设备点检Equipment monitoring SOP

设备点检设备点检SOPSOPEquipmentmonitoringSOP目目 录录 Catalog前言点检的定义设备状态监测没有仪器怎么办？一二三四PrefaceInspectiondefinitionEquipmentConditionMonitoringNoinstrumentavailableformonitoringFaultBreakdownisonlythetipoftheicebergHiddendefectsPollutant,temperature,vibration,looseness,deformation,abnormalsound,etc.Thepotentialshortcomingsrevealedcanpreventsfailure!一、前一、前 言言 Preface二、点检定义二、点检定义它是一种及时掌握设备运行状态，指导设备状态检修的一种严肃的它是一种及时掌握设备运行状态，指导设备状态检修的一种严肃的科学管理方法科学管理方法通过人的五感或先进仪器，按照点检标准对设备进行预通过人的五感或先进仪器，按照点检标准对设备进行预防性检查，防性检查，以使设备的隐患和缺陷能够得到早期发现、以使设备的隐患和缺陷能够得到早期发现、早期预防、早期处理。早期预防、早期处理。Byusingourfivesensesoradvancedequipment,conductingpreventivemaintenancebyfollowingstandardprocedures,itispossibletoearlydetectfailureonequipmentdetection.Preventive or predictive maintenance is routine maintenance which is designed to prevent the need for more costly repairs.Inspectiondefinition三、设备状态监测（预测性）三、设备状态监测（预测性）CorrectivemaintenancePredictiveMaintenanceBadrepairAnalysisHigh inputTimeoutDamagePredictiveEliminate defectsLife extensionAccurateReduced workloadEquipmentConditionMonitoring(predictive)点检是预测性维修的核心Inspectionisthecoreofpredictivemaintenance1、VBT35振动巡检仪1不平衡不平衡不对中不对中23轴承故障轴承故障机械松动机械松动45齿轮损坏及磨损齿轮损坏及磨损6噪音、裂纹噪音、裂纹能解决什能解决什能解决什能解决什么问题？么问题？么问题？么问题？UnbalanceMisalignmentNoise、crackGeardamageandwearMechanicalloosenessBearingfaultSolvetheSolvethefollowingfollowingproblemproblemVBT35Vibrationanalyzer1.1振动总值测量利用ISO10816-3标准评价机器振动，并指示报警状态正常正常警告警告危险危险NormalWarningDangerVibrationMeasurementUsingISO10816-3toevaluationmachinevibrationandindicatealarmstatus1.2轴承状态测量正常正常警告警告危险危险测量时，利用经验值判断轴承好坏，并提示报警值BearingstatusSomeexperienceisrequiredtojudgethedifferencebetweengoodandfaultybearings.NormalWarningDanger1.3听诊器轴承故障监听StethoscopeBearingfaultmonitoring1.4温度测量一般用于设备或轴承温度检测TemperatureGenerallyusedforequipmentorbearingtemperaturedetectionVBT35开机，选择（数据采集）选择设备数据存储位置1.5数据采集DataAcquisitionVBT35boot,select(dataacquisition)Selectthedevicedatastoragelocation按顺序进行振动数据采集Sequentiallyvibrationdataacquisition上传数据至PC机UploadthedatatoaPC1.6数据分析DataAnalysis1.6.1、趋势分析TrendAnalysis1.6.2、频谱分析SpectrumAnalysis根据采集到数据对设备进行分析，判断哪种故障及损坏程度Spectrumanalysisoftheequipmentaccordingtothecollecteddata,soastoarrivedamagedpartsandtheextentofdamage1.7、数据报告DataReportVBT软件生成报警报告VBTsoftwaretogeneratethealarmreport设备状状态监测润滑滑状状态监测气气体泄漏体泄漏检测电气气局放局放监测液液压系系统检测超超声声波波检检测测仪仪SDT2002、超声波的应用UltrasonicdetectorEquipment conditionLubrication conditionGas leak detectionElectrical discharge monitoringHydraulic Testing System2.1、超声波设备监测Ultrasonicequipmentmonitoring超声波对轴承的状态检测超声波对轴承的状态检测 Ultrasonicdetectionofbearingcondition 轴承的状态监测通常使用振动监测的方法，但是轴承的最早期的故障频率一般在2560kHz，属于超声频率20100kHz范围，中后期的故障频率往往在5kHz以下。Vibrationmeasurementisthetypicalmonitoringmethodsforbearings.Thefrequencyofearlyfailureofthebearingisgenerally2560kHz,belonging to the range of 20 100kHz ultrasonic frequency,thefrequencyoffailuresinthelateoftenthan5kHz.而振动探头的响应范围一般在10kHz以下，也就是说振动监测只能发现中后期的轴承故障，这时轴承已经进入较明显的磨损阶段，最早期的故障如润滑不良、很轻微的磨损等是很难监测到的，而超声波检测符合要求。Thevibrationoftheproberesponserangeat10kHzorlessgeneral,thatvibrationmonitoringcanonlybefoundinthelatterpartofthebearingfailure,thenthebearinghasenteredobviouswearstage,theearliestfailuressuchaspoorlubrication,veryslightwearisdifficulttodetect,andultrasonictestingtomeettherequirements.轴承状态监测Bearingconditionmonitoring轴承轴承dBdB值（相对于值（相对于基准值）基准值）Bearing dB valueBearing dB value轴承状态轴承状态Bearingstate升高升高8dB 8dB Rise 8dB Rise 8dB 润滑良好的润滑良好的状态状态 Goodlubrication升高升高8dB 8dB Rise Rise 8dB8dB润滑润滑不良不良 Poorlubrication升高升高12dB 12dB Rise Rise 12dB12dB出现显微镜下可见的磨损出现显微镜下可见的磨损Wearvisibleunderthemicroscope升高升高16dB 16dB Rise Rise 16dB16dB出现肉眼可见的出现肉眼可见的磨损磨损 Visiblewear升高升高35dB 35dB Rise Rise 35dB35dB出现出现严重磨损严重磨损 Severewear注：以轴承无故障情况下的注：以轴承无故障情况下的dB值为基准，根据实测值为基准，根据实测dB与该基准振值之比与该基准振值之比来进行判断的标准。（以上数值为经验值，仅为参考）来进行判断的标准。（以上数值为经验值，仅为参考）Note:InthecaseofbearingfailuresdBvaluebasis。相对判定标准：轴承dB值趋势图 Bearing dB value trend当设备、轴承出现异常时，超声波检测也可以结合振动监测，进一步了解轴承的状况，以决定是否需要立刻更换轴承。Whentheequipment,bearingabnormalultrasoundtodetectvibrationmonitoringcanalsobecombinedtobetterunderstandtheconditionofthebearingtodeterminetheneedforimmediatereplacement.HighalarmvalueLowalarmvalueReferencevalue2.2.超声波润滑检测应用l以时间为基准Time-basedl以状态为基准BasedonStatesl什么时候加油？Whenrefueling?l该加多少油？Themuchfuel?l听声音、看数据Listentothevoicedata,seeLubricationdetectionapplications加油前45dB加油后Afterrefueling37dBBeforerefueling1、加油枪打半下、加油枪打半下refuelinggunfightunderhalf2、等待、等待15到到30秒左右（视情况而定）秒左右（视情况而定）waitfor15to30seconds(dependingonthesituation)3、听超声波的声音、看、听超声波的声音、看dB值值listentothesound,seethedBvalueofultrasonic润滑检测标准Lubricationtestingstandardsu重复以上步骤直到超声波强度降下来Repeattheabovestepsuntiltheultrasoundintensitydownu一旦超声波声音降下来之后，立即停止加油Oncetheultrasonicsounddown,immediatelystoprefuelingu加油后，记录超声波及温度数值变化Afterrefueling,ultrasonicandtemperaturevaluesrecordedchangesu过几天之后，再观察超声波及温度数值变化AfterafewdaysandthenobservedchangesinultrasonicandtemperaturevaluesEnd