World's Largest Operational Coal-to-Olefins Project

Case Duration:

November 2020 – Present (3+ Years)

Client Background:

The Chemical Branch of ZTHC Energy Co., Ltd. operates China's largest coal-to-olefins facility with

Client Background

The Chemical Branch of ZTHC Energy Co., Ltd. operates China's largest coal-to-olefins facility with:

1. Total investment: CNY 60 billion

2. Annual production capacity:
1) 3.6 million tons methanol (intermediate product)
2) 1.37 million tons polyolefins

3. Designation:
1) National coal deep-processing demonstration project
2) Key project of Inner Mongolia Autonomous Region

Client Requirements & Solutions

Predictive Maintenance System for Centralized Equipment Management

Comprehensive Predictive Maintenance System:

1. Monitors 340+ critical equipment units across:
1) 19 production units
2) 6 operational departments

2. Covers key assets including:
1) Extruders
2) Compressors
3) Coal mills
4) Pumps & fans

3. Provides:
1) Early anomaly detection
2) Precise fault localization
3) Degradation trend analysis

Plant-wide Centralized Control:

1. Integrated predictive maintenance system with RONDS Remote O&M Center

2. "Edge-Cloud" collaborative monitoring architecture

3. Unified equipment status dashboard

Application Value

24/7 Equipment Monitoring & Control:

1. 300+ alarms and maintenance recommendations issued

2. Detected failures including:
1) Bearing defects
2) Power frequency abnormalities
3) Component wear alerts

Data-Driven Maintenance Optimization:

1. Monthly equipment health reports for all assets

2. Proactive hazard notifications

3. Data-supported maintenance planning

Standardized & Lean Management:

1. Implemented condition-based maintenance

2. Improved spare parts utilization

3. Reduced maintenance complexity

4. Achieved:
1) fewer over-maintenance cases
2) reduction in maintenance backlog

Success Cases

Zhongtian Hechuang Coal Chemical No. 3 furnace induced draft fan A

1.Equipment Information
Equipment Type: Centrifugal Fan
Rated speed: 991rpm
Related measurement points in this case: Motor non-drive end 1H; Fan drive end 3H; Fan non-drive end 4H
2.Alarm and analysis process
Equipment alarm events:
2.1Analysis process
2.1.1Explanation of trends, indicator parameters and other evidence
The speed vibration at each measuring point of the motor and fan has continued to increase recently.
No. 3 furnace induced draft fan A/fan drive end 3H/8k speed waveform (10-1000)_Equipment Multi-trend
2.1.2Explanation of evidence such as time domain, spectrum, and envelope demodulation
There was no obvious impact on the speed waveforms of the motor and fan at each measuring point.
No. 3 furnace induced draft fan A/fan drive end 3H/8k speed waveform (10-1000)_time domain waveform
The speed spectra of each measuring point of the motor and fan are dominated by the characteristic frequency of the outer ring of the bearing on the output side of the liquid coupling.
No. 3 furnace induced draft fan A/fan drive end 3H/8k speed waveform (10-1000)_spectrum analysis
3.Diagnostic conclusions and recommendations
3.1Diagnostic conclusion
2023-05-31 09:35 Push diagnosis conclusion: The speed of each measuring point of the motor and fan has increased significantly. It is judged that it is related to the abnormality of the bearing on the output side of the liquid coupling, which has deteriorated recently.
3.2Inspection and maintenance suggestions
The equipment is currently in a monitorable operating state. It is recommended to arrange an inspection at an appropriate time. Pay attention to whether there are obvious abnormalities in vibration and temperature at both ends of the liquid coupling. If the abnormalities are obvious, it is recommended to check the damage of the bearing on the output side of the liquid coupling at an appropriate time.
4.On-site inspection and maintenance process
2023-06-13 23:58 On-site engineer Wu reported that the 6040 bearing on the output side of the liquid coupling was replaced, and the bearing raceway was obviously damaged.
5.On-site inspection and maintenance photos
The inspection photos show that there is obvious circumferential damage to the inner and outer ring raceways of the bearing, and the damage is located on one side, indicating that there is an unbalanced load during the operation of the bearing, resulting in obvious force on one side and wear due to long-term operation. From the signal, the fault characteristics of the outer ring of the bearing are obvious. Although the inner ring is also damaged, no obvious characteristics of the inner ring of the bearing can be seen. It is speculated that the damage to the outer ring is more obvious, resulting in the lack of characteristics of the inner ring. The damage results also verify this.

Maintenance photo_1

Maintenance photo_2

Maintenance photo_3

Maintenance photo_4

Maintenance photo_5

Maintenance photo_6
6.Verification after inspection and maintenance
After overhauling and replacing the bearings, the speed vibration at each measuring point of the motor and fan dropped significantly, and the trend became flat.
No. 3 furnace induced draft fan A/fan drive end 3H/8k speed waveform (10-1000)_Equipment Multi-trend
After the bearings were overhauled and replaced, the amplitude of the speed waveform at the fan measuring point dropped significantly.
No. 3 furnace induced draft fan A/fan drive end 3H/8k speed waveform (10-1000)_time domain waveform
After the bearing was overhauled and replaced, the damage characteristics of the outer ring of the fluid coupling bearing in the velocity spectrum disappeared significantly, and the spectrum amplitude decreased significantly.
No. 3 furnace induced draft fan A/fan drive end 3H/8k speed waveform (10-1000)_spectrum analysis
7.Customer feedback form
None
8.Monitoring fault range
Timely and effective collection of equipment operating status data (vibration, temperature) is subject to the constraints of network connectivity and data transmission time, and also needs to consider interference from factors such as the equipment's own attributes and production processes. At the same time, the analysis and diagnosis of equipment status is based on changes in vibration effects caused by rotating parts failures. Therefore, the status monitoring system cannot guarantee monitoring of all types of faults. The monitoring system is configured according to the measurement point scheme recommended by Party B, and the range of faults that can be monitored and the description are as follows:
9.Notes
1. If the client of this report cannot provide basic unit parameters (such as unit transmission chain diagram, gearbox structure diagram, gearbox teeth number, related bearing models and brands), the accuracy of analysis and diagnosis will be affected;
2. This report is the analysis, diagnosis and maintenance opinions of the unit by Rongzhi professional technicians, which is for reference only. The specific maintenance and repair measures shall be decided by the client.
3. This report shall not be used as evidence for any claims, litigation, etc.;
4. The client has the obligation to keep the analysis report confidential and shall not provide this report to a third party, print it into other promotional materials, or publish it on the Internet or other public information platforms without the written permission of the trustee.

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Zhongtian Hechuang Coal Chemical 122X0301 coal mill reducer

1.Equipment Information
Equipment Type: Ball Mill
Rated speed: 994 rpm
Related measurement points in this case: Reducer 1 axis input level 3H
2.Alarm and analysis process
Equipment alarm events:
2.1Analysis process
2.1.1Explanation of trends, indicator parameters and other evidence
Recently, the low-frequency acceleration vibration at each measuring point of the reducer has been slowly increasing.
122X0301 coal mill reducer/reducer 2, 3 axis input vertical 5V/128k acceleration waveform (0.1-2000)_Equipment Multi-trend
2.1.2Explanation of evidence such as time domain, spectrum, and envelope demodulation
There are obvious periodic impacts in the low-frequency acceleration time domain waveform, and the impact interval is approximately the pinion rotation frequency.
122X0301 coal mill reducer/reducer 2, 3 axis input vertical 5V/128k acceleration waveform (0.1-2000)_time domain waveform
The frequency spectrum is mainly composed of the frequency band of large and small gear meshing and the frequency sidebands.
122X0301 coal mill reducer/reducer 2, 3 axis input vertical 5V/128k acceleration waveform (0.1-2000) _ spectrum analysis
3.Diagnostic conclusions and recommendations
3.1Diagnostic conclusion
2023-07-25 17:11 Push diagnosis conclusion: The tooth surface of the pinion on the output shaft of the reducer is pitted and peeled off, the gear positioning may be abnormal, and there has been slow deterioration in the near future.
3.2Inspection and maintenance suggestions
The equipment is currently in a monitorable operating state, and it is recommended to arrange an inspection at an appropriate time. Pay attention to the meshing of the large and small teeth, and check the damage of the pinion tooth surface at an appropriate time.
4.On-site inspection and maintenance process
2023-08-17 15:57 On-site feedback: The pinion has been overhauled, the tooth surface is damaged, and the pitting wear is severe.
5.On-site inspection and maintenance photos
From the inspection photos, it can be seen that the pinion tooth surface is severely pitted and worn.

Maintenance photo_1

Maintenance photo_2
6.Verification after inspection and maintenance
After the overhaul, the low-frequency acceleration vibration trend decreased significantly, which was consistent with the vibration value during the previous stable operation.
Low-frequency acceleration vibration trend at the reducer input end
The periodic impact in the low-frequency acceleration time domain waveform disappears, and the impact amplitude also decreases significantly.
Comparison of low-frequency acceleration time domain waveforms before and after maintenance
The number of sidebands in the meshing frequency band and the pinion rotation frequency in the spectrum is also significantly reduced.
Comparison of low-frequency acceleration spectrum before and after maintenance
7.Customer feedback form
None
8.Monitoring fault range
Timely and effective collection of equipment operating status data (vibration, temperature) is subject to the constraints of network connectivity and data transmission time, and also needs to consider interference from factors such as the equipment's own attributes and production processes. At the same time, the analysis and diagnosis of equipment status is based on changes in vibration effects caused by rotating parts failures. Therefore, the status monitoring system cannot guarantee monitoring of all types of faults. The monitoring system is configured according to the measurement point scheme recommended by Party B, and the range of faults that can be monitored and the description are as follows:
9.Notes
1. If the client of this report cannot provide basic unit parameters (such as unit transmission chain diagram, gearbox structure diagram, gearbox teeth number, related bearing models and brands), the accuracy of analysis and diagnosis will be affected;
2. This report is the analysis, diagnosis and maintenance opinions of the unit by Rongzhi professional technicians, which is for reference only. The specific maintenance and repair measures shall be decided by the client.
3. This report shall not be used as evidence for any claims, litigation, etc.;
4. The client has the obligation to keep the analysis report confidential and shall not provide this report to a third party, print it into other promotional materials, or publish it on the Internet or other public information platforms without the written permission of the trustee.

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Zhongtian Hechuang Coal Chemical 1#A reversible crusher

1.EquipmentInformation
Equipment type: impact crusher
Rated speed: 600rpm
Related measurement points in this case: 3H at the input end of the first shaft of the crusher coupling
2.Alarm and analysis process
Equipment alarm events:
2.1Analysis process
2.1.1Explanation of trends, indicator parameters and other evidence
The speed vibration of the crusher at multiple measuring points increased significantly.
1#A reversible crusher/crusher coupling second shaft input end 5H_Equipment Multi Trend
2.1.2Explanation of evidence such as time domain, spectrum, and envelope demodulation
There is no obvious impact or disturbance in the time domain waveform.
1#A reversible crusher/crusher coupling second shaft input end 5H_time domain waveform
The frequency spectrum is dominated by the rise of rotation frequency energy.
1#A reversible crusher/crusher coupling second shaft input end 5H_spectrum analysis
3.Diagnostic conclusions and recommendations
3.1Diagnostic conclusion
2023-10-21 01:34 Push diagnosis conclusion: The speed vibration of the unit has increased significantly, which is speculated to be related to the damage of the crusher hammer head.
3.2Inspection and maintenance suggestions
During the inspection, pay attention to the vibration of the crusher and check whether the hammer head is damaged.
4.On-site inspection and maintenance process
2023-10-24 09:08 On-site feedback showed that the hammer head was damaged and 23 hammer heads were replaced.
5.On-site inspection and maintenance photos
The inspection photos show that the hammer head is damaged and part of it has fallen off.

Maintenance photo_1

Maintenance photo_2

Maintenance photo_3

Maintenance photo_4
6.Verification after inspection and maintenance
After the overhaul, the speed vibration at multiple measuring points decreased significantly.
1#A reversible crusher/motor drive end 2H/8k speed waveform (10-1000)_Equipment Multi-trend
The transfer frequency energy in the spectrum decreases significantly.
1#A reversible crusher/crusher coupling one shaft output end 4A (loss)/8k speed waveform (10-1000)_spectrum analysis
7.Customer feedback form
None
8.Monitoring fault range
The timely and effective collection of equipment operating status data (vibration, temperature) is restricted by network connectivity and data transmission time, and also needs to consider interference from factors such as the equipment's own properties and production processes. At the same time, the analysis and diagnosis of equipment status are based on the changes in vibration effects caused by faults in rotating moving parts. Therefore, condition monitoring systems cannot guarantee monitoring of all types of faults. The monitoring system is configured according to the measurement point scheme recommended by Party B. The fault range that can be monitored and the description are as follows:
9.Notes
1. If the client of this report cannot provide basic unit parameters (such as unit transmission chain diagram, gearbox structure diagram, gearbox teeth number, related bearing models and brands), the accuracy of analysis and diagnosis will be affected;
2. This report is the analysis, diagnosis and maintenance opinions of the unit by Rongzhi professional technicians, which is for reference only. The specific maintenance and repair measures shall be decided by the client.
3. This report shall not be used as evidence for any claims, litigation, etc.;
4. The client has the obligation to keep the analysis report confidential and shall not provide this report to a third party, print it into other promotional materials, or publish it on the Internet or other public information platforms without the written permission of the trustee.

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Zhongtian Hechuang Coal Chemical 124P0108A Washing tower water pump

1.Equipment Information
Equipment Type: Centrifugal Pump
Rated speed: unknown
Related measurement points in this case: Motor non-driving end 1H
2.Alarm and analysis process
Equipment alarm events:
2.1Analysis process
2.1.1Explanation of trends, indicator parameters and other evidence
The acceleration trend at both ends of the motor is increasing.
124P0108A Scrubber Feed Pump/Motor Drive End 2H/64k Acceleration Waveform (0.1-20000)_Equipment Multi-Trend
2.1.2Explanation of evidence such as time domain, spectrum, and envelope demodulation
The time domain waveform shows the characteristic frequency interval impact of the bearing cage.
124P0108A Washing tower water pump/motor drive end 2H/64k acceleration waveform (0.1-20000)_time domain waveform
Spectrum envelope demodulation shows that the characteristic frequency energy of the bearing cage is quite obvious.
124P0108A Scrubber Feed Pump/Motor Drive End 2H/64k Acceleration Waveform (0.1-20000)_Envelope Demodulation
3.Diagnostic conclusions and recommendations
3.1Diagnostic conclusion
2024-01-30 11:48 Push diagnosis conclusion: The bearings at both ends of the motor are damaged in the early and mid-term, with the main damage being the wear and sticking of the bearing retainer, which is slightly more obvious at the non-drive end and has slowly deteriorated recently.
3.2Inspection and maintenance suggestions
Pay attention to abnormal noise and temperature rise of the bearings at both ends of the motor, and improve lubrication when appropriate to delay deterioration.
4.On-site inspection and maintenance process
2024-02-21 15:11 On-site feedback: The bearing retainer is scattered.
5.On-site inspection and maintenance photos
The inspection photos show that the bearing retainers are scattered.

Maintenance photo_1

Maintenance photo_2

Maintenance photo_3
6.Verification after inspection and maintenance
After the overhaul, the total acceleration of the non-drive end of the motor decreased.
124P0108A Scrubber Feed Pump/Motor Drive End 1H/64k Acceleration Waveform (0.1-20000)_Trend Analysis
After the overhaul, the amplitude of the time domain waveform decreased and the background noise energy in the spectrum decreased significantly.
124P0108A Scrubber Feed Pump/Motor Drive End 1H/64k Acceleration Waveform (0.1-20000)_Time Domain Waveform and Spectrum Analysis
7.Customer feedback form
None
8.Monitoring fault range
Timely and effective collection of equipment operating status data (vibration, temperature) is subject to the constraints of network connectivity and data transmission time, and also needs to consider interference from factors such as the equipment's own attributes and production processes. At the same time, the analysis and diagnosis of equipment status is based on changes in vibration effects caused by rotating parts failures. Therefore, the status monitoring system cannot guarantee monitoring of all types of faults. The monitoring system is configured according to the measurement point scheme recommended by Party B, and the range of faults that can be monitored and the description are as follows:
9.Notes
1. If the client of this report cannot provide basic unit parameters (such as unit transmission chain diagram, gearbox structure diagram, gearbox teeth number, related bearing models and brands), the accuracy of analysis and diagnosis will be affected;
2. This report is the analysis, diagnosis and maintenance opinions of the unit by Rongzhi professional technicians, which is for reference only. The specific maintenance and repair measures shall be decided by the client.
3. This report shall not be used as evidence for any claims, litigation, etc.;
4. The client has the obligation to keep the analysis report confidential and shall not provide this report to a third party, print it into other promotional materials, or publish it on the Internet or other public information platforms without the written permission of the trustee.

Learn More

World's Largest Operational Coal-to-Olefins Project

Client Background

Client Requirements & Solutions

Application Value

Success Cases

1.Equipment Information

2.Alarm and analysis process

2.1Analysis process

3.Diagnostic conclusions and recommendations

3.1Diagnostic conclusion

3.2Inspection and maintenance suggestions

4.On-site inspection and maintenance process

5.On-site inspection and maintenance photos

6.Verification after inspection and maintenance

7.Customer feedback form

8.Monitoring fault range

9.Notes

1.Equipment Information

2.Alarm and analysis process

2.1Analysis process

3.Diagnostic conclusions and recommendations

3.1Diagnostic conclusion

3.2Inspection and maintenance suggestions

4.On-site inspection and maintenance process

5.On-site inspection and maintenance photos

6.Verification after inspection and maintenance

7.Customer feedback form

8.Monitoring fault range

9.Notes

1.EquipmentInformation

2.Alarm and analysis process

2.1Analysis process

3.Diagnostic conclusions and recommendations

3.1Diagnostic conclusion

3.2Inspection and maintenance suggestions

4.On-site inspection and maintenance process

5.On-site inspection and maintenance photos

6.Verification after inspection and maintenance

7.Customer feedback form

8.Monitoring fault range

9.Notes

1.Equipment Information

2.Alarm and analysis process

2.1Analysis process

124P0108A Scrubber Feed Pump/Motor Drive End 2H/64k Acceleration Waveform (0.1-20000)_Envelope Demodulation

3.Diagnostic conclusions and recommendations

3.1Diagnostic conclusion

3.2Inspection and maintenance suggestions

4.On-site inspection and maintenance process

5.On-site inspection and maintenance photos

6.Verification after inspection and maintenance

7.Customer feedback form

8.Monitoring fault range

9.Notes

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