First, the reason to carry out condition monitoring and fault diagnosis working <br> technology, the characteristics of Qilu Petrochemical Company Acrylic Fiber Plant is a high level of automation, strong production continuity, once a production process fails, will affect the continuous operation of the entire device. In past equipment management work, they realized that simply judging from experience and experience to judge equipment failure has been unable to meet the needs of modern production. For example: In March 1995, the N2 circulating fan motor in the spinning workshop was highly vibrated. The factory organized the relevant technical experts to conduct a consultation and determined that there was no abnormality in the motor. The next day, the motor bearings were burned out and the entire production line was parked. The economic loss amounted to one million yuan. In recent years, through practice, the company has improved its understanding of the status monitoring and fault diagnosis work. Using a simple vibrometer as a device vibration trend analysis map, it has avoided multiple equipment accidents and has strengthened its determination to carry out this work.
Since 1999, the acrylic fiber factory of Qilu Petrochemical Company decided to vigorously promote the application of condition monitoring and fault diagnosis techniques. In daily equipment management and maintenance, vibration analysis, wall thickness detection, infrared temperature measurement and other means have been used to solve and deal with many The hidden danger of equipment, equipment integrity rate from the previous less than 98% to 99.4%, the failure downtime rate dropped to 0.09%, for our plant turning losses into profits, increase the efficiency made a great contribution.
Second, the condition monitoring equipment condition monitoring and fault diagnosis apparatus <br> application technique generally refers to a characteristic parameter (such as vibration, temperature) measuring device, to check its state. When the characteristic parameter is less than the allowable value, it is considered normal, otherwise it is considered abnormal. The equipment fault diagnosis technology is to know, grasp the status of the online use of the equipment, combine the operating history of the equipment, predict, analyze and judge the faults that may occur or have occurred, and determine the nature, type, degree, and cause of the fault. Parts, indicating the occurrence and development of faults and their consequences, suggesting measures to control the continued development of faults, and eliminating the faults by adopting measures for adjustment, maintenance, and management, and eventually returning the equipment to its normal state.
At present, the equipment condition monitoring and fault diagnosis technology is an important part of modern equipment management and is an indispensable means for equipment management and maintenance management. Especially in today's increasingly fierce market competition, the maintenance and reduction of equipment maintenance costs is one of the most tappable potential for companies. Therefore, the application of condition monitoring and fault diagnosis techniques makes it a historical necessity that predictive maintenance replaces traditional and backward maintenance and regular preventive maintenance.
Acrylic Fiber Factory of Qilu Petrochemical Company purchased LC-8000 dual-channel data collector, LC-2200 vibrometer, DVM-63 vibrometer, ST-6 red line thermometer, and PM30L infrared temperature measurement according to the actual operation of equipment. Instruments, E260 tachometers and other advanced monitoring equipment, and gradually carry out state monitoring work.
Third, the application of state monitoring and fault diagnosis technology is significant <br> Application of state monitoring and fault diagnosis technology, with the Qilu Petrochemical Company Acrylic Factory inspection system implementation, regular monitoring of key equipment, to track the device with the signs of failure Monitoring to avoid downtime and ensure smooth operation of production.
1. The implementation of key equipment has been carried out and the failure has been eliminated in the embryonic state. In the daily inspection, technicians found that the temperature of a bearing of a turbine blower was high with an infrared thermometer, and once the flat wind phase of the prisoner was broken, it would cause the entire The production line is interlocked and parked. After a state analysis was performed with a data logger, it was found that there was an oil film vortex phenomenon and it was judged that the lubricating oil in the shaft box was emulsified. The workshop took a series of safety measures and gradually replaced the lubricant without stopping the machine. The temperature of the bearing bush was reduced from 60°C to 40°C, which prevented equipment accidents and ensured safe production.
2. Unswervingly deal with hidden dangers to ensure long-term operation of the device.
The 3.4MPa condensate line of the spinning device frequently leaks, especially at elbows. After measuring with a thickness gauge, it was found that the wall thickness of the straight pipe section of the 89×4 seamless pipe was reduced by 0.5 mm, and the thinning of the elbow at 1 to 3.5 mm directly endangered the normal operation of the entire device. After repeated argumentation, our factory decided to change the pipeline without stopping. After the original pipeline was dismantled, it was found that the inner wall of the pipe was scoured severely and was nearly scrapped; the hidden dangers were accurately judged by the thickness gauge, and timely treatment was performed to ensure the continuous operation of the device and the operating cycle of the device was extended from the previous year to one and a half years.
3, timely and accurately diagnose the equipment failure, to avoid the unit to stop in July July, the thermoelectric workshop 6 # boiler induced fan vibration suddenly increased, after measurement, the fan side bearing horizontal vibration severity of 10mm / s, determine the impeller is not balanced . The thermoelectric workshop adopted boiler pressure fire and other measures. After removing the dust on the impeller, the operation was normal and the entire unit was prevented from parking.
4. Follow-up monitoring of equipment with faulty symptoms and timely processing
P66 fan is the process exhaust fan of the 5# and 6# washing machines in the spinning workshop. In the condition monitoring, it was found that the vibration has been continuously intensified, and the vibration value suddenly increased to 46mm/s at the end of July. The initial judgment was a bearing failure. The spinning workshop actively organizes balanced production, uses half a day's time for repairs, and after inspection, it finds that the bearing cage has been damaged and has been repaired in time to ensure continuous production.
5. Accurately judge and deal with unexpected failures and shorten the maintenance time Since the spinning washing tower fan has been installed since the installation, the state has been poor. For this reason, the acrylic fiber factory of Qilu Petrochemical Company has invested a lot of manpower and material resources every year to overhaul. The maintenance work is heavy and the disassembly is difficult. At the end of September, the vibration value of the fan was found to be 45mm/s during the monitoring and the initial diagnosis was that the equipment was not balanced. According to our overhaul experience, we believe that the bolts on the impeller shaft end fall off, so that it can be processed in a short time and the inspection time is greatly shortened and the maintenance cost is reduced.
6, strengthen the inspection of electrical equipment to ensure the safe operation of the device
In August, when electricians used a spot thermometer to check, they found that the temperature at the connection between CT and the busbar at the C-phase outlet of the 3# steam turbine was as high as 150°C. After analysis, this may be due to the looseness of the nut and the large contact resistance. of. The factory set up to deal with hidden dangers. When the maintenance personnel unscrew the nut, it is found that the screw and nut thread are damaged and cannot be used continuously. Replace the CT and resume operation. Due to the meticulous patrols, monitoring was in place and a major accident was avoided.
7. The use of water balance testing methods to reduce pipe network leakage analysis from the measurement data of the pipe network of acrylic fiber factory of Qilu Petrochemical Company, with higher network loss. For this purpose, professional survey personnel are required to use the RD-400 precision underground pipeline detector to detect underground water supply pipelines and carry out water balance analysis. A total of more than 20 leakage points have been measured, and 173,000 tons of water can be saved annually after the leakage is treated. The net loss of production water dropped from the original 6% to 4.5%, and the net loss of domestic water dropped from the original 18% to the present 10%.
8, strengthen the lubrication management, to ensure that the pump in the oil pass rate of 100%
First of all, the routine testing of the lubricating oil entering the factory, insisting that the unqualified lubricating oil is not allowed in the human bank, and at the same time regularly inspecting the lubricating oil for three months. Adhere to the "five set" and "three filter", the monthly motorized organizations organized large units, pump equipment for oil sampling, through the sampling can be judged: (1) whether the index of the lubricant itself changes. (2) Whether the lubricant is deteriorated by medium contamination. (3) Whether there is mechanical abrasive grain. Through the "check-reform-recheck" closed loop mode, the pump's passing rate of oil has been significantly increased, from the past 95% to 100%, to ensure that the equipment is in good condition.
Fourth, summing up <br> In summary, the use of condition monitoring and fault diagnosis technology, can be more convenient, faster, more effective grasp of equipment operation, improve equipment maintenance. Although my company has accumulated some experience in this area, but because of equipment failure diagnosis technology is a new comprehensive discipline, but also need to further explore and improve in practice. Coupled with the vast differences in equipment, external operating conditions are different, there are often a variety of different signal responses to the same fault. On the contrary, some signals are often between two or more possible failures, not one-to-one correspondence. This requires us to proceed from reality and analyze specific issues. We usually diligently observe and collect first-hand information, continuously improve our own technical level, accurately judge and use them flexibly, and raise equipment management and maintenance to a new level.
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