Group-wide Deployment & Comprehensive Application

Case Duration:

August 2020 – Present

Client Background:

As a subsidiary of CHN Energy specializing in coal and coal-to-liquids (CTL) chemical production

Client Background

As a subsidiary of CHN Energy specializing in coal and coal-to-liquids (CTL) chemical production:

1. Coal Operations:

1) 14 active mining sites

2) Primary products: Anthracite, coking coal, thermal coal

3) Approved capacity: 82.4 million tons/year

4) Current production: 60 million tons/year

2. CTL Chemical Operations:

1) World's largest CTL chemical production base

2) Annual output: 11 million tons of: Oil-based chemicals、Polyolefins、Methanol

Client Requirements & Solutions

Integrated Data Platform for Centralized Management

Smart Hardware Deployment & Data Integration：

1. Predictive maintenance systems deployed across:
1) 7 coal mines
2) 3 coal preparation plants
3) CTL subsidiary
4) Olefins No.2 subsidiary

2. Real-time monitoring of various critical assets

3. Early fault detection with precise degradation assessment

Centralized Diagnostic Center：

Unified platform integrating data from all sites

Enabled 24/7 equipment status tracking

Expert Technical Support:

Established RONDS remote O&M center linkage

Provided on-demand technical support

Application Value

All Critical Equipment Under Secure Monitoring:

Online real-time monitoring has been implemented for 400+ critical equipment units across:

1. 7 subordinate mines

2. 3 coal preparation plants

3. Coal-to-Liquids subsidiary

4. Olefins No.2 subsidiary

Ensuring Efficient, Safe and Green Production:

1. Generated 300+ equipment health reports

2. Resolved 100+ equipment failure cases through closed-loop management, including:
1) Midnight rapid equipment degradation incidents
2) Predictive maintenance cases
3) Guided repair cases

3. Directly recovered economic losses exceeding CNY 15 million

4. Avoided over 400 hours of unplanned downtime

Eliminating Information Silos to Achieve Centralized and Intelligent Equipment O&M Management:

RONDS has deployed a diagnostic center for the customer that:

1. Aggregates equipment status data from all mines and coal preparation plants

2. Breaks down information silos

3. Establishes a complete equipment O&M management system

4. Realizes centralized and intelligent enterprise equipment O&M management

Success Cases

National Energy Group Ningxia Coal Industry Shuangma Coal Washing Plant 308 Gangue Screen

1. Equipment Information
Equipment Type: Vibrating Screen
Rated speed: 990rpm
Related measurement points in this case: coupling level 3H
2. Alarm occurs
At 00:20 on 2022-02-09, a level 1 alarm occurred at coupling level 3H.
2.1 Analysis Process
2.1.1 Explanation of trends, indicator parameters and other evidence
The total acceleration value of the coupling horizontal 3H measuring point continues to rise slowly.
308 Gangue Screen/Coupling Horizontal 3H/16k Acceleration Waveform (2-20000)_Equipment Multi-Trend
2.1.2 Explanation of evidence such as time domain, spectrum, and envelope demodulation
The impact is not obvious in the acceleration time domain waveform of the coupling horizontal 3H measuring point.
308 Gangue Screen/Coupling Horizontal 3H/16k Acceleration Waveform (2-20000)_Time Domain Waveform
The characteristic frequency and harmonics of the bearing cage can be seen in the envelope demodulation spectrum of the horizontal 3H measuring point of the coupling.
308 Gangue Screen/Coupling Horizontal 3H/16k Acceleration Waveform (2-20000)_Long Waveform
There is an impact of the rotation frequency interval in the acceleration time domain waveform of the motor drive end.
308 Gangue Screen/Motor Load End Horizontal 2H/16k Acceleration Waveform (2-20000)_Long Waveform
The characteristic frequencies and harmonics of bearing inner ring damage can be seen in the envelope demodulation spectrum of the motor drive end.
308 Gangue Screen/Motor Load End Horizontal 2H/16k Acceleration Waveform (2-20000)_Long Waveform
3. Push diagnostic conclusions
3.1 Diagnostic Conclusion
2022-02-09 09:45 Push diagnosis conclusion: The bearing retainer and raceway on the side of the coupling near the pulley are worn and continuously deteriorating; the inner ring of the bearing on the motor drive end is pitted and peeled off, and the characteristics are stable.
3.2 Inspection 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 the temperature changes of the bearing on the side of the coupling near the pulley, pay attention to the abnormal noise of the bearing on the motor drive end, and regularly improve the bearing lubrication.
4. On-site inspection and maintenance process
2022-02-20 18:52 On-site feedback: The output shaft assembly was replaced and installed, and the vibration decreased after the replacement.
5. On-site inspection and maintenance photos
The photo shows the replaced output shaft assembly.
Repair photos
6. Verification after inspection and maintenance
After the bearing was replaced, the total acceleration value of the coupling horizontal 3H measuring point decreased significantly.
308 Gangue Screen_Equipment Trends
7.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:
8.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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Renjiazhuang Coal Mine of Ningxia Coal Industry of China National Energy Group 4# belt motor

1. Equipment Information
Equipment type: belt conveyor main drive
Rated speed: 1490rpm
Related measurement points in this case: Motor drive end 2H
2. Alarm and analysis process
At 00:20 on 2022-02-09, a level 1 alarm occurred at coupling level 3H.
2.1 Analysis Process
2.1.1 Explanation of trends, indicator parameters and other evidence
The speed amplitude at the motor drive end continues to increase slowly, from 1.3mm/s to 2.7mm/s.
4# belt motor/motor drive end 2H/16k speed waveform (2-1000)_trend analysis
The acceleration amplitude trend is relatively stable.
4# belt motor/motor drive end 2H/128k acceleration waveform (0.1-20000)_trend analysis
2.1.2 Explanation of evidence such as time domain, spectrum, and envelope demodulation
The increase in speed amplitude is mainly based on the energy of 1 times the motor frequency.
4# belt motor/motor drive end 2H/16k speed waveform (2-1000)_spectrum analysis
The acceleration time domain waveform has motor frequency interval impact.
4# belt motor/motor drive end 2H/128k acceleration waveform (0.1-2000)_time domain waveform
The frequency spectrum is rich in motor rotation frequency and its harmonics.
4# belt motor/motor drive end 2H/128k acceleration waveform (0.1-2000)_spectrum analysis
3. Diagnostic conclusions and recommendations
3.1 Diagnostic conclusion
2023-09-25 Monthly physical examination issued: The looseness characteristics of the motor load end are obvious, which is presumed to be related to the wear of the coupling and the slow deterioration. 【Key points to watch this month】
3.2 Inspection and maintenance suggestions
Pay attention to abnormal noise of the coupling and changes in motor vibration, regularly check the wear of the coupling, and recheck the alignment.
4. On-site inspection and maintenance process
2023-09-28 13:24 On-site feedback: The 4# motor coupling is severely worn and the coupling has been replaced during maintenance today. And provide maintenance photos.
5. On-site inspection and maintenance photos
The inspection photos show wear on the gear teeth, but no photos of the serpentine spring are provided.
Maintenance photo_1
Maintenance photo_2
Maintenance photo_3
Maintenance photo_4
Maintenance photo_5
6. Verification after inspection and maintenance
After on-site maintenance, the speed amplitude of the motor drive end dropped significantly and the trend remained stable.
4# belt motor/motor drive end 2H/16k speed waveform (2-1000)_trend analysis
After on-site maintenance, the low-frequency acceleration time domain waveform impact at the motor drive end basically disappeared.
4# belt motor/motor drive end 2H/128k acceleration waveform (0.1-2000)_time domain waveform
The energy of the transfer frequency harmonics in the acceleration spectrum decreases significantly.
4# belt motor/motor drive end 2H/128k acceleration waveform (0.1-2000)_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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National Energy Group Ningxia Coal Industry Zaoquan Coal Washing Plant 201 belt

1. Equipment Information
Equipment type: belt conveyor
Rated speed: 1500rpm
Related measurement points in this case: Motor load end level 2H
2. Alarm occurs
At 06:22 on 2022-01-19, a level 3 alarm occurred at the motor load end level 2H.
2.1 Analysis Process
2.1.1 Explanation of trends, indicator parameters and other evidence
The acceleration amplitude at the load end of the motor has been rising slowly and continuously recently.
201 belt/motor load end horizontal 2H/128k acceleration waveform (2-2000)_trend analysis
There is a synchronous upward trend in the speed amplitude at the load end of the motor, and the speed amplitude can reach about 11mm/s.
201 belt/motor load end horizontal 2H/16k speed waveform (2-1000)_trend analysis
2.1.2 Explanation of evidence such as time domain, spectrum, and envelope demodulation
The acceleration time domain waveform approximates the motor frequency disturbance interval.
201 belt/motor load end horizontal 2H/128k acceleration waveform (2-2000)_time domain waveform
The motor rotation frequency and its harmonics are relatively abundant in the acceleration spectrum.
201 belt/motor load end horizontal 2H/128k acceleration waveform (2-2000)_spectrum analysis
The speed spectrum is also mainly composed of motor frequency and its harmonics.
201 belt/motor load end horizontal 2H/16k speed waveform (2-1000)_spectrum analysis
3. Push diagnostic conclusions
3.1 Diagnostic conclusion
2022-01-19 06:41 Push diagnosis conclusion: The looseness characteristics of the motor load end are obvious, which is speculated to be related to the wear of the coupling and has been slowly deteriorating recently.
3.2 Inspection and maintenance suggestions
The equipment is currently in a monitorable operating state. It is recommended to arrange an inspection at an appropriate time. During inspections, attention should be paid to motor vibration. Coupling wear should be checked and alignment should be rechecked when appropriate.
4. On-site inspection and maintenance process
1. 2022-01-19 06:41 The diagnostic engineer pushed the diagnostic conclusion to inform that the coupling was damaged. 2. After receiving the notification at 13:03 on 2022-01-19, the site inspected and found that the coupler connection disc of the motor was broken.
5. On-site inspection and maintenance photos
On-site communication_1
Coupler connection plate cracked_2
On-site maintenance_3
6. Verification after inspection and maintenance
After on-site maintenance, the vibration has dropped significantly and the current operation is stable.
201 belt/motor load end horizontal 2H/16k speed waveform (2-1000)_time domain waveform spectrum combination diagram
7.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:
8.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

Group-wide Deployment & Comprehensive Application

Client Background

Client Requirements & Solutions

Application Value

Success Cases

1. Equipment Information

2. Alarm occurs

2.1 Analysis Process

3. Push diagnostic conclusions

3.1 Diagnostic Conclusion

3.2 Inspection and maintenance suggestions

4. On-site inspection and maintenance process

5. On-site inspection and maintenance photos

6. Verification after inspection and maintenance

7.Monitoring fault range

8.Notes

1. Equipment Information

2. Alarm and analysis process

2.1 Analysis Process

3. Diagnostic conclusions and recommendations

3.1 Diagnostic conclusion

3.2 Inspection 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 occurs

2.1 Analysis Process

3. Push diagnostic conclusions

3.1 Diagnostic conclusion

3.2 Inspection and maintenance suggestions

4. On-site inspection and maintenance process

5. On-site inspection and maintenance photos

6. Verification after inspection and maintenance

7.Monitoring fault range

8.Notes

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