Emerson da Bently Nevada: Haɗaɗɗen Kula da Muhimman Kayan Masana’antu
Tsadar Rarrabuwar Tsarin Kula da Kariyar Na’ura
Tsarin sarrafa kansa na masana’antu yana raba tsarin kula da aiki (PLC/DCS) daga tsarin kariyar injina (TSI). Yawancin masana’antu suna barin waɗannan matakai suna rarrabe. PLC yana sarrafa aikin tsari amma baya kula da lafiyar injin. Tsarin TSI yana sa ido kan girgiza amma ba zai iya umartar DCS ta rage nauyi ba. Wannan gibi yana haifar da tsayawar aiki ba a shirye ba da kuma asarar kuɗi. Emerson da Bently Nevada suna rufe wannan gibi da tsari guda ɗaya. Maganinsu yana ba da damar rabon bayanai na ainihin lokaci tsakanin kula da aiki da tsarin sa ido ba tare da buƙatar ƙarin middleware na musamman ba.
Haɗin Fasaha: Yadda DeltaV ke Mu’amala da Tsarin 3500
Haɗin yana amfani da madaidaicin haɗin backplane tsakanin kayan aikin Bently Nevada 3500 da DeltaV DCS na Emerson. Firikwensin eddy current da accelerometers suna aika sigina marasa tacewa zuwa rak ɗin 3500. Rak ɗin yana sarrafa siginar zuwa muhimman ma’aunai: jimillar girman girgiza, 1X da 2X phase vectors, da matsayi na axial. Maimakon a aika ƙararrawa kaɗai, tsarin yana watsa bayanan waveform da aka ajiye da ƙimomin trend zuwa DeltaV. Ƙaruwa a girgizar shaft sama da 4.5 mils na iya tayar da rage nauyi ta atomatik kafin a sami tsayawar gaggawa.
Sarrafa a Gaba (Edge Processing) da Gano Daban-daban ta AI
Rak ɗin 3500 yana ɗauke da module da aka gina a ciki don nazarin FFT da time-waveform a wurin. Yana kwatanta sabbin spectrums na girgiza da matakin asali da aka koya cikin kwanaki 14 zuwa 30. Lokacin da tsarin ya gano canjin kashi 15% a harmonic sidebands a kusa da gearmesh frequency, yana nuna farkon lalacewar gear. Wannan tsarin gano abin da ya saba (adaptive anomaly detection) yana rage adadin ƙarya masu faɗakarwa zuwa ƙasa da 2% a aikace-aikacen filin. Injiniyoyi za su iya dogara da faɗakarwar ba tare da dakatar da samarwa ba.
Daga Kula da Hasashen Lalacewa zuwa Kula da Umarnin Gyara Kai Tsaye
Kula da hasashen lalacewa (predictive maintenance) yana gaya maka cewa bearing zai lalace cikin kwanaki 60. Kula da umarnin gyara (prescriptive maintenance) yana gaya maka ka daidaita rotor kuma ka canza kaurin mai (viscosity). Tsarin da aka haɗa yana samar da takamaiman action codes. Ga centrifugal compressor da ke da subsynchronous vibration a 0.43X, yana ba da shawarar duba orifice. Wannan shawara tana shiga kai tsaye cikin CMMS ɗinka a matsayin takardar aikin gyara (work order). Wannan fasalin yana rage matsakaicin lokacin gyara (MTTR) da kashi 35% a masana’antu da ke da ƙarancin ma’aikatan kula da ingantacciyar aiki.
Haɗa Tsofaffin Kayan Aiki ba Tare da Musanya Su Gaba ɗaya ba
Ba lallai ne ka maye gurbin PLC ko DCS ɗin da kake da shi ba. Rak ɗin Bently Nevada 3500 yana fitar da siginar 4-20 mA da Modbus TCP zuwa kowanne tsohon mai kula. Don cikakken haɗin bayanai a kowane shugabanci, ƙara katin DeltaV LX. Wannan kati yana canja bayanan girgiza zuwa cikin bayanan tag na tsarin kula da tsoho. Ci gaba da amfani da tsohon PLC ɗinka don jerin matakai na asali. Yi amfani da tsarin Emerson-Bently a matsayin layin sa ido kan lafiyar na’ura a gefe. Ka yi sauya manyan loops cikin shekaru biyu zuwa uku. Wannan mataki-mataki yana guje wa haɗarin aiki.
Kare Turbine a Masana’antar Karfe
Wata masana’antar karfe ta Turai ta shigar da wannan mafita a kan turbines biyu na tururi masu 25 MW. Tsarin ya gano ƙaruwa da 0.6 mil a girgizar shaft cikin kwanaki 10. Nazarin phase ya nuna canji na digiri 14, alamar rashin daidaiton coupling. Masana’antar ta tsara gyaran daidaita alignment na rana guda. Ba tare da tsarin ba, rashin daidaiton zai haifar da lalacewar journal bearing cikin makonni shida. Masana’antar ta rage lokacin tsayawar turbine da kashi 40% kuma ta ƙara tsawon rayuwar kayan aiki da kashi 15%.
Kula da Lafiyar Kayan Aikin Masana’antar Sinadarai
Wata masana’antar sinadarai a Arewacin Amurka ta yi amfani da tsarin ga famfunan reactor da heat exchangers. Module na AI ya danganta girgizar famfo da matsayi na bawul ɗin sarrafa kwarara. Ya gano jinkirin karkacen bawul da ke haddasa cavitation. Ma’aikata suka gyara daidaiton kalibreshan. Ga heat exchangers, firikwensin acoustic emission sun bi sawun raguwar kaurin bangon tube bundle. Tsarin ya gano raguwar kauri da kashi 22%, wanda ya ba da damar maye gurbin lokacin gyaran da aka riga aka tsara. Wannan ya hana asarar mai ko ruwa da darajar dala $800,000. Faɗakarwa ta atomatik ta rage sa’o’in aikin kula da gyare-gyare da kashi 25%.
Sa Ido kan Gearbox na Gonar Iskar Wuta
Wata babbar gonar iskar wuta a ƙasar Arewacin Turai ta aiwatar da wannan mafita a kan turbines 42. Accelerometers masu mitar sama sun sa ido kan matakin planet na gearbox da high-speed shaft. A cikin makonni takwas, AI ta gano ƙaruwa da 9 dB a gearmesh amplitude a harmonic na biyu, alamar lalacewar saman haƙoran gear. Gonar ta tsara sauya planet carrier a matakai, ta guji saukar gearbox na makonni uku ga kowace turbine. A shekara ta farko, yawan makamashin da aka Samar ya ƙaru da kashi 12% kuma kuɗin kula da gyare-gyare ya ragu da kashi 30%.
Jagorar Ƙayyadaddun Bayanai ga Injiniya don Sabbin Ayyuka
Ga kowane sabon aikin injin mai juyawa, ka fayyace waɗannan buƙatu: madaidaicin hanyar sadarwa kai tsaye tsakanin tsarin TSI da babban DCS/PLC, damar samun bayanan waveform da aka ajiye daga HMI na ɗakin kula, AI-based adaptive alarming maimakon ƙayyadaddun matakan gargaɗi na dindindin, da prescriptive action codes da ke shiga cikin CMMS. Bin wannan ƙayyadaddun yana kawar da babbar hanyar gaza guda ɗaya a amincin muhimman kayan aiki: gibi tsakanin tsarin kula da tsarin kariya.
Rubutacce daga Fang Zekai, injiniya ƙwararre da ya mayar da hankali kan tsarin sarrafa masana’antu da na’urar kula da tsari ga abokan ciniki na man fetur & iskar gas na duniya.
