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 of 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 of pumps, compressors, fans, gear units, step-up gears and other rotating equipment. Diagnostics in continuous mode helps to exclude sudden equipment failures.
Main tasks execution of process monitoring in the process of operation, remote control , data transmission; automatic diagnostics and localization of a fault source at early stage of fault progress as well as detection of reasons of its occurrence; 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 • exclusion of accidents at the production SERVICE OPTIMIZATION • maintenance and repair works based on real state of equipment; • extension of interrepair life; • reduction of maintenance costs (no unscheduled, emergency repairs) GROUTH OF PROFITS • guaranteed fulfillment of production plan; • minimization of emergency stops and downtime possibility
Diagnosed faults
Advantages of SADKO systems Automatic expert diagnostics • 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.
Advantages of SADKO systems Standard input devices • Transducers and sensors of technological parameters with standard output signals ; Standard • Devices produced by various manufacturers can be used; • Interchangeable components .
Advantages of SADKO systems Unified data transfer • 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.
Advantages of SADKO systems Common database • Uniform database of stationary and portable diagnostic systems; • Interested specialists have access to these data.
Advantages of SADKO systems Wa Customer support from manufacturer • 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.
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 3. Comparison of the current parameters with setting limits and output of electrical, light and sound signals to process control system.
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.
Equipping of monitoring systems with diagnostic tools Software, developed by ZAO “PromServis”, can be integrated to stationary monitoring systems of other manufacturers, for example, Bently Nevada 3500 , in order to upgrade them up to monitoring and expert diagnostic systems.
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”: ~ 25 000 USD in chemical and petrochemical industries Prevention of at least 1 hour of downtime allows ~ 36 000 USD to pay back in paper-and- expenses on pulp industry diagnostic 1 hour equipment completely . ~ 42 000 USD in metallurgy, oil and gas production
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 Decrease of number of carried out technical maintenances from (machines with rotating 274 to 14 elements) Oil processing plant (electric Service cost reduction by 75% motors) $ 250 000, that is 10 times more than expenses on purchase Paper mill of devices for monitoring of mechanical oscillations $ 3,000,000 due to reduction $ 19,000,000 additional increase Nuclear power plant of income of maintenance costs
Examples of effective implementation of vibration diagnostics. The following data can be obtained from open sources, including statistics of various vibration-measuring equipment manufacturers. 1) Results of first 5 years of vibration diagnostics technologies implementation at one of gas energy plants in the USA : expences $ 2.2 costs 40% 14% million production electric power expenses on maintenance costs production drives replacement reduced by 40% increased reduced from by 14% 3,2 to 1 million USD
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: 130 thousand 5 million USD USD productivity expenses on unreasonable repairs 3) Similar data were obtained at the largest pulp and paper mill in New Zealand: Annual 66% 60% economy 500 000 USD planned emergency downtimes downtimes
Reference List Chemical and Petrochemical Industry Company Implemented systems, projects JSC “ Kuybyshevazot ” 1) Vibration monitoring of fans in vacuum draw-down system Nitrogen processing (2005). 2) Control system for vibration of compressors (2006). JSC “ Tomskneftehim ” 1) Automated system of vibration diagnostics at aggregates www.sibur.ru/tnhk/ of pump equipment in monometers production (2011). Production of polymers: polypropylene and 2) Automated system of vibration diagnostics of turbo compressor equipment in monometers production (2011). polyethylene of high pressure. 3) Automated system of vibration diagnostics of turbogenerator in monometers production (2011). JSC “SIBUR - PETF” Automated system for vibration diagnostic and condition www.sibur.ru monitoring SADKO (2012). Production of polyethylene terephthalate
Reference List Oil and Gas JSC Novokuibyshevsy Oil 1) Control and monitoring of Primary oil refining machine (2007); Processing Plant 2) Automated diagnostic and control of hydrotreating unit (2007); Oil Processing 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 Automated system of remote control and monitoring of water International” , supply point (2009). Novy Urengoy Natural gas production
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