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Metallurgical Equipment
ArticleName Development of protective shutdown systems, control and functional diagnostics of technological equipment of metallurgical enterprises
ArticleAuthor E. N. Ishmetyev, A. N. Panov, E. E. Bodrov, S. M. Andreev

JSC KonsOM SKS (Magnitogorsk, Russia):

E. N. Ishmetyev, Dr. Eng., Prof., Director on Strategic Development
A. N. Panov, Cand. Eng., Associate Prof., Head of Innovation Development Dept.


Nosov Magnitogorsk State Technical University (Magnitogorsk, Russia):
E. E. Bodrov, Cand. Eng., Associate Prof., Dept. of Electronics and Microelectronics
S. M. Andreev, Cand. Eng., Associate Prof., Head of Automatic Control Systems Dept.



This paper describes and analyses different approaches to the subject of constructing the protective shutdown, monitoring, and functional diagnostic systems for technological equipment in metallurgy. Those systems are based on measuring and analyzing equipment’s acoustic vibration. Stationary protective shutdown, monitoring, and functional diagnostic systems were installed on non-rotating parts of rotary equipment that includes rolling bearings and slide bearings of AC/DC motors, bearing supports, and gearboxes. Those systems were implemented and tested on Iron and Steel Works in Magnitogorsk, Russia, and SSGPO in Rudny, Kazakhstan. Exploitation of those systems for a number of years has shown that they are very effective in defect diagnostics, in development or correction of preventive maintenance schedule, and in accident prevention. This paper also considers various components which forms the protective shutdown, monitoring, and functional diagnostic systems. These components are accelerometers, electronic diagnostic devices that are built around signal processors, vibration sensors, noise meters, smart sensors, and signal lamps. Combining those components in different ways one can built flexible stationary and mobile protective shutdown, monitoring, and functional diagnostic systems. The protective shutdown, and monitoring systems monitor the vibration velocity’s root mean square value and compare it to the threshold value regulated by the State Standard. The functional diagnostic systems analyze vibration acceleration signal in combination with its direct spectrum and envelope spectrum. As a result of this analysis and subsequent comparison of vibration acceleration amplitude on specific frequencies in the spectrums to the empirically obtained threshold values, the functional diagnostic system daily reports found defects, if any, in a form of tables and graphs. This functional diagnostic system allows conducting a search for defects in industrial equipment in metallurgy and other industries either in automatic or in manual mode that should be executed by vibration expert.

keywords Protective shutdown, control, functional diagnostics, bearing, electric motor, monitoring, accelerometer, smart sensor, signal lamp, noise meter, vibration, spectrum analysis

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