The stationary computer monitoring system for accidents prevention and condition control COMPACS® for the first time in the world was implemented in 2005 at the wheel-rolling mill (WRM) of WRC PSU of "VSW" JSC.
The system COMPACS®-WRM, installed on the wheel rolling mill, provides the WRM technical condition monitoring of the rotating equipment - by 22 channels of vibration, 4 - temperature, 2 – rotating frequency; and of the static equipment - by 3 channels of fluid pressure in the WRM hydraulic system as well as an additional channel for the wheel billet temperature control.
The system is included in the enterprise diagnostic network Compacs-Net®, through which the information about the WRM condition goes to the WRC specialists: PSU mechanists, WRM PSU technologists, as well as the technical diagnostics laboratory of "VSW" JSC.
Real-time condition monitoring provides a timely WRM withdrawal in the repair and significantly reduces its period.
The latest example of an adequate operation of this system is the detection of the bearing defect of the lower motor, installed after overhaul, at the time of its scrolling at idle. The system identified the defect of the outer bearing cage, on the basis of which it was decided to replace that electric motor.
Thus, a possible emergency situation and a 6-hour downtime of the rolling line were prevented and the repair was held by the actual technical condition in real time, so more than 700 wheels were additionally produced.
The implementing of the system in the "VSW" WRM allowed to transit to the maintenance and repair of equipment by the actual technical condition in real time. According to officially published data, in the first six months of operation the system has prevented more than 30 WRM downtimes and paid off more than tenfold, having provided a direct economic effect of more than 50 million rubles. The payback period was less than one week.
Authors: Director O.V. Kuznetsov / 2008
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