Monitoring equipment health
Systems and methods for monitoring operational health of an equipment unit. An example system may include a plurality of sensors operable to facilitate operational measurements indicative of operational status of the equipment unit, a video output device, and a processing device comprising a processor and a memory storing an executable program code. The processing device may be communicatively connected with the sensors and the video output device. The processing device may be operable to receive the operational measurements and determine a plurality of operational health indicators based at least partially on the operational measurements. Each operational health indicator may be indicative of operational health of the equipment unit with respect to a different operational health category. The processing device may then output the operational health indicators for display on the video output device.
1. An apparatus comprising:
a system for monitoring operational health of an equipment unit in an assembly of equipment units operatively coupled to one or more controllers, wherein the system comprises:
a plurality of sensors operable to facilitate operational measurements indicative of operational status of the equipment unit;
a video output device; and
a processing device comprising a processor and a memory storing an executable program code, wherein the processing device is communicatively connected with the sensors and the video output device, and wherein the processing device is operable to:
receive the operational measurements;
receive one or more operational triggers associated with the equipment unit, wherein each of the one or more operational triggers comprises a threshold operational value within an operating range of the equipment unit and wherein each threshold operational value within the operating range is selected based on historical operational measurements indicative of the operational status of the equipment unit;
determine a plurality of independent operational health indicators based on the operational measurements exceeding at least one of the threshold operational values of the one or more operational triggers, wherein each of the independent operational health indicators is indicative of the operational health of the equipment unit with respect to a different operational health category;
determine a cumulative operational health indicator based on the plurality of independent operational health indicators; and
simultaneously display the plurality of independent operational health indicators based on at least one of the operational measurements exceeding at least one of the threshold operational values of the one or more operational triggers and the cumulative operational health indicator for the equipment unit on the video output device.
2. The apparatus of claim 1 wherein each of the independent operational health indicators and the cumulative operational health indicator is or comprises a number indicative of the operational health of the equipment unit.
3. The apparatus of claim 1 wherein each of the independent operational health indicators and the cumulative operational health indicator is or comprises a color indicative of operational health of the equipment unit.
4. The apparatus of claim 1 wherein one of the independent operational health indicators is indicative of a fraction of an operational capacity of the equipment unit at which the equipment unit is operating.
5. The apparatus of claim 1 wherein one of the independent operational health indicators is indicative of states of operation alarms associated with the equipment unit.
6. The apparatus of claim 1 wherein one of the independent operational health indicators is indicative of an amount of deviation of the operational measurements facilitated by the sensors from expected operational measurements determined based on a mathematical model of the equipment unit.
7. The apparatus of claim 1 wherein one of the independent operational health indicators is indicative of completion status of maintenance work orders for the equipment unit.
8. The apparatus of claim 1 wherein the equipment unit is or comprises a top drive, a mud pump, or a drawworks of a well construction system operable to construct a well at a wellsite.
9. The apparatus of claim 1 , wherein the cumulative operational health indicator is centered with respect to the independent operational health indicators.
10. The apparatus of claim 1 , wherein the cumulative operational health indicator comprises a sum or an average of the independent operational health indicators.
11. An apparatus comprising:
a system for monitoring operational health of an equipment unit in an assembly of equipment units operatively coupled to one or more controllers, wherein the system comprises:
a plurality of sensors operable to facilitate operational measurements indicative of operational status of the equipment unit;
a video output device; and
a processing device comprising a processor and a memory storing an executable program code, wherein the processing device is communicatively connected with the sensors and the video output device, and wherein the processing device is operable to:
receive the operational measurements;
receive a first operating threshold value associated with the equipment unit, wherein the first operating threshold value is selected based on historical operational measurements indicative of the operational status of the equipment unit;
receive a second operating threshold associated with the equipment unit, wherein the second operating threshold is selected based on a manufacturer recommended maximum value and wherein the second operating threshold is greater than the first operating threshold;
determine a plurality of independent operational health indicators based on the operational measurements or a work order status, wherein a first of the plurality of operational health indicators is indicative of a fraction of an operational capacity of the equipment unit at which the equipment unit is operating, wherein a second of the plurality of operational health indicators is indicative of states of operation alarms associated with the equipment unit, wherein the operation alarms are indicative of the operational measurements being between the first operating threshold and the second operating threshold, and wherein a third of the plurality of operational health indicators is indicative of a percent of maintenance work orders completed for the equipment unit; and
determine a cumulative operational health indicator based on the plurality of independent operational health indicators; and
simultaneously output the independent operational health indicators and the cumulative operational health indicator for the equipment unit for display on the video output device.
12. The apparatus of claim 11 wherein at least one of the independent operational health indicators and the cumulative operational health indicator is or comprises a number indicative of the operational health of the equipment unit.
13. The apparatus of claim 11 wherein at least one of the independent operational health indicators and the cumulative operational health indicator is or comprises a color indicative of operational health of the equipment unit.
14. The apparatus of claim 11 wherein a fourth of the plurality of independent operational health indicators is indicative of states of operational triggers associated with the equipment unit, wherein each operational trigger comprises a threshold of the operational measurements within an operating range of the equipment unit, and wherein each threshold of the operational measurements is selected based on historical operational measurements indicative of operational status of the equipment unit.
15. The apparatus of claim 11 wherein a fourth of the plurality of independent operational health indicators is indicative of an amount of deviation of the operational measurements facilitated by the sensors from expected operational measurements determined based on a mathematical model of the equipment unit.
16. A method comprising:
commencing operation of a monitoring system for monitoring operational health of an equipment unit in an assembly of equipment units operatively coupled to one or more controllers, wherein commencing operation of the monitoring system causes the monitoring system to:
receive operational measurements indicative of operational status of the equipment unit from a plurality of sensors;
receive a maximum operational capacity of the equipment unit, wherein the maximum operational capacity comprises a first threshold operational value;
receive a rated operational capacity of the equipment unit, wherein the rated operational capacity comprises a second threshold operational value and wherein the first threshold operational value is greater than the second threshold operational value;
determine a plurality of independent operational health indicators based on the operational measurements, wherein each of the plurality of independent operational health indicators is indicative of the operational health of the equipment unit with respect to a different operational health category, wherein one of the independent operational health indicators is indicative of the equipment unit being in one of a plurality of conditions, including a first condition in which the operational measurements exceed the second threshold operational value, but not the first threshold operational value, and a second condition in which the operational measurements exceed both the first threshold operational value and the second threshold operational value;
determine a cumulative operational health indicator based on the plurality of independent operational health indicators; and
simultaneously display the independent operational health indicators and the cumulative operational health indicator for the equipment unit on the video output device.
17. The method of claim 16 wherein each of the independent operational health indicators and the cumulative operational health indicator is or comprises a number and/or a color indicative of the operational health of the equipment unit.
18. The method of claim 16 wherein one of the plurality of independent operational health indicators is indicative of states of operation alarms associated with the equipment unit.
19. The method of claim 16 wherein one of the plurality of independent operational health indicators is indicative of completion status of maintenance work orders for the equipment unit.
20. The method of claim 16 wherein the equipment unit is or comprises a top drive, a mud pump, or a drawworks of a well construction system operable to construct a well at a wellsite.