and specified
operating conditions assumed to be experienced by the involved
components during the execution of each of said usage;
means for (120) for determining a theoretical useful life for each
component involved in a duty profile, said theoretical useful life
being based on component wear/stress/strain parameters assumed
to occur under the specified operating conditions;
a plurality of sensors (302, 402) for determining and monitoring the
occurrence of equipment operation corresponding to a usage, and
acquiring data in respect of actual operating conditions experienced
in the operation;
a memory (210) for storing the acquired data of actual operating
conditions for the plurality of components; and

means for (120) for computing an adjusted theoretical useful life
for a component after it has experienced one or more operations
by:
responsive to the measurements of actual operating
conditions, calculating one or more calculated wear/stress/strain
parameters for each operation and accumulating these calculated
parameters for such component;
based on a comparison of the accumulated, calculated
wear/stress/strain parameters from actual operating conditions to
accumulated wear/stress/strain parameters assumed to occur
under the specified operating conditions in the determination of a
theoretical useful life, determining the amount of the theoretical
useful life consumed in the one or more operations, and deducting
the life consumed from the theoretical useful life to determine the
adjusted theoretical useful life; and
means for (120) comparing the adjusted theoretical useful life to a
replacement range and a critical range and issuing a replacement
signal when the adjusted theoretical useful life is within the
replacement range and issuing an expedited report when the
adjusted theoretical useful life is within a critical range;

characterized in that the system is enabled to reduce sudden and
unplanned stoppages of the equipment by determining from real-
time data of actual operating conditions for components involved
in a duty profile an anticipated useful life.
2. The system as claimed in claim 1 wherein the actual operating conditions
comprise load and the duration of a load.
3. The system as claimed in claim 1 wherein the duty profile involves a
specified number of assumed operations, and wherein the system is enabled to
track the number of operations in which a replaceable component is involved.
4. The system as claimed in claim 1 wherein the sensors are configured to
provide data relating to actual operating conditions for calculation of a
wear/stress/strain parameter corresponding to the work performed by a
component.
5. The system as claimed in claim 1 wherein the system is remotely disposed
from the equipment for computing an adjusted theoretical useful life for a
component and the sensors are resided on the equipment.
6. The system as claimed in claim 5 wherein the sensors resident on the
equipment are configured by remotely operating from the equipment on a
processor, a program module to produce selected data of actual operating
conditions.

7 The system as claimed in claim 5, wherein the sensors resident on the
equipment communicate with a computer apparatus associated with the
equipment.
8. The system as claimed in claim 1 comprising a supervisory computer module
for computing the adjusted theoretical useful life for a component in response to
a real-time request received by the supervisory module or in response to a
periodic analysis initiated by the supervisory module.
9. A method for monitoring of the condition of remote equipment (300, 400)
having a plurality Of wear components, said plurality of wear components_each
having a useful life dependent on the operating conditions each component
experiences, comprising:
defining a duty profile (220) comprising a plurality of data sets
relating to usages the remote equipment, each usage data set
involving two or more of the plurality of components and specified
operating conditions assumed to be experienced by the involved
components during the execution of each of the usages;
defining two or more raw data measurements relating to the usage
data and/or operating condition of one or more of the plurality of
components;

receiving data from a plurality sensors (302, 402) cooperating with
the equipment to sense operating conditions and to produce the
two or more raw data measurements and for transmitting said
sensor data to a central monitoring processor (100);
parsing the sensor data into the two or more raw data
measurements for post processing;
calculating from the two or more raw data measurements a
calculated wear parameter for each of the plurality of wear
components, the value of the wear parameter being weighted by
values of the two or more raw data measurements used in the
calculation;
collecting a time sequence of the values of the calculated wear
parameter for each wear component and from the time sequence
of values calculating an accumulated wear value over the usage of
each wear component; and
evaluating the accumulated wear value against a maximum wear
rating for each wear component and responsive thereto providing a
forecast on a useful life operations, wherein, the forecast on useful
life operations provides indication of a replacement need

when the useful life is within a replacement range and the forecast
useful life operations includes an expedited report when the
useful life is within a critical range.
10. The method as claimed in claim 9, wherein said at least one accumulated,
calculated wear parameter is a load-weighted running hour parameter.
11. The method as claimed in claim 9, wherein the equipment to which the
method is applied has two or more wear components that are replaceable.
12. The method as claimed in claim 9, wherein the equipment to which the
method is applied is selected from the group consisting of cranes, winches, top-
drives and mud pumps.

Documents:

771-KOLNP-2006-ABSTRACT 1.1.pdf

771-kolnp-2006-abstract.pdf

771-KOLNP-2006-AMANDED CLAIMS 1.1.pdf

771-KOLNP-2006-AMANDED CLAIMS.pdf

771-kolnp-2006-assignment.pdf

771-kolnp-2006-assignment1.1.pdf

771-KOLNP-2006-CANCELLED PAGES 1.1.pdf

771-kolnp-2006-claims.pdf

771-KOLNP-2006-CORRESPONDENCE 1.1.pdf

771-kolnp-2006-correspondence.pdf

771-kolnp-2006-correspondence1.2.pdf

771-KOLNP-2006-DESCRIPTION (COMPLETE) 1.1.pdf

771-kolnp-2006-description (complete).pdf

771-KOLNP-2006-DRAWINGS 1.1.pdf

771-kolnp-2006-drawings.pdf

771-kolnp-2006-examination report.pdf

771-kolnp-2006-examination report1.1.pdf

771-KOLNP-2006-FORM 1 1.1.pdf

771-kolnp-2006-form 1.pdf

771-kolnp-2006-form 18.1.pdf

771-kolnp-2006-form 18.pdf

771-KOLNP-2006-FORM 2 1.1.pdf

771-kolnp-2006-form 2.pdf

771-kolnp-2006-form 26.pdf

771-kolnp-2006-form 3.1.pdf

771-kolnp-2006-form 3.pdf

771-KOLNP-2006-FORM 5 1.1.pdf

771-kolnp-2006-form 5.2.pdf

771-kolnp-2006-form 5.pdf

771-KOLNP-2006-FORM-27.pdf

771-kolnp-2006-gpa.pdf

771-kolnp-2006-granted-abstract.pdf

771-kolnp-2006-granted-claims.pdf

771-kolnp-2006-granted-description (complete).pdf

771-kolnp-2006-granted-drawings.pdf

771-kolnp-2006-granted-form 1.pdf

771-kolnp-2006-granted-form 2.pdf

771-kolnp-2006-granted-specification.pdf

771-KOLNP-2006-OTHER PATENT DOCUMENT.pdf

771-kolnp-2006-others.pdf

771-KOLNP-2006-REPLY TO EXAMINATION REPORT.pdf

771-kolnp-2006-reply to examination report1.1.pdf

771-kolnp-2006-specification.pdf


Patent Number 250126
Indian Patent Application Number 771/KOLNP/2006
PG Journal Number 49/2011
Publication Date 09-Dec-2011
Grant Date 08-Dec-2011
Date of Filing 30-Mar-2006
Name of Patentee Hydralift AmClyde, Inc.
Applicant Address 240 EAST PLATO BOULEVARD ST. PAUL, MN
Inventors:
# Inventor's Name Inventor's Address
1 FRAFJORD, ERIK KLOVERVEIEN 20, SOLA, NORWAY NO-4050
2 LONG WAYNE R. 811 QUAIL RIDGE ROAD, EAGAN, MN 55123
3 WALLER, AARON D. 811 8TH STREET APT. 22, FARMINGTON, MN 55024
4 HOLME, ANDERS HINNAVAGEN 32A, STAVANGER, NORWAY, NO-4118
5 ORKE, PER REIDAR KJOTVESGATE 10, HAFRSJORD, NORWAY NO-44-4
6 GJEDEBO, JON GRUDE 14/41 QUEENSGATE TERRACE LONDON, UNITED KINGDOM SW7 MPN
7 BOOTH, MICHAEL L. 4232 MONROE STREET, COLUMBIA HEIGHTS, MN 55421
PCT International Classification Number G06F
PCT International Application Number PCT/US2004/034016
PCT International Filing date 2004-10-14
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 60/567,705 2004-05-03 U.S.A.
2 60/512,108 2003-10-17 U.S.A.