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Situation – Two old pulp mill production lines were replaced with a single higher-output line.
The scope included causticization, vaporizer, lime kiln and soda boiler, with a new 145 MW steam turbine.
The criticality of the single line for the production was greater than the previous two lines,
as there were no spare machines on the new production line.
Solution – 10 Dynamic Scanning Modules (DSM) covered 50 machines and 220 measurement points on all
production areas. A 3500 monitoring system was on the steam turbine. All systems were connected to System 1®
optimization and diagnostic software. An OPC link was installed from System 1 to the DCS to give direct
amplitude values of selected machines to operators at all times. 8 Display stations were on the plant network, including:
4 for the condition monitoring group; 1 for plant control room; 2 for the maintenance department; and 1 for the
maintenance manager. The system was installed and commissioned prior to test runs for the
new production lines.
Result – Several equipment problems were detected during the
test run period, preventing failures. Several structural handicaps were detected in the early operation stage that
were able to be corrected in the first overhaul. A number of traditional, essential equipment faults were
detected in time to give the maintenance department enough time to do corrective actions in a proactive manner.
Payback for the system was determined to be less than 2 months.
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