Intelligent diagnosis, precise monitoring, and rapid response to reduce the hidden costs of equipment operating with defects.
Release time：2025-08-15
A petrochemical platform water injection booster pump 4102B The pump was 2025 Year 3 Month 27 Day 20：00 The pump was started and run. After the equipment was running, On the same evening Triggered IEPLAT The intelligent operation and maintenance platform online monitoring system issued an early warning. The platform data showed that the acceleration value of the pump drive end suddenly increased from the normal range ( ≤ 5m/s ² ) to 60m/s ² , and maintained a high value operation. The spectrum analysis showed 7000Hz-8500Hz Peak and bearing defect frequency, time domain waveform has periodic impact signal, envelope spectrum shows bearing defect frequency and its frequency multiplication, It is preliminarily judged that this is a wear phenomenon in the equipment bearing, and it is necessary to shut down the machine for troubleshooting.
Figure 1 Abnormal characteristic value waveform triggers alarm
After the threshold alarm information is generated, the intelligent operation and maintenance platform automatically gives a specific diagnosis conclusion: other bearing failures (inner and outer rings, balls, cages)
After analyzing the fault data, the diagnostic engineer confirmed the alarm information and notified the on-site operation and maintenance personnel to check the abnormal equipment operation status by email.
Figure 2 System confirms alarm and diagnosis conclusion
Figure 3 Alarm information communication record
After receiving the platform early warning and email notification, the platform on-site construction personnel arrived at the equipment on 3 Month 28 Day to reach the equipment Site For data monitoring and recording, the measured acceleration value of the pump drive end bearing far exceeds the normal range, confirming that there is a fault in the bearing . After the equipment was shut down, the bearing was inspected and pitting and wear were found on the rolling elements and inner ring. The Babbitt alloy of the lower tile block of the bearing bush is severely corroded, showing pitting and holes 。
Figure 4 Vibration detector detects faulty equipment
Figure 5 Bearing wear
Figure 6 Pump drive end bearing bush wear
4 Month 8 After the maintenance work was completed on the day, the acceleration value of the drive end dropped to 4m/s ² or so , the motor temperature is stable at 55 ℃ The following, the vibration amplitude returns to the normal range.
Figure 7 Measured value of pump running acceleration after maintenance
Figure 8 Waveform value of equipment monitoring platform after maintenance
The equipment intelligent monitoring platform gives an early warning, and it is estimated that it will be 1-2 Months to discover equipment failures, reducing tens of thousands of yuan in losses caused by unplanned shutdowns and equipment damage, as well as the hidden costs of over-maintenance and frequent disassembly, and promoting intelligent and healthy production.
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