English
Project background
A Cement Co., Ltd. in Guizhou has a 5000t / d clinker production line. The equipment management is based on the traditional planned maintenance and preventive maintenance. Manual spot inspection is adopted. Only some late faults can be found, passive emergency repair, high staff pressure and occasional accidents. At present, cement enterprises lack effective fault monitoring means for some key equipment on the production line, such as vertical mills, fans, rotary kilns, hoists, etc. equipment faults can not be warned in advance and can not be accurately located in case of faults, resulting in problems such as long maintenance time and untimely procurement of spare parts, which brings great pressure to production. The enterprise urgently needs to comprehensively monitor the equipment status through intelligent online monitoring means, so as to find and deal with equipment hidden dangers as soon as possible
Heavy inspection workload
Equipment hidden dangers are not found in time
More fault shutdown
The index is not advanced
National policy call
Market competition pressure
Customer pain points
Extensive management
The patrol inspection is not timely, there are a large number of missed inspections, and the equipment operation status cannot be understood in time
High operation and maintenance cost
A large number of spare parts are hoarded, occupying enterprise funds
Unplanned downtime loss
Unplanned shutdown, resulting in serious economic losses
The equipment has high temperature, high location, poor environment and dispersion
Difficult maintenance and patrol inspection
Project content
Installation of on-line monitoring device
Construction of equipment management system
Failure case verification
System operation effect evaluation
Implementation process
Business diagnosis
Overall planning
formulate a scheme
Investigation and analysis
Pre sales consultation
project organization
Project start
Training start
project plan
Video surveillance installation
system configuration
System training
System operation
Installation of on-line monitoring device
Local operation
Overall start
Switching system
Examination certification
System acceptance
Operation and maintenance
Continuous support
Field support
Project preparation
project construction
Project delivery
Support operations
Project results
Since the equipment management system independently developed and implemented by Nanjing Kaisheng was officially put into operation, the equipment health status has been monitored in real time, and the abnormality has been warned in advance in time, which has greatly improved the reliability of equipment management. Equipment management has changed from preventive maintenance to predictive maintenance.
Direct economic benefits
Avoid serious fault shutdown twice, reduce the maintenance time and reduce the maintenance cost
Streamlining personnel and institutions
Online monitoring and predictive maintenance replace manual inspection, reducing inspection personnel and inspection frequency
Management and awareness improvement
From traditional preventive maintenance to predictive maintenance, the reliability and safety of equipment management have been greatly improved
Project summary
Nanjing Kaisheng equipment management system has been in stable operation on site for more than half a year. Through on-line monitoring of main equipment and off-line patrol inspection of auxiliary equipment, abnormalities are timely warned and handled to realize the closed loop of equipment maintenance. The project uses advanced technologies such as industrial Internet, Internet of things, edge computing, artificial intelligence, big data and cloud computing to carry out equipment intelligent health management, diversified data collection of equipment operation, equipment data management, establish equipment digital model, and realize equipment intelligent health management through packaging equipment mechanism model + algorithm model Equipment fault prediction and closed-loop management of the whole life cycle, and gradually promote post maintenance and process maintenance to predictive maintenance, so as to realize cost reduction and efficiency increase.
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