for diagnostics and monitoring of industrial equipment condition. - - PowerPoint PPT Presentation

Software and hardware unit "SADKO" is an automated system for diagnostics and monitoring of industrial equipment

• condition. The system is based on analysis of vibroacoustic

noises and technological parameters.

Main blocks of the System:

• Server of data collection and processing,

and automated workstations with installed Software (SADKO, DIAES, SCADA-system). Qty of channels: 1…300, Qty of machines: unlimited.

• Hardware for communication (Ethernet,

Wi-Fi, GPRS);

• Vibration controller VK-1, (16,32,48

channels), with power supply and connection cables; blocks of RMS values

• f vibration velocity calculation and

commutation of signals.

• Sensors: vibration velocity transducers

(piezoaccelerometers or proximeters); process parameter transducers (temperature, pressure, flow, load current, rotation frequency, etc).

Application Control of technical condition

• f pumps, compressors, fans,

gear units, step-up gears and

• ther rotating equipment.

Diagnostics in continuous mode helps to exclude sudden equipment failures.

Main tasks

automatic diagnostics and localization of a fault source at early stage of fault progress as well as detection of reasons of its occurrence; execution of process monitoring in the process of operation, remote control , data transmission; detection of equipment faults and timely notification of personnel; help in making decisions to eliminate dangerous situations; generation of reports, accumulation and archiving of equipment measuring parameters.

Benefits of monitoring and diagnostic system application

SAFETY

• maintenance and repair works based on real state of

equipment;

• extension of interrepair life;
• reduction of maintenance costs (no unscheduled, emergency

repairs)

SERVICE OPTIMIZATION GROUTH OF PROFITS

• exclusion of accidents at the production
• guaranteed fulfillment of production plan;
• minimization of emergency stops and downtime possibility

Diagnosed faults

Advantages of SADKO systems

• Automatic diagnostics with indication of defective unit, type of

defect, its reason and level of severity.

• Complex inspection: during procedure of diagnostics each

assembly is considered as an integral structure.

• Prediction of equipment state during operation, automatic

calculation of the next repair time and volume of repair jobs.

Automatic expert diagnostics

Standard

Standard input devices

Advantages of SADKO systems

• Transducers and sensors of technological parameters with

standard output signals;

• Devices produced by various manufacturers can be used;
• Interchangeable components.

• Wireless technology of data transmission (Ethernet, Wi-Fi, GPRS);
• Standard network interfaces (Ethernet, RS-485);
• Information transfer to automatic control systems through standard

protocols (OPC, SQL) and to system of enterprise management: OPC, SQL, SAP R/З, etc;

• Application of internet technologies.

Unified data transfer

Advantages of SADKO systems

• Uniform database of stationary and portable diagnostic systems;
• Interested specialists have access to these data.

Common database

Advantages of SADKO systems

Wa

• Systems are delivered with configured and adjusted database of

customer’s equipment;

• Customized monitoring and diagnostic technologies;
• Free consultations;
• Free updates and upgrades of purchased software version;
• Remote diagnostic center.

Customer support from manufacturer

Advantages of SADKO systems

Main Functions

• 1. Measurement, registration and

conversion of analog signals from transducers of vibration and other parameters (temperature, pressure, flow rate, etc) into digital signals.

Main Functions

• 2. Periodical automatic diagnostics and detection of faults.

Prediction of defect progress.

Main Functions

• utput of electrical,

light and sound signals to process control system.

• 3. Comparison of the current parameters with setting limits and

Main Functions

• 4. Visualization of monitored parameters values, diagnostic results

and equipment state.

The whole operation data are displayed in the form of a semaphore and functional graphs. If a parameter value is not within the setting limits, the corresponding indicator changes its color into yellow or red and a warning message is displayed, accompanied with sound (speech) notification.

Main Functions

Multifunctional spectrum analyzer for the profound manual analysis of machines state.

Main Functions

Review of orbital curves

Main Functions

• 5. Generation of reports and

lists of required repair jobs

In spite of the fact that the system is local, all reports and archives are accessible for viewing in the local net.

Software, developed by ZAO “PromServis”, can be integrated to stationary monitoring systems of

• ther manufacturers, for example,

Bently Nevada 3500, in order to upgrade them up to monitoring and expert diagnostic systems.

Equipping of monitoring systems with diagnostic tools

Economic efficiency

Implementation of monitoring and diagnostic systems

• prevention of sudden emergencies (failures) and downtime of equipment;
• early fault detection and timely prevention of defects development;
• cancellation of routine repairs of operable equipment;
• proper planning of repair works and accurate calculation of consumables at

scheduled maintenance;

• lifetime extension for diagnosed objects;
• input control of assemblies after repair and installation at plants.

Economic efficiency

Average cost of 1 hour of unplanned machine downtime, according to data received by American research center “ARC Advisory Group”: ~ 42 000 USD in metallurgy,

• il and gas

production ~ 36 000 USD in paper-and- pulp industry ~ 25 000 USD in chemical and petrochemical industries

1 hour

Prevention of at least 1 hour of downtime allows to pay back expenses on diagnostic equipment completely.

Examples of effective implementation of vibration diagnostics. Bruel and Kjaer Company (Denmark): Annual economic effect of transition from scheduled maintenance to maintenance based on actual state of equipment.

Chemical plant (machines with rotating elements) Decrease of number of carried out technical maintenances from 274 to 14 Oil processing plant (electric motors) Service cost reduction by 75% Paper mill $ 250 000, that is 10 times more than expenses on purchase

• f devices

for monitoring of mechanical oscillations Nuclear power plant $ 3,000,000 due to reduction

• f maintenance costs

$ 19,000,000 additional increase

• f income

1) Results of first 5 years of vibration diagnostics technologies implementation at

• ne of gas energy plants in the USA :

The following data can be obtained from open sources, including statistics of various vibration-measuring equipment manufacturers. electric power production increased by 14%

expences

$ 2.2 million

expenses on drives replacement reduced from 3,2 to 1 million USD

costs

40% 14%

production

maintenance costs reduced by 40%

Examples of effective implementation of vibration diagnostics.

2) Application of technologies of vibration diagnostics at plants of one of leading cement manufacturers in South East Asia. Results of the first year:

5 million USD 130 thousand USD

productivity expenses on unreasonable repairs 3) Similar data were obtained at the largest pulp and paper mill in New Zealand:

66% 60%

planned downtimes emergency downtimes

Annual economy 500 000 USD

Examples of effective implementation of vibration diagnostics.

Reference List

Company Implemented systems, projects JSC “Kuybyshevazot” Nitrogen processing 1) Vibration monitoring of fans in vacuum draw-down system (2005). 2) Control system for vibration of compressors (2006). JSC “Tomskneftehim” www.sibur.ru/tnhk/ Production of polymers: polypropylene and polyethylene of high pressure. 1) Automated system of vibration diagnostics at aggregates

• f pump equipment in monometers production (2011).

2) Automated system of vibration diagnostics of turbo compressor equipment in monometers production (2011). 3) Automated system of vibration diagnostics of turbogenerator in monometers production (2011). JSC “SIBUR-PETF” www.sibur.ru Production of polyethylene terephthalate Automated system for vibration diagnostic and condition monitoring SADKO (2012).

Chemical and Petrochemical Industry

Reference List

JSC Novokuibyshevsy Oil Processing Plant Oil Processing 1) Control and monitoring of Primary oil refining machine (2007); 2) Automated diagnostic and control of hydrotreating unit (2007); 3) Automated diagnostic and control of delayed coking unit (2008); 4) Automated diagnostic and control for assembly 35/6 (2008); 5) Automated diagnostic and control for assembly 35/8 (2008); 6) Automated diagnostic and control for assembly 35/11-300 (2008- 2009); 7) Automated diagnostic and control for assembly 43/102-1 (2009). JSC “ROSPAN International”, Novy Urengoy Natural gas production Automated system of remote control and monitoring of water supply point (2009).

Oil and Gas

Reference List

JSC NLMK http://nlmk.com Production of clean and durable steel 1) System of diagnostics and vibration monitoring of exhausters, sintering (agglomeration) plant, house №1 (2005); 2) System of diagnostics and vibration monitoring of exhausters, sintering plant, house №2 (2005-2006); 3) Converter plant №2 - automated system of temperature and vibration monitoring (2007); 4) System of diagnostic and vibration monitoring at ventilation units in coke-chemical production (2008); 5) Automated system for vibration and temperature control of fan coolers, blower ventilators of furnace and aspirating process plants (2009). JSC “Severstal” www.severstal.com Integrated steel and steel related mining company System for monitoring of technical condition of bearing assemblies in exhausters at sintering plant (2009).

Metallurgy

Reference List

Power industry

JSC “State Scientific Center – Research Institute of Atomic Reactors” (JSC “NIIAR”) www.niiar.ru One of the World’s largest scientific and research entity in the nuclear industry. 1) Automated system for diagnostics and control of turbogenerator (2010). 2) Automated system of diagnosing and control of main circulating pumps (2010).

Engineering

JSC “Dimitrovrgad Automobile Units Plant” www.daaz.ru Manufacturing of automobile components for national carmakers System of monitoring and control for pumping station (2008).

Dimitrovgrad, Russian Federation Global Business Department

• Mr. Denis Bychkov

Tel: +7 (84235) 4-30-02, 4-18-07 Fax: +7 (84235) 4-58-32 E-mail: promservis@promservis.ru, workingbox@gmail.com Visit us at www.promservis.ru

Thank you for your attention!

“Seg Techno Solutions & Services” Bangalore, INDIA.

• Mr. K N SAKTHIVEL (CEO),
• Mr. Nikhil H S – (Sales Manager)

Email: segtechnosolutions@gmail.com Mobile: +91 8197623204 +91 9036435055 +91 9620689880 +91 08553421078 www.segtechno.com