Demir ve çelik tesislerinde bakım uygulamaları
The Maintenance applications in iron and steel industry
- Tez No: 14435
- Danışmanlar: PROF.DR. MUSTAFA SAVCI
- Tez Türü: Yüksek Lisans
- Konular: Endüstri ve Endüstri Mühendisliği, Industrial and Industrial Engineering
- Anahtar Kelimeler: Belirtilmemiş.
- Yıl: 1991
- Dil: Türkçe
- Üniversite: İstanbul Teknik Üniversitesi
- Enstitü: Fen Bilimleri Enstitüsü
- Ana Bilim Dalı: Belirtilmemiş.
- Bilim Dalı: Belirtilmemiş.
- Sayfa Sayısı: 237
Özet
ÖZET Bu çalışmada genel bakım ve onarım yöntemleri incelen miş ve özel olarak bu yöntemlerin demir ve çelik tesisle rindeki uygulamaları ele alınmıştır. Birinci bölümde; bakım tekniğinin teknik, ekonomik, ve sosyal yönden önemine değinilerek, çok genel tanımlar ve rilmiştir. İkinci ve bunu takip eden üçüncü bölümlerde sırasıyla hasar teorisi ve hasar durumunun belirlenmesi konuları üzerinde durulmuştur. Bakım ve onarım tekniğinin incelendiği dördüncü bölümü takiben, ekonomik bakımdan büyük yararlar sağlayan parça onarım yöntemleri beşinci bölümde etraflıca ele alınmış tır. Teknik sistemlerin gün geçtikçe gelişerek, fonksiyon kapasitelerini arttırmaları bu sistemlerde güvenilirlik kavramının öneminin artmasına sebep olmaktadır. Gerek teknik sistemlerdeki güvenilirlik kavramı ve gerekse arıza dağılımları, güvenilirlik teorisi başlığı altında altıncı bölümde ele alınmıştır. Çalışmanın yedinci bölümünde genel bakım giderleri, sekizinci bölümünde ise bakım tekniğinin organizasyon, planlama ve yedek parça gibi özel sorunları üzerinde du rulmuştur. Dokuzuncu bölümde bakım tekniğinin demir ve çelik te sislerindeki uygulamaları, bakım masrafları, işgücü, işgü cünün eğitimi, durum izleme metodları ve bilgisayar des tekli bakım faaliyetleri açısından etraflıca incelenmiş, onuncu bölümde ise bilgisayar destekli bakım yönetimine örnek teşkil edecek bir sistem verilmiştir. xvı
Özet (Çeviri)
SUMMARY THE MAINTENANCE APPLICATIONS IN IRON AND STEEL INDUSTRY Maintenance has crucial importance to provide a successful production in plants and the existence of a plant which has no need to the maintenance is not possible. Although maintenance activities vary widely with the kind of production of the plants» there is a broad agreement on the necessity of maintenance as an important means for production. Machine damages and failures in technical field cause lots of economic losses. Thinking of the total plant downtime in addition to the costs of labour for maintenance and repair and the costs of spares and other maintenance materials, it will be obvious to comprehend the grade of total economic losses. The main reason of the failures are wear and friction occuring in machines and machine parts. Some researches show that 3S% of energy generated all over the world is consumed as a result of friction [13. On the other hand a research performed in England in 1966 has indicated that the effects of wear cause 6 Billion DM economic losses per year. The same problem caused 10 Billion DM in West Germany İn 197S and lOO Billion $ in USA economic losses respectively C2]. So, it is obvious that maintenance plays an important role on the security of proper production processes and the decreasing of economic losses. In order to prevent machines from damaging and failing it is necessary to take some measures. Maintenance can be defined as all of the measures which must be taken to keep the technical systems working and to gain their technical properties lost before [23. In this study, general maintenance methods and the applications of these methods for iron and steel industry exami ned. xvixIn general, maintenance activities can be examined as three parts. These are: -Inspection -Periodical maintenance -Repair technology The necessary working steps for these three activities can be shown in Figure 1. : INSPECTION PI anni ng Pr epar at i on Applications Present at i on of results Evaluation MAINTENANCE PERIODICAL MAINTENANCE PI anni ng Preparation Application Reporting back REPAIR Task PI anni ng Make desicion Preparation Take measures Control Application Function control Presentation of results Evaluation Figure 1. Classification of maintenance. In chapter 2, damage theory is studied. There are very different types of damages occuring in technical systems according to both their reasons and their formation. In general, their effects can be classified into two groups. One of them can be named as technical -physical effects and the other one as technical -economical effects £23. Technical -physical effects can be stated as the variation of machine parts in dimension, shape and and surface. Wear, fatigue and corrosion can be included in the technical -physical effects. As a result of the rapid improvements of technology the validity of technical systems will be very short in the view of productivity, security, conform and ergonomics. These can be given as examples to the technical -economical effects. xvmTo determine the damages it is necessary to take measurements and to make inspections. The measurements are evaluated by means of some methods and compared with the reference values. The measurement methods can be grouped into two parts according to the measurement principle. These are: -Direct measurement methods -Indirect measurement methods By using direct measurement methods it is possible to determine directly the situation of machine parts both before and after damage. In the other method the situation of technical systems is obtained by using diagnosis techniques which is the correlation of the signals generating from the system with the diagnosis parameters. The general maintenance activities and the three main parts of maintenance technique are examined in chapter 4. One of them is inspection which is the most important and necessary activity to determine the situation of machines. There are a lot of methods with which it is possible to determine the situation of machine parts without demontaging and destroying. The second one is the repair technology studied also in detail in chapter S. Although there are many restrictions to practice the repair methods in technical, technological, economic and organizational fields, we can get lots of advantages by using them. Some of these methods are given below: -Welding methods -Injection methods -Galvanic electro-plating methods -Chemi c al pi a t i ng met hods -Special plastic plating methods -Metal paste methods The reliability theory is intensively studied in chapter 6. It is very important to know the distribution of damages. For these reasons it is necessary to make some statistical calculations and to compare the results with the theoretical distribution functions. The subject of maintenance is of crucial importance to the successful operation of any steelworks, the techniques involved reach into the very heart of the equipment and their control systems and demand increasing technical competence and expertise from all the people involved. The statements reflects the importance placed on maintenance by steel industries in industrialized countries where it is now the third highest cost item after raw materials and manpower. :axAlthough maintenance practices vary widely around the steel plants of the world there is broad agreement on the improvements and strategies needed. Major objectives for any maintenance manager are: -To reduce the costs of labour for maintenance and repair. -To reduce the costs of spares and other maintenance materials. -To reduce total plant downtime. These can be achieved by the development of an integrated programme which must include the following items: -Design of new plant and modifications to existing plant to reduce the need for maintenance and/or simplify the maintenance work which is needed. -Organization and planning of maintenance work to maximize the utilization and productivity of maintenance 1 abour. -Quality of spares, repair technology and design to improve the life of components. -Avoidance of failures and the resultant cost of r epai r i ng damage. Such considerations lead to the need for substantial improvements in the systems which are used to plan the maintenance activity, to analyze its effectiveness and to identify areas for further improvement. A comprehensive condition monitoring scheme provides one of the valuable inputs for good planning. The knowledge and skills of the maintenance management and work force are key factors which have a bearing on the achievement of high maintenance quality and thus on plant availability and reliability. It is therefore essential to the success of maintenance function that there is a formal, structured system for on the job training and continuing education of the maintenance management and wor k er s. Improvements in labour efficiency are being sought by moves to the use of mult i skilled craftsmen. Combining crafts in the mechanical area is more common than in the electrical and electronic fields. Many companies are considering integration of the maintenance crafts with the operational function and this will be an increasing trend for the future. A variety of monitoring techniques are being widely used to good effect as part of condition based/predictive maintenance strategies. For rotating machines, the main tools are vibration measurement instruments, supplemented by lubricant checks and wear debris analysis for items xxsuch as gearboxes, where vibration may not provide the complete answer. There have been major advances in the collection and analysis of vibration data and the techniques can now provide a relatively cheap, simple and cost effective prediction of a substantial proportion of a works' maintenance needs. Although continuous monitoring systems are only applied, at present, to a small proportion of monitoring requirements it is anticipated that their use will grow. Where major schemes have been implemented the expenditure appears to have been more than adequately repaid in improved availability and reliability. The trend is towards increased use of computers for the analysis of monitoring data and to provide assistance with diagnosis. Expert systems/artificial intelligence for diagnosis of maintenance requirements are still at an early stage of development. If satisfactory techniques can be developed there will be pressure for greater integration of the condition monitoring database with the computer systems for maintenance planning and control. Such integration will in any case be required to automate the maintenance response to monitoring results. The developments in hardware and software for condition monitoring are leading to decentralization and devolution of the measurement, diagnosis and decision making to inspectors/craftsmen. This has significant implications for maintenance implications for maintenance organization, responsibility and training. It is not possible to generalize on the costs and benefits for a condition monitoring scheme, each application having its own specific parameters. Electronic Data Processing CEDPD systems have been applied in support of the maintenance activity for over 20 years, although even now some 30% of the systems used are still manual systems. In addition to the basic maintenance planning and control, systems typically include facilities for equipment and drawing management, repair shop planning and control and personnel and cost control. There has been continuous development in hardware and software and thus in the scope and features of the maintenance systems in use and planned. Chapter 9 provides some historical perspective on these developments, the clear trend now being to real time, interactive systems, with a high level of integration to provide direct access of data from and to the various sub-systems. xxxWith the developments in the maintenance technology discussed in chapter 9 the pressures for total system integration will undoubtedly intensify. In discussion 'Strategies and Methods' emphasis was placed on the need of comprehensive analysis of delays and plant failures. In chapter 9, 'Condition Monitoring', the growing requirements for automation of diagnosis and of the maintenance response to problems were identified. These needs can only be satisfied if there is simultaneous access to monitoring data, plant history, equipment specifications and job planning etc. There is limited availability of standard software for maintenance in the steel industry and the costs of modifying systems designed for more general use can be high. As a result it is obvious that efficient and effective maintenance can not be achieved without taking up the following three headings: -TRAINING -COMPUTER SYSTEMS -CONDITION MONITORING xxxi
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