Alpha PdM Achieve 400% Return on Investment in Shiyaodian CHPP

1. What ALPHA has done to Shiyaodian CHPP?

Shiyaodian Coal Preparation Plant is a 5 million tons steam coal preparation plant which belongs to Shenmu Coal Industry Group of Shanxi Province. It was designed, constructed and operated by Techgart, the strategic partner of ALPHA. In April, 2018, the ALPHA Predictive Maintenance System was deployed, and the ALPHA Predictive Maintenance Sensors were installed on key equipment, including centrifuges, belt conveyors, scrapers and motors, reducers, rotating drums and so on. The real-time data collection and analysis of field equipment operation were carried out to ensure the long-term, efficient and healthy operation of the equipment.

http://www.coalepc.com/case/shiyaodian-coal.html

ALPHA installed total 100 sensors in the Shiyaodian CHPP.The annual maintenance cost of these complete sets of equipment is about 200000 USD. It realizes predictive maintenance of the monitored equipment and helps the operation and management of the whole plant equipment. Many real mechanical faults have been successfully predicted many times in more than a year, which helped to improve the operation and management of the whole plant. By avoiding sudden failures and productivity gains, the return on investment has almost reached 400%.

2. How we achieve the predictive maintenance?

2.1 Daily Operation Guidance

ALPHA pays close attention to the operation of the equipment in the coal preparation plant in real time through the cloud AI Platform. This time, the internal bearing of the rear drum of the 302 scraper in Shiyaodian Coal Preparation Plant, has been worn out, and the operation of about 504 chains is unbalanced. The predictive maintenance system has already been detected in the initial stage of the problem, and timely reminds the site personnel to complete the pre-maintenance. It avoids unplanned downtime.

Due to the high-level operation and management of Shiyaodian coal preparation plant, for several months, ALPHA PdM and ALPHA remote maintenance experts have been assisting site inspectors and maintenance personnel to do routine maintenance work. The equipment is in good working condition and there is no special malfunction.

2.2 Faults Prediction

Starting from the daily report on December 1st and during the evening production on November 30, fine abnormal data were monitored by sensors on the non-driving side of the tail drum of 302 and 504 scrapers. By observing the change of peak frequency spectrum of 302 scraper vibration, irregular fluctuation appears. It is preliminarily recognized that 302 scraper may have internal wear of the equipment. 504 scraper vibration is unbalanced, the chain may have problems.

As shown in figures:

Abnormal Vibration Curve of 302 Scraper Tail Drum

Abnormal Vibration Curve of 504 Scraper Tail Drum

According to the discussion with ALPHA Equipment Maintenance Experts, site maintenance personnel also decide to remove the drum cover and inspect the interior during the daytime overhaul shift.

2.3 Faults Confirmation and Troubleshoot

The results show that the bearing balls of both sides of the 302 scraper tail drum are badly worn,

As shown in figure:

302 Scraper Tail Drum Bearing

And after checking with the 504 scraper, chains on both sides are unevenly loaded and unbalanced in operation due to the deviation of coal blanking point.

Two new bearings were replaced at the tail drum of 302 scraper machine, and new chains were replaced at both sides of 504 scraper, then the two scrapers resumed normal operation. Greater and possibly even cause sudden failure of the equipment shutdown fault is predicted in advance again, timely troubleshooting is achieved.

3. Conclusion

The ALPHA method uses the real-time monitoring technology to ensure the normal operation of the equipment. Through cloud core AI data processing, the health status of each device is assessed, so as to assist field personnel to manage the equipment more intelligently and pertinently.

The technology demonstrated by ALPHA is 100% useful. It provides an economical and efficient solution for the maintenance team of Shiyaodian Coal Preparation Plant. It can monitor the equipment and remind the possible abnormal situation, so that the equipment can run safely 24 hours. It provides not only safety but also economic benefits for the plant equipment.

For more about ALPHA PdM, feel free to contact us:

E-mail: kyle.lee@alpha-technology.com.au

Tel/whatsapp(Skype): +86-157-5687-5803

Web:www.alpha-technology.com.au/coal-preparation-plant-monitoring-warning