JP5487591B2 - Diagnosis method of rotating equipment - Google Patents
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- JP5487591B2 JP5487591B2 JP2008276992A JP2008276992A JP5487591B2 JP 5487591 B2 JP5487591 B2 JP 5487591B2 JP 2008276992 A JP2008276992 A JP 2008276992A JP 2008276992 A JP2008276992 A JP 2008276992A JP 5487591 B2 JP5487591 B2 JP 5487591B2
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- 238000000034 method Methods 0.000 title claims description 12
- 238000003745 diagnosis Methods 0.000 title claims description 5
- 238000011156 evaluation Methods 0.000 claims description 45
- 238000005098 hot rolling Methods 0.000 claims description 15
- 238000005096 rolling process Methods 0.000 claims description 12
- 238000001514 detection method Methods 0.000 claims description 11
- 229910000831 Steel Inorganic materials 0.000 claims description 10
- 239000010959 steel Substances 0.000 claims description 10
- 230000008439 repair process Effects 0.000 claims description 9
- 230000001186 cumulative effect Effects 0.000 claims description 6
- 238000012423 maintenance Methods 0.000 description 14
- 230000006866 deterioration Effects 0.000 description 13
- 238000007689 inspection Methods 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 239000011159 matrix material Substances 0.000 description 4
- 238000004364 calculation method Methods 0.000 description 3
- 125000004122 cyclic group Chemical group 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000011084 recovery Methods 0.000 description 2
- 238000012937 correction Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000002405 diagnostic procedure Methods 0.000 description 1
- 238000012631 diagnostic technique Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000009661 fatigue test Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000012502 risk assessment Methods 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
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Description
本発明は、重量物を大量に搬送し加工する設備（たとえば製鉄プラント等）で使用される様々な回転機器の経年劣化型損傷（たとえば疲労，腐食，摩耗等）を診断して、補修あるいは更新の時期を決定する方法に関するものである。 The present invention diagnoses and repairs or renews aged deterioration type damage (such as fatigue, corrosion, wear, etc.) of various rotating equipment used in facilities that transport and process large quantities of heavy objects (for example, steel plants). It relates to a method for determining the timing of the period.
鋼材のような重量物を大量に搬送しかつ加工する設備には、様々な回転機器が使用される。それらの回転機器は、重量物を搬送加工する故に経年劣化型損傷（以下、劣化損傷という）を生じる。回転機器の劣化損傷が進行すると、その回転機器の故障を引き起こし、一連の設備の稼動に支障をきたす。そのため、回転機器の劣化損傷を診断して、回転機器が故障する前に補修あるいは更新を行なう必要がある。 Various rotating devices are used in facilities for transporting and processing heavy objects such as steel in large quantities. These rotating devices cause aged deterioration type damage (hereinafter referred to as deterioration damage) because they convey and process heavy objects. When the deterioration damage of the rotating equipment progresses, the rotating equipment breaks down and hinders the operation of a series of facilities. Therefore, it is necessary to diagnose deterioration damage of the rotating device and repair or update it before the rotating device breaks down.
そこで、回転機器の診断技術が種々検討されている。
たとえば特許文献１には、回転機器の状態を示す振動や電流を測定し、その測定値を劣化指数に変換して、劣化損傷の進行を診断する技術が開示されている。
特許文献２には、回転機器の振動と回転数を測定し、その測定値を所定の関数で補正して、得られた補正値と予め設定した閾値とを比較することによって劣化損傷の進行を診断する技術が開示されている。
Accordingly, various diagnostic techniques for rotating equipment have been studied.
For example, Patent Document 1 discloses a technique for diagnosing the progress of deterioration damage by measuring vibration and current indicating the state of a rotating device and converting the measured value into a deterioration index.
In
これらの技術は、いずれも単に回転機器の劣化損傷を診断するものであり、一連の設備におけるその回転機器の経済的な優先度は考慮されていない。
たとえば、加熱した鋼スラブを圧延して熱延コイルを製造する熱間圧延設備では、粗圧延機，仕上げ圧延機，巻取り機，搬送コンベア等に様々な回転機器が使用されており、故障が発生したときの復旧に要する時間や費用は、回転機器が配設される装置に応じて異なる。そのため、限られた人員で熱間圧延設備の保守点検を行なうためには、補修あるいは更新を行なう回転機器を選択する際に、経済的な観点から評価した優先度を考慮する必要がある。
All of these technologies merely diagnose deterioration damage of rotating equipment, and the economic priority of the rotating equipment in a series of facilities is not considered.
For example, in a hot rolling facility that produces hot-rolled coils by rolling a heated steel slab, various rotating devices are used for roughing mills, finish rolling mills, winders, conveyors, etc. The time and cost required for recovery when it occurs vary depending on the device in which the rotating device is installed. Therefore, in order to perform maintenance and inspection of the hot rolling facility with a limited number of personnel, it is necessary to consider the priority evaluated from an economic viewpoint when selecting a rotating device to be repaired or updated.
ところが特許文献１，２に開示された技術では、経済的優先度を考慮していないので、復旧作業の期間中に生産が停止することによる経済的な損失を最小に抑えることは困難である。
経済的優先度を考慮したプラントの診断技術としては、米国石油協会（ＡＰＩ）が作成した規格API581（Risk-Based Inspection BRD, May 2000）が知られている。しかし、この技術は石油化学プラントの圧力容器や配管等の静機械の損傷を診断するものであり、回転機器の劣化損傷の診断に適用するのは困難である。
A standard API581 (Risk-Based Inspection BRD, May 2000) prepared by the American Petroleum Institute (API) is known as a plant diagnosis technique considering economic priority. However, this technique diagnoses damage to static machines such as pressure vessels and piping in petrochemical plants, and is difficult to apply to diagnosis of deterioration damage of rotating equipment.
本発明は、多数の回転機器の劣化損傷を診断するにあたって、補修あるいは更新を行なう回転機器を選択する際に、故障に起因する経済的損失を考慮して優先順位を決定することによって、設備の稼動停止による経済的な損失を最小に抑えることが可能な診断方法を提供することを目的とする。 In diagnosing deterioration damage of a large number of rotating equipment, the present invention determines the priority of the equipment by determining the priority in consideration of economic loss due to failure when selecting the rotating equipment to be repaired or updated. An object of the present invention is to provide a diagnostic method capable of minimizing an economic loss due to a shutdown.
本発明は、鋼スラブの熱間圧延設備における粗圧延機、仕上げ圧延機、巻取り機、搬送コンベアの各回転機器に、加速度計をセンサーとして配設し、各センサーから得られるデータを繰返し応力範囲Ｒangeに変換して当該回転機器の応力振幅Ａmp＝Ｒange／２を求め、応力振幅Ａmpを予め設定したマスターカーブに適用して寿命回転数Ｎを求め、寿命回転数Ｎから損傷度ｄ＝１／Ｎを算出し、所定の日数の間に得られる損傷度ｄを累積して累積損傷度Ｄ＝Σｄを算出し、累積損傷度Ｄを用いてＤ＝１となる寿命日数Ｌを算出し、次に、当該回転機器の使用日数Ｕと寿命日数Ｌを用いて寿命消費率Ｓ＝Ｕ／Ｌを算出し、寿命消費率Ｓのレベルに応じて寿命評価点ＳPを付与し、予め故障検知のレベルに応じて設定した故障検知度評価点ＴPと寿命評価点ＳPとを用いて故障発生リスク評価点ＲP＝ＴP×ＳPを算出し、次いで、予め故障に起因する経済的損失のレベルに応じて設定した経済リスク評価点ＥPと故障発生リスク評価点ＲPとに基づいて、当該回転機器の補修あるいは更新の必要性を判定し、その他の回転機器についても同様に補修あるいは更新の必要性を判定し、相互に比較することによって補修あるいは更新を行なう回転機器を選択する回転機器の診断方法である。 The present invention, rough rolling mill in the hot rolling mill of the steel slab, finishing mill, coiling machine, each rotating device conveyor, disposed accelerometer as a sensor, repeat data obtained from each sensor stress By converting into the range Range, the stress amplitude Amp = Range / 2 of the rotating device is obtained, the life amplitude N is obtained by applying the stress amplitude Amp to a preset master curve, and the damage degree d = 1 from the life revolution N / N is calculated, the damage d obtained during a predetermined number of days is accumulated to calculate the cumulative damage D = Σd, and the life days L where D = 1 is calculated using the cumulative damage D, Next, the life consumption rate S = U / L is calculated by using the use days U and the life days L of the rotating device, and a life evaluation point SP is given according to the level of the life consumption rate S, and the failure is detected in advance. failure detection evaluation point T P and life evaluation set depending on the level of It calculates the failure risk assessment point R P = T P × S P by using the S P, then economic risk evaluation points E P and failure risks set depending on the level of economic losses due to pre-failure Based on the evaluation point R P , the necessity of repair or update of the rotating equipment is determined, and the necessity of repair or update is similarly determined for other rotating equipment, and repair or update is performed by comparing with each other. This is a rotating device diagnosis method for selecting a rotating device to perform the operation.
本発明によれば、多数の回転機器を備えた設備の各回転機器の中から補修あるいは更新（以下、設備保全という）の対象とする回転機器を選択する際に、故障に起因する経済的損失を考慮して優先順位を決定するので、設備保全作業の期間中に生産が停止することによる経済的な損失を最小に抑えることができる。 According to the present invention, when selecting a rotating device to be repaired or updated (hereinafter referred to as facility maintenance) from each rotating device of a facility having a large number of rotating devices, the economic loss due to the failure. Therefore, the priority order is determined in consideration of the above, so that the economic loss due to the production stoppage during the period of the equipment maintenance work can be minimized.
重量物を大量に搬送しかつ加工する設備（たとえば製鉄プラント等）には、様々な回転機器が使用される。製鉄プラントの一例として、加熱した鋼スラブを圧延して熱延コイルを製造する熱間圧延設備を模式的に図１に示す。熱間圧延設備では、粗圧延機２，仕上げ圧延機３，巻取り機４，搬送コンベア等に様々な回転機器が使用される。なお図１では、搬送コンベアは図示を省略する。
Various rotating devices are used in equipment (for example, an iron manufacturing plant) that conveys and processes heavy objects in large quantities. As an example of an iron manufacturing plant, a hot rolling facility for rolling a heated steel slab to produce a hot rolled coil is schematically shown in FIG. In a hot rolling facility, various rotating devices are used for a rough rolling
これらの回転機器が劣化損傷によって故障すると、一連の設備の稼動に支障をきたす。そこで、各回転機器にセンサーを配設して、設備の稼動によって進行する劣化損傷を診断する。
回転機器に配設するセンサーは、加速度計を使用する。
If these rotating devices fail due to deterioration damage, the operation of a series of facilities will be hindered. Therefore, a sensor is disposed in each rotating device to diagnose deterioration damage that progresses due to the operation of the equipment.
Sensors disposed in rotating equipment uses the accelerometer.
そのセンサーから得られるデータを繰返し応力範囲Ｒangeに変換して、さらに当該回転機器の応力振幅Ａmp＝Ｒange／２を求める。ここで応力振幅Ａmpは、繰返し応力の最大応力と最小応力の差である繰返し応力範囲Ｒangeの１／２とした振幅であり、Ａmp＝Ｒange／２で算出される。たとえば熱間圧延設備では、１日あたり数百回程度の鋼スラブの圧延が行なわれ、その圧延回数に相当する数のＡmp値が得られる。それらのＡmp値は全て同一ではなく、正規分布を示す。 The data obtained from the sensor is repeatedly converted into a stress range Range, and the stress amplitude Amp = Range / 2 of the rotating device is obtained. Here, the stress amplitude Amp is an amplitude that is ½ of the cyclic stress range Range, which is the difference between the maximum stress and the minimum stress of the cyclic stress, and is calculated as Amp = Range / 2. For example, in a hot rolling facility, a steel slab is rolled several hundred times per day, and Amp values corresponding to the number of rolling times are obtained. Their Amp values are not all the same, but show a normal distribution.
一方で、予め回転機器の応力振幅と寿命との関係を求めておく。ここで寿命は、回転数で表わされ、新品から故障発生に到るまでの総回転数（以下、寿命回転数という）を指す。つまり寿命回転数は、新品の回転機器に特定の応力振幅の負荷が継続して作用した場合の故障発生に到るまでの総回転数を表わすものである。その応力振幅と寿命回転数との関係を示すグラフ（以下、マスターカーブという）の例を図２に示す。なお図２は、回転機器に用いられている鋼材の一例である。 On the other hand, the relationship between the stress amplitude and the life of the rotating device is obtained in advance. Here, the life is represented by the number of rotations, and indicates the total number of rotations (hereinafter referred to as the life rotation number) from the new article to the occurrence of a failure. That is, the life rotation speed represents the total rotation speed until a failure occurs when a load having a specific stress amplitude is continuously applied to a new rotating device. An example of a graph (hereinafter referred to as a master curve) showing the relationship between the stress amplitude and the life rotation speed is shown in FIG. In addition, FIG. 2 is an example of the steel material used for the rotating equipment.
そのマスターカーブに、当該回転機器のセンサーから得たデータから得た応力振幅Ａを適用して、寿命回転数Ｎを求める。次に、寿命回転数Ｎを用いて損傷度ｄ＝１／Ｎを算出する。たとえば熱間圧延設備では、１日あたり数百回程度のＡmp値が得られるので、その都度、損傷度ｄを求める。
さらに、所定の日数の間に得られた損傷度ｄを累積して累積損傷度Ｄ＝Σｄを算出する。本発明では損傷度ｄを累積する日数は特に限定しないが、簡潔な演算処理を行なうために１日分の損傷度ｄを累積することが好ましい。たとえば熱間圧延設備では、１日あたり数百回程度のｄ値が得られるので、それを累積して累積損傷度Ｄを求める。
The life rotation speed N is obtained by applying the stress amplitude A obtained from the data obtained from the sensor of the rotating device to the master curve. Next, the damage degree d = 1 / N is calculated using the life rotation speed N. For example, in a hot rolling facility, an Amp value of several hundred times per day can be obtained, and the damage degree d is obtained each time.
Further, the cumulative damage degree D = Σd is calculated by accumulating the damage degree d obtained during a predetermined number of days. In the present invention, the number of days for which the damage degree d is accumulated is not particularly limited, but it is preferable to accumulate the damage degree d for one day in order to perform a simple calculation process. For example, since a d value of about several hundred times per day is obtained in a hot rolling facility, the accumulated damage degree D is obtained by accumulating the d value.
次に、Ｄ＝１となる日数Ｌ（以下、寿命日数という）を算出する。そして、当該回転機器の使用日数Ｕと寿命日数Ｌとを用いて寿命消費率Ｓ＝Ｕ／Ｌを算出する。得られた寿命消費率Ｓのレベルに応じて寿命評価点ＳPを付与する。寿命消費率Ｓが低い（すなわち使用日数の少ない）ものは小さい寿命評価点ＳPを付与し、寿命消費率Ｓが高い（すなわち使用日数の多い）ものは大きい寿命評価点ＳPを付与する。本発明では寿命評価点ＳPの数値は特に限定せず、回転機器の仕様やその回転機器が配設される設備の稼動条件等に応じて適宜設定する。 Next, the number of days L at which D = 1 (hereinafter referred to as the number of life days) is calculated. And the lifetime consumption rate S = U / L is calculated using the usage days U and the lifetime days L of the rotating equipment. A life evaluation point S P is given according to the level of the obtained life consumption rate S. Life consumption rate S is low (i.e. less number of days used) those imparts a small life evaluation point S P, (busy i.e. number of days used) is higher lifetime consumption rate S what confers greater life evaluation point S P. Numerical life evaluation point S P in the present invention is not particularly limited and appropriately set in accordance with the operating conditions of the equipment specifications and the rotary device of the rotating device is arranged.
一方で、予め回転機器の故障を検知する度合（たとえば日常点検の頻度等）に応じて故障検知度評価点ＴPを付与しておく。故障の検知が容易なものは小さい故障検知度評価点ＴPを付与し、故障の検知が困難なものは大きい故障検知度評価点ＴPを付与する。したがって、全ての回転機器の故障検知度評価点ＴPは必ずしも同一ではない。たとえば熱間圧延設備では、粗圧延機，仕上げ圧延機，巻取り機，搬送コンベア等に配設される回転機器の故障検知度評価点ＴPをそれぞれ個別に設定する。 On the other hand, a failure detection degree evaluation point TP is given in advance according to the degree of detecting a failure of the rotating device (for example, the frequency of daily inspection). Those that are easy to detect a failure are assigned a small failure detectability evaluation point T P, and those that are difficult to detect are assigned a large failure detectability evaluation point T P. Thus, failure detection evaluation point T P of all of the rotating device is not necessarily the same. For example, in the hot rolling mill, roughing mill, finishing mill, coiling machine, each set separately failure detection evaluation point T P of the rotating device which is disposed conveyor like.
そして当該回転機器の寿命評価点ＳPと故障検知度評価点ＴPとを用いて、故障発生リスク評価点ＲP＝ＳP×ＴPを算出する。
また、予め回転機器の故障が発生した場合の経済的損失の度合（たとえば復旧作業に要する時間や費用等）に応じて経済リスク評価点ＥPを付与しておく。経済的損失が低いものは小さい経済リスク評価点ＥPを付与し、経済的損失が高いものは大きい経済リスク評価点ＥPを付与する。したがって、全ての回転機器の経済リスク評価点ＥPは必ずしも同一ではない。たとえば熱間圧延設備では、粗圧延機，仕上げ圧延機，巻取り機，搬送コンベア等に配設される回転機器の経済リスク評価点ＥPをそれぞれ個別に設定する。
Then, a failure occurrence risk evaluation point R P = S P × T P is calculated using the life evaluation point S P and the failure detection degree evaluation point T P of the rotating device.
In addition, an economic risk evaluation point E P is given in advance according to the degree of economic loss (for example, time and cost required for restoration work) when a failure of the rotating device occurs. Those with a low economic loss are assigned a small economic risk score E P, and those with a high economic loss are assigned a large economic risk score E P. Therefore, the economic risk evaluation points E P of all rotating devices are not necessarily the same. For example, in a hot rolling facility, economic risk evaluation points E P of rotating equipment arranged in a roughing mill, a finish rolling mill, a winder, a conveyor, etc. are individually set.
このようして得た故障発生リスク評価点ＲPと経済リスク評価点ＥPとに基づいて、当該回転機器の設備保全（すなわち補修あるいは更新）の必要性を判定する。その判定に用いるマトリックスの一例を図３に示す。当該回転機器の故障発生リスク評価点ＲPと経済リスク評価点ＥPがＡの領域にあれば、故障発生のリスクと経済的なリスクがともに大きいので設備保全の対象と判定される。Ｂの領域では、故障を早期に発見するために重点的に点検を行なう対象と判定される。Ｃの領域では、通常通りの点検を行なう対象と判定される。 Based on the failure occurrence risk evaluation point R P and the economic risk evaluation point E P obtained in this way, the necessity for facility maintenance (that is, repair or update) of the rotating equipment is determined. An example of the matrix used for the determination is shown in FIG. When the failure occurrence risk evaluation point R P and the economic risk evaluation point E P of the rotating device are in the range of A, the failure occurrence risk and the economic risk are both large, so that it is determined as the object of equipment maintenance. In the region B, it is determined that the inspection is focused on in order to detect the failure at an early stage. In the area C, it is determined that the inspection is performed as usual.
なお、図３は判定基準の一例を示したものであり、本発明では判定基準を特に限定しない。判定基準は、回転機器の仕様やその回転機器が配設される設備の稼動条件等に応じて適宜設定する。たとえば熱間圧延設備では、粗圧延機，仕上げ圧延機，巻取り機，搬送コンベア等の判定基準をそれぞれ個別に設定する。
その他の回転機器についても同様にして、設備保全の必要性を判定する。そして、それらを相互に比較することによって、設備保全の対象とする回転機器を選択する。なお、選択された回転機器の補修を行なう、あるいは更新を行なう等の決定は、担当者が状況に応じて行なう。
FIG. 3 shows an example of the determination criterion, and the determination criterion is not particularly limited in the present invention. The determination criterion is appropriately set according to the specifications of the rotating device, the operating conditions of the facility where the rotating device is installed, and the like. For example, in a hot rolling facility, determination criteria such as a roughing mill, a finishing mill, a winder, and a conveyor are set individually.
In the same manner for other rotating devices, the necessity for facility maintenance is determined. Then, by comparing them with each other, a rotating device to be subjected to equipment maintenance is selected. Note that the person in charge makes a decision to repair or update the selected rotating device depending on the situation.
故障発生リスク評価点ＲPと経済リスク評価点ＥPとに基づいて得られる図３に示すようなマトリックス中に、回転機器が占める位置を表示する手段は、従来から知られている装置（たとえば紙に印刷する，画面に表示する等）を使用すれば良い。
以上に説明した回転機器の診断を定期的に行なうことによって、故障の発生を精度良く予測し、限られた人員によって設備の点検および設備保全を効率良く行なうことができ、回転機器の故障を未然に防止し、しかも設備保全作業の期間中に生産が停止することによる経済的な損失を最小に抑えることができる。
A means for displaying the position occupied by the rotating device in the matrix as shown in FIG. 3 obtained based on the failure occurrence risk evaluation point R P and the economic risk evaluation point E P is a conventionally known device (for example, Print on paper, display on screen, etc.).
By regularly diagnosing rotating equipment as described above, it is possible to accurately predict the occurrence of a failure, and efficiently perform inspection and maintenance of equipment by a limited number of personnel. In addition, the economic loss due to the production stoppage during the maintenance work can be minimized.
また設備の稼動体制が変更されるような場合に、その生産計画から、回転機器の補修あるいは更新を行なう時期の変化を予測することも可能である。 Further, when the operation system of the facility is changed, it is possible to predict a change in the timing for repairing or updating the rotating equipment from the production plan.
図１に示すような熱間圧延設備の各回転機器にセンサーを配設し、所定の期間内に得られる繰返し荷重のデータを繰返し応力範囲Ｒangeに変換して、当該回転機器の応力振幅Ａmp＝Ｒange／２を求めた。
一方で、予め回転機器の応力振幅と寿命回転数との関係を示すマスターカーブを作成した。マスターカーブは、回転機器に用いられている鋼材の疲労試験データ等を用いて作成した。その一例を図２に示す。
A sensor disposed to the rotation device of the hot-rolling equipment shown in FIG. 1, is converted into stress range Range repeated data of repeated load obtained during the period of Jo Tokoro stress amplitude Amp of the rotating equipment = Range / 2 was determined.
On the other hand, the master curve which shows the relationship between the stress amplitude of a rotation apparatus and lifetime rotation speed was created beforehand. The master curve was created using fatigue test data of steel materials used in rotating equipment. An example is shown in FIG.
そのマスターカーブに当該回転機器の応力振幅を適用して、寿命回転数Ｎ（すなわち新品から故障発生に到るまでの回転数）を求めた。
次に、寿命回転数Ｎを用いて損傷度ｄ＝１／Ｎを算出した。その１日分の損傷度ｄを加算していき、累積損傷度Ｄ＝Σｄを算出した。さらに、Ｄ＝１となる寿命日数Ｌを算出した。たとえば粗圧延機の回転機器の寿命日数Ｌは187ケ月と算出された。その寿命日数Ｌと当該回転機器の使用日数Ｕとを用いて寿命消費率Ｓ＝Ｕ／Ｌを算出し、得られた寿命消費率Ｓのレベルに応じて寿命評価点ＳPを付与した。すなわち、寿命消費率Ｓの低いものをＳp＝１とし、寿命消費率Ｓの高いものをＳP＝５として、５段階に分類した。
By applying the stress amplitude of the rotating device to the master curve, the life rotation speed N (that is, the rotation speed from the new article to the occurrence of the failure) was obtained.
Next, the damage degree d = 1 / N was calculated using the life rotation speed N. The damage d for one day was added and the cumulative damage D = Σd was calculated. Furthermore, the life days L for which D = 1 was calculated. For example, the life days L of the rotary machine of the rough rolling mill was calculated as 187 months. The lifetime consumption rate S = U / L was calculated using the lifetime days L and the usage days U of the rotating equipment, and the lifetime evaluation points SP were given according to the level of the obtained lifetime consumption rate S. That is, the low life consumption rate S was classified into 5 stages, with S p = 1, and the high life consumption rate S having S P = 5.
一方で、予め回転機器の故障を検知する度合に応じて故障検知度評価点ＴPを付与した。すなわち、故障の検知が容易なものをＴP＝１とし、故障の検知が困難なものをＴP＝４とし、４段階に分類した。
そして当該回転機器の寿命評価点ＳPと故障検知度評価点ＴPとを用いて、故障発生リスク評価点ＲP＝ＳP×ＴPを算出した。
On the other hand, to impart failure detection evaluation point T P according to the degree to detect the failure of the pre-rotation device. That is, T P = 1 for easy detection of failure and T P = 4 for failure detection of failure was classified into four stages.
Then, the failure occurrence risk evaluation point R P = S P × T P was calculated using the life evaluation point S P and the failure detection degree evaluation point T P of the rotating device.
また、予め回転機器の故障が発生した場合の経済的損失の度合に応じて経済リスク評価点ＥPを付与した。すなわち、経済的損失が低いものをＥP＝１とし、経済的損失が高いものをＥP＝８として、８段階に分類した。
このようして得た故障発生リスク評価点ＲPと経済リスク評価点ＥPとを用いて、図３に示すようなマトリックスから、当該回転機器の設備保全の必要性を判定した。
In addition, an economic risk evaluation score E P was given in advance according to the degree of economic loss when a rotating machine failure occurred. That is, E P = 1 for low economic loss, E P = 8 for high economic loss, and classified into 8 stages.
Using the failure risk evaluation point R P and the economic risk evaluation point E P obtained in this way, the necessity for equipment maintenance of the rotating equipment was determined from the matrix as shown in FIG.
その他の回転機器についても同様に、設備保全の必要性を判定した。そして、それらを相互に比較することによって、多数の回転機器の中から設備保全の対象とするものを選択した。
このようにして、限られた人員によって熱間圧延設備の点検および設備保全を効率良く行ない、回転機器の故障を未然に防止し、かつ設備保全作業の期間中の生産停止による経済的な損失を最小に抑えることができた。
Similarly, the necessity of equipment maintenance was also determined for other rotating equipment. Then, by comparing them with each other, an object for equipment maintenance was selected from a large number of rotating devices.
In this way, inspection and maintenance of hot rolling equipment can be efficiently performed by a limited number of personnel to prevent rotating equipment from being damaged beforehand, and economic loss due to production stoppage during equipment maintenance work can be avoided. We were able to keep it to a minimum.
なお上記した各回転機器の荷重の測定から故障発生リスク評価点を算出するまでの演算、および故障発生リスク評価点と経済リスク評価点とに基づいて得られるマトリックス中に回転機器が占める位置の表示は、コンピューターで処理した。 It should be noted that the calculation from the load measurement of each rotating device to the calculation of the failure occurrence risk evaluation point, and the display of the position occupied by the rotation device in the matrix obtained based on the failure occurrence risk evaluation point and the economic risk evaluation point Was processed on a computer.
１ 鋼スラブ
２ 粗圧延機
３ 仕上げ圧延機
４ 巻取り機
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