JP2006079322A - Maintenance management method of rotary equipment - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To realize maintenance management to each equipment in response to its property by certainly avoiding an occurrence of not allowable situation caused by a maintenance failure, without increasing costs resulted from excessive maintenance. <P>SOLUTION: A maintenance management method of a plurality of sets of rotary equipment used in a plant evaluates importance of the sets of the equipment by an importance evaluating process, evaluates vibration levels of the sets of the equipment by a vibration level evaluating process, and furthermore, determines management levels of the sets of the equipment to maintain them on the basis of the importance and the vibration levels. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a novel maintenance management method for a plurality of rotating devices used in a plant.

  Rotating equipment used in a plant needs to perform appropriate maintenance measures between installation and disposal. And it is important to perform this maintenance procedure appropriately according to the characteristics of the equipment in order to avoid the increase of expenses due to over-maintenance and also to avoid the occurrence of unacceptable situation due to inadequate maintenance. .

  In FIG. 2 of Patent Document 1 below, based on an empirical rule, more specifically, a maintenance history record indicating maintenance that has already been performed, a failure that has occurred so far, a failure indicating a failure, and a maintenance process based on the failure record. A maintenance method to perform is disclosed. Further, FIG. 1 of Patent Document 1 below quantitatively evaluates the risk related to the specific device, and more specifically, identifies the maintenance device by quantitatively evaluating the risk using the occurrence probability of the failure and the influence level of the failure as a risk enhancement factor. A maintenance method is disclosed.

  In addition, the present inventors, in the determination of the maintenance mode of the specific equipment used in the plant, the importance evaluation process for evaluating the importance, the deterioration sensitivity evaluation process for evaluating deterioration / damage sensitivity, and these evaluations A maintenance style determination method comprising a maintenance style determination process for determining the maintenance style of the specific device based on the result has been proposed (Japanese Patent Application No. 2004-167495).

JP 2002-123314 A

  However, the method and the like are for determining a maintenance method for static devices among the devices used in the plant, and have not been evaluated by specifically capturing the failure phenomenon of rotating devices. .

  In other words, since various types of failure modes occur due to the characteristic that the rotating equipment used in the plant is an assembly of parts and is always moving, the next time just evaluating and analyzing past failure history It is difficult to quantitatively specify the time of failure occurrence.

  For this reason, time-based maintenance (TBM) that performs maintenance before a failure occurs assuming the shortest lifetime of the equipment has been adopted, but in this maintenance, the burden of expenses due to excessive maintenance is large. There was a problem.

  In addition, state-based maintenance (CBM: Condition Based Maintenance) is performed in which a failure of a device is detected by measuring vibration of the rotating device, and the device is stopped and maintenance is performed when the failure is found. This method continuously monitors the rotating equipment used in the plant with the expectation that it can be used up to the maximum life and prevent the occurrence of sudden failures by continuously measuring vibrations and managing trends. (Online) Vibration diagnostic system is installed.

  However, since there is no clear classification of rotating equipment when installing a vibration diagnosis system, this system is installed even for equipment that does not affect production even if it is broken or equipment that has little impact. The burden of expense by management became large, and it was in the situation where management focusing on important equipment could not be performed.

  Furthermore, even if a vibration diagnosis system is installed, the occurrence of sudden failures still exists, and the phenomena, causes, and factors are different. In order to solve this, it is necessary to shift from equipment management (macro management) to parts management (micro management), but applying parts management to all rotating equipment is over-maintenance, reducing failure. However, there is a problem that the burden of expenses becomes large.

  In view of the above fact, the present invention avoids an increase in expenses due to excessive maintenance while preventing a serious failure related to the stop of the plant, and appropriately performs maintenance measures according to the characteristics of each rotating device. It proposes a maintenance management method that enables it.

  As a result of intensive studies, the present inventors have found that the above-described problems can be achieved by performing maintenance management according to the importance and vibration level of the rotating device.

  That is, according to the present invention, in the maintenance management method for a plurality of rotating devices used in a plant, the importance level of the rotating device is evaluated by the importance level evaluation step, and the vibration level of the rotating device is determined by the vibration level evaluation step. Further, the present invention provides a maintenance management method for a rotating device characterized in that, based on the importance and the vibration level, a maintenance level of the rotating device is determined and maintenance is performed.

  Further, in the present invention according to the invention, in the importance level evaluation step, the impact level-1 evaluation stage for evaluating the impact on productivity in the impact on the plant when the rotating equipment stops, and the productivity Except for the impact, the impact level-2 for evaluating other impacts, the impact level-1 evaluated at the impact level-1 evaluation stage, and the impact level-2 evaluated at the impact level-2 evaluation stage In accordance with the present invention, there is provided a maintenance management method for rotating equipment including an importance level deriving step for deriving the importance level.

  Furthermore, the present invention performs detailed maintenance management up to the component unit for the rotating equipment classified into the most important management level, and performs maintenance management by vibration diagnosis by constant monitoring during operation. The present invention provides a maintenance management method for rotating equipment characterized by distinguishing maintenance management methods from rotating equipment classified into other management levels.

  If maintenance management of the rotating equipment is carried out by the maintenance management method of the present invention, an appropriate maintenance method can be adopted according to the importance and vibration level of the rotating equipment, without increasing the cost due to excessive maintenance, and also maintenance. It is possible to reliably avoid the occurrence of an unacceptable situation due to deficiencies, and put each device in a management system according to its characteristics.

  Hereinafter, with reference to the accompanying drawings, a preferred embodiment of the maintenance management method for rotating equipment of the present invention will be described in detail.

  The maintenance management method of the present invention includes an importance evaluation step for evaluating the importance of a plurality of rotating devices used in a plant. In the preferred embodiment of the importance degree evaluation step, as shown in FIG. 1, the evaluation is performed based on the influence degree-1 evaluation stage, the influence degree-2 evaluation stage, and the influence degree-1 and the influence degree-2. It includes an importance derivation stage.

  In the present invention, the influence degree-1 evaluation stage is for evaluating the influence degree exerted on the productivity of the plant when the rotating equipment stops. One of the features of the present invention is that an influence level-1 evaluation stage is provided in the importance level evaluation step. That is, the degree of influence −1 on the productivity of the plant when the rotating equipment is stopped and the other degree of influence −2 other than the productivity of the plant shown below are evaluated separately, and further, By evaluating the importance level based on the impact level-1 and the impact level-2, it is possible to place an emphasis on productivity in a rotating device having a large factor due to a stop, and perform more efficient maintenance management. it can.

  The influence-1 evaluation stage of the present invention will be described with reference to FIG. In the illustrated influence level-1 evaluation stage, the influence on the productivity of the plant is evaluated. For example, if any stoppage has an impact on productivity, a, if a sudden stoppage has an impact on productivity, b, or if the backup function has no impact or a reduction in productivity. The case where there is an influence is c, and the case where there is no influence on the productivity which can be compensated by the driving technique is evaluated as d and the influence degree -1.

  In the present invention, the influence level-2 evaluation stage is for evaluating other influences except the influence on productivity in the influence given when the rotating device is stopped. Specifically, impact-2 is an impact that evaluates the impact on the quality of products produced in the plant, the impact on maintenance costs, the impact on the environment, and the risk of substances handled in the plant. It is determined from the degree. Referring to FIG. 3, the method of evaluating the impact level −2 will be described in detail. First, the impact level−2 includes the impact level on the product quality, the impact level on the maintenance cost, the impact level on the environment, and A four-stage evaluation of a, b, c, and d is individually performed on the degree of influence by which the risk is evaluated by the type and pressure of the material handled by the rotating device. As shown in FIG. 3, the influence on the product quality is evaluated as, for example, “a” when there is an influence and “d” when there is no influence. The maintenance cost can be evaluated according to the amount of money. For example, when the total of the material cost and the labor cost is 5 million yen or more, a, when the total of 1 million yen or more and less than 5 million yen is b, 20 If it is 10,000 yen or more and less than 1,000,000 yen, it is evaluated as c, and if it is less than 200,000 yen, it is evaluated as d. Regarding the environmental impact, for example, a is evaluated if it affects outside the company, b is evaluated if it affects the company, c is evaluated if it affects only the plant, and d is evaluated if there is no effect. . When evaluating the danger of a substance to be handled, it is possible to evaluate the degree of influence by dividing it into the type and characteristics of the substance. Specifically, regarding the type of substance, a is a toxic gas, b is a flammable gas, c is a poisonous and deleterious substance flammable liquid, and other substances are used. Evaluates to d. Further, with respect to the characteristics of the substance, the pressure of the substance is illustrated in FIG. 3 as follows. And evaluate.

  Next, in the influence level-2 evaluation stage of the present invention, these evaluation results are shown in FIG. 4, as shown in FIG. 4, when there are two or more evaluations a, the risk is 1 (high), and the evaluation a is one. Is a risk level 2 (medium), if a is zero and b is 1 or more, a risk level 3 (small), and if a is zero and b is zero, a risk level 4 (minimum). Evaluate impact -2.

  In the importance degree derivation stage in the importance degree evaluation process of the present invention, it is important based on the influence degree-1 evaluated in the influence degree-1 evaluation stage and the influence degree-2 evaluated in the influence degree-2 evaluation stage. Deriving degrees. In this importance degree derivation stage, the stricter of the influence degree-1 evaluation and the influence degree-2 evaluation is selected, that is, the importance degree is derived based on the matrix shown in FIG. For example, when the influence level-1 evaluation is b and the influence degree-2 evaluation is 3, the importance degree is evaluated as ii, and when the influence degree-1 evaluation is c and the influence degree-2 evaluation is 1, the importance degree is evaluated. Evaluates to i.

  The maintenance management method of the present invention includes a vibration degree evaluation step for evaluating the vibration degree of the rotating equipment. In the vibration level evaluation step, the items and the number of classifications for the method for evaluating the rotating device may be appropriately determined according to the characteristics of the equipment, but as the vibration level obtained by vibration measurement, the displacement value, speed value, acceleration value Among these, it is preferable to apply a speed value. When the displacement value is applied, it is difficult to evaluate the influence on the rotating device because the generation cycle of the displacement cannot be grasped. On the other hand, when the acceleration value is applied, it is effective for the analysis of individual parts, but it is difficult to evaluate the influence on the rotating device because the phenomenon occurring in the entire device cannot be widely grasped. Therefore, it is preferable to apply the speed value in order to evaluate the effects of damage and failure of the rotating equipment. As the vibration evaluation standard using the velocity value used in the vibration value evaluation process, a known standard or a uniquely determined standard can be used without any limitation. For example, if the foundation is solid, the speed value range can be simply determined and the vibration evaluation level can be classified into 3 to 7 ranks. For example, as shown in FIG. The vibration evaluation level can be classified into 3-7 ranks by determining the speed value range from the conditions classified into 3-7 ranks in combination. In particular, the vibration evaluation standard of JIS B 0906 and the vibration evaluation standard of ISO108161 that take into account the machine type and basic conditions can be suitably used.

  FIG. 6 shows a specific classification of rotating equipment when the vibration evaluation standard of JIS B 0906 is used. The standard shown in FIG. 6 refers to JIS Annex B Table 1 typical zone limit values. In FIG. 6, class I is an engine and machine incorporated as a part of the entire finished machine under normal operating conditions, class II is a medium-sized machine with no special foundation, class III is large Large prime movers and large rotating machines that are installed on rigid foundations or thought foundations that have relatively high rigidity in the measurement direction of vibration, and Class IV is large prime movers and large rotation machines that measure vibration. Fig. 1 shows the one installed on a foundation with relatively soft rigidity.

  FIG. 7 shows an example of the vibration degree evaluated based on the classification shown in FIG. The vibration level (strength of vibration) in the vibration level evaluation step is derived based on the zone derived from FIG. For example, as shown in FIG. 7, the D zone is evaluated with a vibration level of 1, the C zone with a vibration level of 2, the B zone with a vibration level of 3, and the A zone with a vibration level of 4.

  As described above, the greatest feature of the present invention is that it is used in the plant based on the importance derived from the importance derivation stage shown in FIG. 5 and the vibration determined from the vibration evaluation process shown in FIG. The maintenance level is determined by determining the management level of a plurality of rotating devices. By determining the management level of the rotating device, excessive maintenance can be prevented and appropriate maintenance can be performed.

  In the present invention, the management level is divided into a plurality of levels. The level for classifying the management level and the number of divisions may be appropriately determined depending on the scale of the target plant, the characteristics of the plant, the danger of the substance to be handled, and the like. For example, as described in detail below, it can be classified into management levels I to IV and the like, and the rotating equipment can be maintained according to each management level. In particular, for rotating equipment classified into the most important management level, detailed maintenance management up to the component unit is performed, and maintenance management is performed by vibration monitoring by on-line monitoring (online) during operation. It is preferable to distinguish from the maintenance management method for rotating equipment classified into management levels.

FIG. 8 shows a matrix for classifying the rotating equipment into each management level divided into a plurality of levels, and FIG. 9 shows an outline of a maintenance management method according to the management level of each rotating equipment. FIG. 8 illustrates a case where the rotating device is classified into four management levels. Based on the matrix shown in FIG. 8, management level I, management level II,
The management level of the rotating device is determined as either the management level III or the management level IV, and the rotating device classified into each management level performs maintenance management corresponding to each level as shown in FIG.

  For example, when the importance is i and the vibration is 1, the rotating device is classified into the management level I. The rotating equipment classified into the most important management level I performs detailed maintenance management up to the component unit, and performs maintenance management by vibration diagnosis by continuous monitoring (online) during operation. It is important to discriminate the rotating equipment classified into the most important management level from the maintenance management method with the rotating equipment classified into other management levels by performing maintenance management by the above method. In other words, the rotating equipment classified into the most important management level I has a large influence on the plant productivity and others, and also vibrates, so that it is more vigorous than those classified into other management levels. It is necessary to take sufficient care. Therefore, it is possible to prevent over-maintenance and perform appropriate maintenance by carrying out maintenance management of the rotating equipment classified into the most important management level I by the above method and distinguishing it from others. Efficient maintenance can be performed.

  Next, when the degree of importance is ii and the degree of vibration is 2, classification is made to management level II. The rotating equipment classified into the management level II performs maintenance management, for example, in units of vibration devices and performs maintenance management by vibration diagnosis based on periodic monitoring.

  Further, when the importance level is iii and the vibration level is 3, the management level III is classified. The rotating equipment classified into the management level III performs maintenance management by, for example, maintenance management by daily inspection by an operator and periodic inspection by specialists.

  Further, when the importance is iv and the sensitivity is 4, the management level is classified into IV. The rotating equipment classified into the management level IV performs maintenance management by daily inspection by an operator, for example.

In this way, it is important to maintain each rotating device according to each management level. By classifying the rotating devices into each management level and maintaining them, there is no increase in expenses due to excessive maintenance. In addition, it is possible to reliably avoid the occurrence of an unacceptable situation due to inadequate maintenance, and put each rotating device in a management system according to its characteristics.

  A more specific maintenance management method at each management level is exemplified below.

  First, a maintenance management method for rotating equipment classified into the most important management level I in the present invention will be described. For the rotating equipment classified into the management level I, maintenance management is performed to perform detailed maintenance management up to the component unit and to perform vibration diagnosis by continuous monitoring (online) during operation.

  In the present invention, for the rotating equipment classified into the management level I, the detailed maintenance management up to the component unit performs failure analysis and life prediction of each component. The means for performing failure analysis and life prediction is determined by the characteristics of the equipment and is not particularly limited. However, in order to perform systematic analysis, RCM (Reliability Centered Maintenance) or LEAF analysis (Life Estimate Analysis) is used. A technique such as “based on Failure Mechanisms: life prediction analysis based on failure physics” is preferably used. When implementing RCM, failure function analysis (FFA) that breaks down the function and performance of the target equipment to the parts and reveals the functional failure, failure mode effect analysis (FMEA) that examines the effect of failure for each failure mode It is preferable to include a step of performing a failure influence / effective maintenance method analysis, that is, a theoretical tree analysis (LTA), for selecting an effective maintenance method, a maintenance item, and a repair cycle. When carrying out LEAF analysis, the function development process of deploying rotating equipment by function, system development and parts development, “failure / deterioration / stress factor” analysis, life prediction method selection, estimated life setting and It is preferable to have a step of creating a life management table.

  Hereinafter, for the rotating equipment classified into the management level I, the process of deploying the rotating equipment to parts, the process of performing failure analysis, the process of investigating the influence of the failure, and the process of setting the estimated lifetime are performed. The maintenance management method when the estimated life is predicted according to the method will be described more specifically. In this case, the LEAF sheet shown in FIG. 10 is used.

  An example of a can pump as an example of function development, system development, and part development in the process of deploying rotating equipment to parts, and the function development is developed into three functions: liquid feeding function, sealing function, and fixing function be able to. The liquid feeding function can be expanded to an energy conversion system, a shaft support system, the sealing function can be a pressure-resistant system, a sealing system, and the like. The energy conversion system is an individual part such as an inducer, impeller, diffuser plate, diffuser (bowl), tip bearing receiver, inner casing, etc. The shaft support system is a shaft, bearing, tip bearing receiver, shaft sleeve, bearing, FB housing, etc. Individual parts, pressure-resistant system is individual parts such as casing, body, RB housing, seal system is parts such as various gaskets, liquid contact and rotating parts are individual parts such as bolts, washers, lock washers, keys, set screws, liquid contact・ Non-rotating parts can be deployed on individual parts such as bolts, holding plates, nuts, and studs.

  The LEAF sheet in FIG. 10 shows a part of the failure analysis result of the can pump. The failure of each component is analyzed by classifying into failure mode, damage mode, deterioration mode and stress factor. In addition, for each failure, there is a history of whether or not there is a past occurrence history, and if so, a history of whether or not countermeasures have been taken, and a judgment based on experience such as whether damage may affect the failure is described. . And about the object location of components, the evaluation mode by the object mode, the inspection method, the judgment standard, the detection time, and the life evaluation logic is described. The components described in the figure are an inducer, an impeller, and a diffuser plate extracted from an energy conversion system that is one of liquid feeding functions. Among these, there is no damage occurrence history for blade wear, which is a damage mode in a pumping failure that is a failure mode of the inducer, and there is little possibility that this will spread to damage or failure. Furthermore, there is no deterioration occurrence history for wear, which is a deterioration mode. The target surface of the wear deterioration mode is the entire blade, and it is determined at the time of disassembly that there is no corrosion by visual inspection for the purpose of inspection of corrosion. As for the rattling in abnormal vibration / abnormal noise, which is a failure mode, there is a history of occurrence of damage and countermeasures have already been taken, and it is unlikely that this will spread to damage or failure. Furthermore, as a result of the life evaluation, it has been derived that the component life is 10 years and the component inspection cycle is 8 years. On the other hand, for failures where there is a failure history in the past and the effect of improvement is not sufficient and there is a high possibility that `` damage '' will spread to `` failure '', the stress factor is set as the target mode and the management method is large. The classification is set as a quantitative inspection target, and an inspection using a measuring device is performed.

  In the present invention, the means for performing vibration diagnosis by constant monitoring during operation for rotating equipment classified into management level I is determined by the characteristics of the equipment and is not particularly limited. A method in which the apparatus is installed in the target device and equipment for performing regular monitoring is suitable. More specifically, an NKK equipment maintenance management system or JFE CMS-5000, which is a commercially available vibration measuring device, is installed in the target device, and a method of performing regular monitoring is preferable. Furthermore, when an abnormality occurs in the trend management based on the regular monitoring, it is preferable to analyze the abnormality that has occurred in the equipment by using a device incorporating FFT frequency analysis software on site.

  In the present invention, it is preferable that the maintenance management method for rotating equipment classified into the management level I further includes a step of managing the operation status of the equipment by daily inspection in addition to the maintenance management method.

  In the present invention, with respect to rotating equipment classified into management level II, maintenance management is performed for each equipment and maintenance diagnosis is performed for vibration diagnosis by regular monitoring. The maintenance management method for each device is determined according to the characteristics of the equipment and is not particularly limited, but the machine number, device name, model, applicable laws, capacity, design pressure, operating pressure, design temperature, operating temperature It is preferable to have a step of creating a device ledger in which all or part of the items of internal fluid and main device material are described. In addition, the means for performing vibration diagnosis by periodic monitoring (offline) is determined by the characteristics of the equipment and is not particularly limited. However, the vibration of the target device is measured using a vibration measuring device, and the vibration A method of performing trend management is preferred. For example, using an Anritsu machine checker, a commercially available vibration measurement device, as a base machine, use a system that transfers data measured in the field to a personal computer and stores and manages the data using a system program. The method of performing is preferably used. Here, when an abnormality occurs in vibration tendency management, it is more preferable to carry out a precise diagnosis by FFT frequency analysis to analyze the abnormality.

  In the present invention, it is preferable that the maintenance management method for rotating equipment classified into management level II further includes a step of managing the operation status of the equipment by daily inspection in addition to the maintenance management method.

  In the present invention, with respect to the rotating equipment classified into the management level III and the management level IV, maintenance management is performed by performing maintenance management in units of equipment and management by daily inspection. The maintenance management method for each device is determined according to the characteristics of the equipment and is not particularly limited, but the machine number, device name, model, applicable laws, capacity, design pressure, operating pressure, design temperature, operating temperature It is preferable to have a step of creating a device ledger in which all or part of the items of internal fluid and main device material are described. In addition, there are no particular restrictions on the method and content of daily inspections, but for rotating equipment classified into management level III, regular patrols by operators and regular intervals such as once a month or once a week. It is preferable to conduct periodic inspections by specialists. Here, if an abnormality occurs during daily patrols and regular inspections by specialists at regular intervals, such as once a month or once a week, use a device with built-in FFT frequency analysis software on site. Therefore, it is preferable to analyze an abnormality that has occurred in the device.

  On the other hand, the rotating equipment classified into the management level IV is less dangerous than the rotating equipment classified into the management level IV, and the security management method is, for example, There is a process of daily inspection. Here, when an abnormality occurs in the daily inspection, it is more preferable to carry out a precise diagnosis by FFT frequency analysis to analyze the abnormality.

  In the present invention, the rotating equipment classified into each management level is rotated by performing maintenance management by further adding a maintenance calendar creation step for determining a maintenance period by life evaluation derived according to each maintenance management method. The accuracy of device management can be further improved.

The simplified block diagram which shows an importance evaluation process. The table which shows an influence degree-1 evaluation stage. Table showing evaluation criteria for degree of impact-2 The flowchart which shows an influence -2 evaluation stage. Matrix showing importance derivation stage. The figure which shows the evaluation criteria of a vibration degree. The table | surface which shows a vibration degree evaluation process. A matrix showing the classification into each management level. The figure which shows the process classified into a management level and maintained. A table showing examples of LEAF analysis.

Claims (3)

  In the maintenance management method for a plurality of rotating equipment used in the plant, the importance of the rotating equipment is evaluated by the importance evaluation step, the vibration degree of the rotating equipment is evaluated by the vibration degree evaluation step, and A maintenance management method for a rotating device, wherein maintenance is performed by determining a management level of the rotating device based on the importance and the vibration level.   The importance evaluation step evaluates other influences except for the influence degree-1 evaluation stage for evaluating the influence on the productivity in the influence on the plant when the rotating equipment is stopped, and the influence on the productivity. The importance level is derived based on the impact level-2 evaluation stage, the impact level-1 evaluated in the impact level-1 evaluation stage, and the impact level-2 evaluated in the impact level-2 evaluation stage. The maintenance management method for a rotating device according to claim 1, further comprising an importance degree derivation step. Rotating equipment classified into the most important management level is classified into other management levels by carrying out detailed maintenance management up to the component unit and performing maintenance management by vibration diagnosis through constant monitoring during operation. The maintenance management method for a rotating device according to claim 1, wherein the maintenance management method is divided from the divided rotating devices.

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