Intelligent maintenance and equipment reliability improvement

1. Precision inspection equipment management system

Precise inspection is an innovative equipment management mode, and the essential improvement of equipment management capability.

It has integrated concept, process, method, tool and effect of equipment management (five-in-one) and a belief and force.

The highest level of equipment management: The superior doctor prevents illness (doctrine)

Comprehensive diagnosis and syndrome differentiation: multi-tech judgment matrix and rules (skill)

The evolutionary process and practical effects of equipment maintenance strategies in the world (result)

Methods of precision inspection:

Taking the full life of equipment as the management object, the multi-tech judgment matrix and rules as the tool, the optimized state detection and precision diagnosis as the core, and guiding optimized maintenance and providing world-class maintenance technology as a guarantee.

Deliverables of precision inspection:

Complete "precision inspection" Work Standards, Technical Standards and Management Standards, accurate and perfect expert intelligent diagnosis system, remote diagnosis platform, overall precision inspection report, complete fault solution, equipment maintenance quality control system, instrument tools and training, and determined results - equipment maintenance costs reduced by 30%; equipment maintenance personnel enjoy a nine-to-five life.

How to conduct precision inspection:

Support from leaders at all levels, enterprising corporate culture, dedicated attitude, advanced and reliable technical means, clear and complete business processes, and objective and pragmatic innovation practices.

Procedures of precision inspection:

2. Five inspections-in-one intelligent maintenance system (intelligent unmanned inspection)

■ Key technologies

(1) Integrate “patrol inspection/precision inspection/technical supervision/intelligent online diagnosis” into a platform;

(2) Unique big data expert knowledge base AI, to determine equipment fault location, fault level, fault cause, fault solution and maintenance cost;

(3) Realize 3D display of equipment state and early warning of deterioration, avoid equipment failure caused by unclear equipment analysis and judgment made by routine means and point inspection, and for lack of equipment maintenance and inspection strategies.

■ Expected effect

(1) Precise inspection reduces equipment failure by 80%, with an average annual income of 3.3 million RMB;

(2) Intelligent diagnosis of equipment failure to streamline maintenance personnel by 30%, reduce equipment maintenance cost by 30%, and make annual contribution of about 2 million RMB;

(3) Innovation in maintenance mode, the regular inspection period of main auxiliary equipment and the overhaul period of the main engine are expanded by at 20%, to make direct contribution at least 3 million RMB;

(4) Improve the equipment management system, realize inheritance of knowledge, and get rid of dependence on individual senior experts. The comprehensive annual contribution of the system is at least 10 million RMB.

Optimized maintenance decision support platform

——Determination of the fault location, the fault cause, the fault level, the treatment plan, and the working hour cost

3. Visualized steam turbine generator set intelligent safety pre-control system

■ Key technologies

(1) Collect steam turbine state characteristic data from TDM, automatically collect fault vector characteristic through the expert diagnosis system, continuous analyze of characteristic matrix changes by the automatic diagnosis engine, and boast of machine self-learning ability;

(2) With the help of the expert diagnosis engine, automatically detect, analyze and judge the running condition, degradation starting point, automatically send maintenance suggestions, and avoid fault trips caused by omitted problems in routine detection, unclear analysis and judgment, and lack of equipment maintenance strategy.

■ Expected effect

(1) Intelligently recommend cold-state rotation-impulsing parameters, display the bearing jacking height in real time, avoid excessive vibration due to skill deviation and bearing bush damage;

(2) Analyze TSI data in real time, intelligently analyze small changes, avoid disturbances and repetitions of shafting changes after overhaul, shorten start-up time by 24 hours;

(3) Accurately lock the reasons behind “the first tripping condition occurred”, such as protection misoperation, unbalance, thermal bending and oil film instability, intelligently send the inspection and verification strategy, and grasp the “golden time” for stating in the extreme hot state, and enable load running with an average of 12 hours ahead;

(4) Based on the above analysis, the contribution of each system startup is no less than 1 million RMB, and the scientific decision-making contribution after the overhaul even reaches 10 million RMB.

Revolutionary contribution in the field of vibration fault diagnosis of steam turbine generator units

The world's first visualized steam turbine monitoring system

Steam turbine fault diagnosis accuracy > 90%

Upgrade of TDM + ES

Eliminate serious accident of steam turbines

■ Shaft state visualization (original)

■ Automatic fault diagnosis and display (original)

■ Operation guidance and troubleshooting suggestions (original)

■ Journal bearing design optimization recommendations

■ Steam turbine visualized regulation valve sequence optimization

■ Professional vibration spectrum (traditional TDM)

4. Visualized important auxiliary equipment intelligent safety pre-control system

■ Key technologies

(1) Add the intelligent monitoring system, have the built-in rotor fault type library, automatically collect fault vector features, and form a closed-loop control over equipment fault degradation through self-learning capability of the big data feature matrix;

(2) The system can automatically diagnose equipment monitoring state, degradation starting point and trend, automatically send the maintenance suggestions to avoid fault trips caused by problems unrecognized by conventional means and unclear technical analysis.

■ Expected effect

(1) Improve reliability of equipment, extend the life cycle of equipment, avoid accidental equipment failure, and the annual income is at least 1 million RMB;

(2) Realize five determinations of fault location, fault cause, fault level, treatment plan, and working hour cost, improve control efficiency by more than 50%, and the annual contribution is at least 2 million RMB;

(3) Reduce the number of personnel in the patrol inspection/point inspection by 30%, reduce the maintenance cost of spare parts by 30%, and contribute an annual income of about 3.5 million RMB;

(4) After comprehensively considering operation time, maintenance efficiency, inspection and maintenance cost, the annual contribution is at least 6.5 million RMB.

5. Visualized boiler anti-wear and explosion-proof intelligent safety pre-control system

■ Key technologies

(1) 3D dynamics of heating surfaces of the four tubes of the boiler, digital twinning coupled with online and offline data, automatic sending of the risk of wear, deterioration and failure of the four tubes;

(2) Mechanism model of life and wear of four tubes and AI of big data expert knowledge base;

(3) Configure special sensors and special monitoring instruments.

■ Expected effect

(1) Establish a heating surface wear mechanism model and a hybrid model test; 

(2) Intelligent planning of four-tube inspection items reduces the monitoring cost by 50%; optimization of boiler overhaul to generate at least 48 hours of start-up time;

(3) Innovative anti-wear and explosion-proof management and control mode realizes dynamic visualized supervision, reduces boiler accidental pipe burst accidents by more than 80%, and indirectly generates annual income of at least 7.5 million RMB.

6. Visualized excellent lubricant management system

■ Key technologies

(1) Gas turbine lubricating oil and EH oil, online intelligent analysis, automatic purification technology;

(2) “Three-in-one” diagnosis and linkage technology for lubrication parts of important equipment, enabling "quantified and visualized" greasing work; 

(3) Online intelligent analysis of key parameters such as oil particle size, moisture, antioxidants, and demulsibility, interacting with the automatic filling robot.

■ Expected effect

(1) Avoid "uninterrupted" operation of the oil filter, reduce system consumption, and cut power consumption and spare parts costs by 200K RMB;

(2) Avoid equipment damage incidents caused by oil deterioration, and prevent fire accidents caused by improper lubrication, with an annual contribution of about 800k RMB;

(3) Scientific support for oil procurement decision-making, reduce inventory cost by 30%; standardize lubrication management, reduce test and oil supply workload by 30%;

(4) Comprehensively considering equipment consumption, damage and inspection and maintenance costs, the annual contribution is at least 1.5 million RMB.