Technical diagnostics of technical devices definition. Technical diagnostics. Reading the documentation
1.1. These "Recommendations for the technical diagnostics of lifting structures" (hereinafter referred to as "Recommendations") are developed in accordance with and in development technical regulations "On the safety of machinery and equipment", approved by the decree of the Government of the Russian Federation of 15.09.2009, No. 753, as well as in accordance with Federal law from 21.07.1997 No. 116-FZ "On industrial safety of hazardous production facilities and are advisory in nature.
1.2. The recommendations are intended for experts and certified specialists of expert organizations performing work on technical diagnostics of substations, owners of substations (regardless of ownership), as well as employees of the federal executive body specially authorized in the field of industrial safety of substations.
2. Scope
2.1. These Recommendations are intended for use in the technical diagnostics of substations: hoisting cranes of all types, electric hoists, monorail trolleys, manipulator cranes, pipe-laying cranes, hoists, towers, lifting devices as part of cranes, individual lifting devices, as well as crane rail tracks for the purpose of determining their technical condition and the possibility of further operation.
The recommendations regulate the procedure for carrying out technical diagnostics, determine the fundamental composition of work that makes it possible to objectively assess the technical condition, the actual bearing capacity of metal structures, substation mechanisms and, if necessary, make reasonable technical decisions on repair and restoration measures or methods of reinforcement.
types, frequency and scope of technical diagnostics of PS, depending on the conditions and specifics of their operation;
methodological foundations and sequence of technical diagnostics;
nomenclature of diagnostic parameters and qualitative features characterizing the technical condition of the lifting structure and ensuring the search for its possible defects and damages;
nominal, permissible, limiting values \u200b\u200bof structural diagnostic parameters and the dependence of parameter values \u200b\u200bon the operating time of the PS;
requirements for the measurement error of parameters;
nomenclature of diagnostic tools, operating modes of the PS and its components during technical diagnostics;
labor protection requirements for technical diagnostics.
3.1. The list of normative documents referenced in these Recommendations is given in section 2. FNP PS.
When excluding from the current normative documents referred to in these Recommendations, the rules introduced instead of the excluded ones should be followed.
4. Terms and definitions
Working condition limited (limited working state) - state metal structures PS, in which the values \u200b\u200bof the parameters characterizing the ability to perform its specified functions are not fully implemented (for example, at a limited departure, or with a limited carrying capacity, etc.), but while ensuring all mandatory safety requirements (strength, stiffness, stability, etc.).
Emergency condition - state metal structures PS, in which its further operation is prohibited until the implementation of measures for repair and / or reinforcement.
Limit state criterion - a sign or a set of signs of the limiting state of a PS established by the regulatory and (or) design (project) documentation, taking into account the assigned permissible risk.
Technical diagnostics - a set of works performed at the substation in order to obtain an objective assessment of its technical condition, as well as to issue an opinion defining the terms and conditions (permissible risk) of further safe operation of the lifting structure.
Primary technical diagnosis - technical diagnostics carried out for the first time at the substation, but no later than the expiration of the assigned service life of the substation.
Technical diagnostics repeated - technical diagnostics carried out after the expiration of the period established by the results of the primary or previous repeated technical diagnostics of the PS.
Extraordinary technical diagnostics - technical diagnostics carried out in the event of significant defects or damages (or signs of the occurrence of these damages) that pose a threat to further operation, carried out in accordance with the requirements set out in the information letters of the manufacturers or the federal executive body specially authorized in the field of industrial safety, or at the request of the owner of the lifting structure.
Form of measures to complete technical diagnostics- a document containing a list of works (repairs, reinforcements, etc.) performed at the substation in order to bring it into a working condition and ensure that static and dynamic tests are carried out on it upon completion of technical diagnostics.
5. General provisions
5.1. Specialized organizations equipped with the necessary instrumental and instrumental base, having qualified specialists in their composition, are allowed to carry out work on the technical diagnostics of PS. Qualification specialized organization and specialists for the right to conduct technical diagnostics must be confirmed by documents established in Russia for the right to perform these activities.
5.2. During technical diagnostics, one should take into account the specifics of the materials from which the PS metal structures are made.
According to this assessment, the metal structures of substations are subdivided into: being in working condition, limited working condition and emergency condition.
In a working condition, the operation of metal structures under actual loads and impacts is possible without restrictions. At the same time, for structures in a working condition, the requirement for periodic inspections during operation can be established.
With a limited working condition of metal structures, it is necessary to monitor their condition, take protective measures, monitor the parameters of the operation process (for example, limiting loads, protecting structures from corrosion, restoring or strengthening structures). If the structures of limited efficiency remain not reinforced, then mandatory repeated diagnostics are required, the terms of which are established on the basis of the diagnostics carried out.
In the event of an emergency state of metal structures, their operation should be prohibited.
5.4. During technical diagnostics of substations located in seismically hazardous regions (or at seismically hazardous facilities), the predictive assessment of the safe state of metal structures should be carried out taking into account the factors of seismic effects:
estimated seismicity of the construction site according to OSR-97 maps;
repeatability of seismic impact;
spectral composition of seismic impact;
categories of soils by seismic properties.
6. Organizational and technical measures carried out before technical diagnostics
6.1. Works on technical diagnostics of PS are carried out at the request of the customer, which is registered with the expert organization in the prescribed manner.
6.2. Based on the application expert organization conducts a preliminary stage of negotiations with the customer, coordinating the necessary list of organizational and technical issues:
types of lifting structures and their number;
technical characteristics and operating conditions of the substation;
a list of information required for technical diagnostics in accordance with the current normative and technical documentation;
requirements for technical diagnostics;
the timing of work on technical diagnostics and the transfer of the conclusion to the owner of the lifting structure;
other organizational and technical issues.
passport, operation manual 22 and other operational and design documents (the latter, if necessary);
PS, test cargo, as well as allocate an experienced crane operator (driver, operator) for the period of technical diagnostics;
equipment and tools for technical diagnostics of metal structures and mechanisms at height (if necessary);
passport of the crane runway, the certificate of delivery and acceptance of the crane runway into operation and the previous act of planned-high-altitude survey of tracks (for substations moving along ground or elevated crane tracks) in accordance with the requirements of regulatory documents;
insulation resistance and grounding resistance test reports;
documents of performed repairs (upgrades, reconstructions), if they were carried out;
a certificate on the nature of the work performed by the substation;
summary printout from the parameter recorder (for PS equipped with the specified device);
maintenance log with records of maintenance and routine repairs;
acts and materials of previously conducted checks and technical diagnostics of this PS.
7. The main stages of work in technical diagnostics
7.1. Technical diagnostics of the PS is carried out in the general case in accordance with the work execution program outlined below. It is specified taking into account the type, design and operating conditions of a particular substation.
The technical diagnostics program provides for 3 stages of work:
preparatory;
working;
final.
selection of regulatory and technical reference documentationrequired for technical diagnostics of this type of PS;
familiarization with certificates, operational, repair, design and construction and other documentation for this substation;
conducting extracts from the passport;
preparation of maps for inspection of the substation (if necessary);
obtaining a certificate on the nature of the PS and a printout from the parameter recorder;
checking the conditions and organization of work to prepare the site for technical diagnostics and testing of substations;
verification of technical means and devices for technical diagnostics of substations;
conducting safety briefing to members of the commission;
publication of an order on the composition of the commission and on the upcoming volume of work.
technical diagnostics of the state of the metal structure;
technical diagnostics of mechanisms (mechanical part of mechanisms);
technical diagnostics of the rope-block system;
technical diagnostics of hydraulic and pneumatic equipment;
technical diagnostics of electrical equipment;
technical diagnostics of safety devices and devices;
technical diagnostics of the condition of the crane and trolley track, as well as track equipment;
high-altitude survey of the position of the crane tracks (if necessary);
taking control samples from the elements of the metal structures of the PS to determine the chemical composition and mechanical properties metal (if necessary);
instrument control of metal structures and welded joints non-destructive testing methods;
testing (static, dynamic, special).
7.4. The final stage includes:
analysis of the results of technical diagnostics;
preparation of a form of measures for the completion of technical diagnostics
registration of acts of non-destructive testing, familiarization with the results of testing insulation resistance and grounding; chemical analysis, etc., registration of test reports for PS.
calculation of the achieved group of classification (mode) PS 23;
making a decision on the possibility and feasibility of extending the service life of the substation;
recommendations for ensuring safe work PS;
checking the implementation of measures to complete technical diagnostics;
development of the document "Safety Justification";
execution of the conclusion of technical diagnostics;
transfer of the opinion to the owner.
8. The volume and content of the main types of work during technical diagnostics
8.1. Acquaintance with the documentation.
8.1.1. The owner of a substation subject to technical diagnostics, before starting work, issues an order for the enterprise to transfer for technical diagnostics (primary, repeated or extraordinary) this substation or a group of substations, to appoint responsible persons for safety at the facility, for preparing the conditions necessary for carrying out works for technical diagnostics of PS.
8.1.2. In the process of performing work on technical diagnostics of the commission, it is necessary to familiarize yourself with the available:
certificates for ropes, hooks, metal, fasteners, etc .;
passports for substations and components for which a separate passport is provided (for example, for removable load-gripping devices, parameter recorders, brakes, etc.);
instructions for maintenance and operation of the lifting structure;
magazines: shift, watch, accounting for checking the knowledge of personnel, safety instructions, qualifications of service personnel; inspection, maintenance and repair of substations and crane tracks;
repair documentation (included);
drawings and calculations performed during the reconstruction or modernization of the substation;
materials of the last full technical examination;
previous conclusions on this PS;
a certificate of the nature of the work of PS 24;
documents on the crane tracks (including the passport of the crane track), certificates of delivery and acceptance of the track, the results of planned-high-altitude surveys, etc.);
acts of checking insulation resistance and grounding;
certificates of verification of safety devices and measuring instruments;
by the instructions of the federal executive body specially authorized in the field of industrial safety of the substation and the technical supervision service of the organization - the owner of the substation.
availability and completeness of documentation;
compliance of the existing equipment and its technical data with passport and certification documents;
compliance with the instructions of the federal executive body, specially authorized in the field of industrial safety of the substation, as well as the conclusions of the commissions that previously performed technical diagnostics of the substation;
the level of technical maintenance of the substation and the compliance of TO with the requirements of instructions and regulations in force at the enterprise;
compliance of the repair documentation with the requirements of regulations, GOSTs of regulatory documents of the owner-company and NTD of the federal executive body specially authorized in the field of industrial safety of the substation.
8.2. Checking the conditions for carrying out technical diagnostics.
8.2.1. When checking the conditions for carrying out technical diagnostics of the lifting structure, the commission should pay attention to the state of the site on which it is installed.
For cranes on railways, the crane track and dead-end stops must comply with the passport characteristics. A type of substation - bridge cranes for the period of technical diagnostics should be installed in the zone landing sitescleaned of debris, dirt and snow, and outside the zones of technological aggressive impact (high temperatures, release of chemicals, gas emissions, etc.).
8.2.2. The installation site of the substation for the period of its technical diagnostics should be fenced with appropriate warning signs, illuminated and accessible for the installation of additional lifting equipment used for diagnostics. On the switch, which turns on the PS 25, there should be a sign with the inscription: "Do not turn on, people are working."
8.2.3. In the area of \u200b\u200btechnical diagnostics, the owner of the aircraft must prepare test cargo (with a documented mass) for cargo tests of the vehicle being diagnosed.
8.2.4. The substation must be cleaned of dirt, grease, icing, etc., the casing must be removed, the hatches are opened, the substation must be de-energized.
8.2.5. Ladders, railings, fences, hatches must be functional and meet the safety requirements for this type of lifting structures.
8.2.6. The substation must have signs indicating registration number lifting structure, its carrying capacity and test date. The inscriptions on the plate must be clearly distinguishable from the ground (from the floor) and correspond to the data in the passport of the vehicle.
8.2.7. The zone of technical diagnostics of the substation must be outside the zone of overhead power lines and taking into account other safety requirements.
8.Z. Checking the condition of metal structures.
8.3.1. Checking the condition of substation steel structures is the main type of technical diagnostics in terms of volume and importance. It includes:
external examination of load-bearing elements of metal structures;
inspection of elements of metal structures by one of the types of non-destructive testing (for example, visual measuring control - VIC). The type and need for the use of other additional types of non-destructive testing are determined by the commission performing technical diagnostics.
quality control of joints of elements of metal structures (welded, bolted, hinged, etc.);
measurement of residual deformations of beams, arrows, trusses and individual damaged elements;
assessment of the degree of corrosion of supporting elements of metal structures (if there are signs of corrosion).
External examination and VIC should be carried out using the simplest optical means and portable light sources, with special attention should be paid to the following places of possible damage:
areas of sharp changes in cross-sections;
places that have suffered damage or shock during installation and transportation;
places where significant stress, corrosion or wear occurs during operation;
areas with welds, bolted and riveted joints.
cracks in the base metal, welded seams and heat-affected zone, indirect signs, the presence of which are paint peeling, local corrosion, rust stains, etc .;
general and local residual deformations;
delamination of the base metal;
poor quality of repair welded joints;
backlash of hinge joints, loosening of bolted and riveted joints.
8.3.5. Inspection of connecting elements of a metal structure (axles, pins, etc.) should begin with an inspection of the state of the fixing elements, indicating the presence of axial or torsional forces in the connection. If external signs of damage to the connection are detected (jolts, sharp impacts, bumpiness, etc.), the axle (pin) is dismantled and measured. In this case, the axle seats should be subjected to a similar inspection and measurements.
8.3.6. Measurement of residual deformations of beams, arrows, trusses and their elements should be carried out in accordance with the recommendations for the types of lifting structures.
8.3.7. When diagnosing metal structures, it should be borne in mind that fatigue cracks occur primarily in the zones of local stress concentrators, namely:
attachment points for braces, racks, kerchiefs to belts;
elements with a sharp difference in cross-sections;
places where linings, edges end;
areas of holes with raw, burnt or welded edges;
places of intersection of welded seams;
zones of differences in the thickness of the joined sheets (joints);
places of repeated welding of cracks in welded seams, etc.
The choice of the type of non-destructive testing for a particular substation is determined by the commission, while the commission bears full responsibility for undetected cracks, especially in tensile elements of the metal structure.
NDT is carried out by members of the commission certified in the field of NDT or by specialists of a certified NDT laboratory (own or third-party).
8.3.9. When assessing the permanent deformation of metal structures, it is necessary to pay attention to damage that leads to a decrease in the bearing capacity of the structure:
deviation from straightness (towers, arrows, spans, racks of truss elements);
twisting (spans, supports, arrows, etc.);
misalignment of connections (sections of arrows, towers, etc.);
the presence of residual deflections of span beams, brackets, consoles, etc .;
distortion of the shape of the superstructure in the plan.
8.3.11. Possible locations for corrosion are:
closed spaces (boxes) of spans, chassis frames, ring beams, belts and portal posts;
support units of booms, towers, "legs" (supports) of gantry and portal cranes;
gaps and slots formed due to loose fit of elements;
welded joints made with an intermittent seam, etc.
8.3.12. Corrosion zones are marked on the schemes of metal structures indicating the size of damage and location coordinates. The question of the further operability of an element affected by corrosion is decided in each case. If necessary, the conclusions of the commission can be confirmed by calculations of the element, taking into account corrosive wear.
8.3.13. Particular attention should be paid to the conformity of the passport data on the steel grades from which the load-bearing metal structures of the lifting structure are made to the actual ones. If the metal structure has undergone repairs, then the choice of steels for repair must meet the requirements of the current NTD for the range of temperatures for using steels.
8.3.14. Repair solutions used to restore the strength (stability, stiffness, etc.) of an element damaged by a crack or permanent deformation must correspond to typical repair solutions for this type of damage. In places with a high concentration of stresses in tensile elements (for example, in the axle units of the end girders of overhead cranes), solutions with simple cutting of edges and subsequent welding of the detected cracks should not be used to repair cracks. In such cases, it is imperative to use additional linings (reinforcements) that reduce the level of stress concentration after the completion of the repair of the damaged element; otherwise, the repair solution should be rejected.
8.3.15. Repair solutions (both design and technological) used to restore the strength (stability, stiffness, etc.) of a fractured or permanent deformation element of a metal structure made of high-strength steel 26 should be comprehensively justified in the Safety Justification document, stored together with crane passport.
8.4. Checking the condition of mechanical equipment
8.4.1. Works on checking the state of nodes and mechanisms of the substation include:
assessment of the compliance of the installed equipment with operational documents;
external examination in order to analyze the general condition, performance and the need for further measurements;
making the necessary measurements.
8.4.3. An external examination reveals:
Completeness and general technical condition of all mechanisms, damage to their individual units and parts;
Lack of deformation, corrosion, as well as the subsequent need to eliminate them;
No grease leakage;
Correspondence of installation of components of mechanisms (for example, brakes
Availability and technical condition of safety devices (casings, covers, etc.).
The need for additional disassembly of mechanisms during inspection is determined by the commission.
8.4.4. Damage revealed by external inspection should be measured. The measurement result is compared either with the size where there is practically no defect, or with the size indicated in the drawing.
The need for measurements can be determined during running-in and testing by indirect signs (noise, grease leakage, unit temperature rise, etc.).
8.4.5. The presence of grease in the gearboxes is checked using a dipstick, oil plugs, peepholes, or through a hatch in the cover.
8.4.6. When checking mechanisms, you should pay attention to:
cracks in gearbox housings, brake levers, pulleys, pads;
breakage of brake springs;
wear of gearing;
wear of running wheels and their positioning;
the presence of backlash in couplings, hinged and keyed joints;
completeness and fastening of bolted joints, especially rotary bearings;
correct installation of brakes, couplings, gearboxes, drums;
correct adjustment of the brakes;
misalignment of the rotary support.
8.4.8. The final check of the mechanisms operability shall be carried out during static and dynamic tests of the lifting structure. At the same time, the following are checked: smooth operation and reliability of holding the mechanisms by brakes, absence of beating of pulleys, blocks and drums, operability and reliability of operation of the slewing ring, nature of noise and temperature in gearboxes, motors, correct operation (installation) of wheels for rail cranes support races, etc.
8.5. Checking the condition of the rope-block system
8.5.1. The following damages are typical for rope-block systems of lifting structures:
cracks and chips of block flanges;
wear along the stream or flange of blocks and drums;
absence and / or leakage of lubricant in bearings;
defects (damage) in the ropes;
absence (damage) of the locking bar in the hook suspension;
displacement in the installation of blocks of the chain hoist system;
deviation from the project in stocking and / or sealing the ends of the rope.
8.5.3. Intensively working sections of the rope, passing through the largest number of blocks or located on equalizing blocks, are more likely to be subject to wear and wire breakage.
Ropes for hoisting structures transporting molten metal and others dangerous goodsmust be subject to mandatory magnetic flaw detection.
8.5.4. Both the places of fastening the ropes on the drums and on the structures of lifting structures are subject to compulsory control. In these places, you should pay attention to the number, conformity of standard sizes and quality of tightening of fasteners.
8.5.5. Hooks and other lifting devices must comply with the passport characteristics and bear the appropriate markings from the manufacturers. In the process of testing the lifting structure, load-gripping bodies (grabs, grippers, electromagnets) are subjected to special tests. The results of these tests (with the load-handling device installed on the substation at the time of the tests) are entered into the PS test report.
8.5.6. Ropes, blocks, drums and hooks should be checked using the maximum rejection rates for elements of lifting structures given in the operational documentation and NTD.
8.5.7. During static and dynamic tests of the lifting structure, the rope-block system is checked for:
correct rope storage;
no beating of blocks and drums;
the correct winding of the rope on the drum;
the reliability of holding the test load with the subsequent check of the condition of the rope and its attachment points to the drum or metal structure of the lifting structure.
Technical diagnostics - area of \u200b\u200bknowledge, covering the theory, methods and means of determining the technical state of the object. The purpose of technical diagnostics in the general maintenance system is to reduce the volume of costs at the stage of operation through targeted repairs.
Technical diagnostics - the process of determining the technical condition of the object. It is subdivided into test, functional and express diagnostics.
Periodic and planned technical diagnostics allows:
carry out incoming control of units and spare units when purchasing them;
to minimize sudden unplanned shutdowns of technical equipment;
manage equipment aging.
Comprehensive diagnostics of the technical condition of the equipment makes it possible to solve the following tasks:
to carry out repairs according to the actual state;
increase the average time between repairs;
reduce the consumption of parts during the operation of various equipment;
reduce the amount of spare parts;
reduce the duration of repairs;
improve the quality of repairs and eliminate secondary breakdowns;
extend the life of operating equipment on a strict scientific basis;
to increase the safety of operation of power equipment:
reduce the consumption of fuel and energy resources.
Test technical diagnostics - this is diagnostics, in which test influences are applied to the object (for example, determining the degree of wear of the insulation of electrical machines by changing the tangent of the dielectric loss angle when voltage is applied to the motor winding from the AC bridge).
Functional technical diagnostics - this is diagnostics, in which the parameters of an object are measured and analyzed during its operation but for its intended purpose or in a special mode, for example, determining the technical condition of rolling bearings by changing vibration during operation of electrical machines.
Express diagnostics - this is diagnostics based on a limited number of parameters for a predetermined time.
Object of technical diagnostics - a product or its component parts subject to (subject) diagnostics (control).
Technical condition - this is a condition that is characterized at a certain point in time under certain environmental conditions by the values \u200b\u200bof the diagnostic parameters established by the technical documentation for the object.
Technical diagnostic tools- equipment and programs with the help of which diagnostics (control) is carried out.
Built-in technical diagnostics - these are diagnostic tools that are an integral part of the object (for example, gas relays in transformers for a voltage of 100 kV).
External devices for technical diagnostics - these are diagnostic devices made structurally separate from the object (for example, a vibration control system on oil transfer pumps).
Technical diagnostics system - a set of tools, objects and performers required to carry out diagnostics according to the rules established by the technical documentation.
Technical diagnosis - the result of diagnosis.
Prediction of technical condition it is a determination of the technical state of an object with a given probability for the forthcoming time interval during which the operable (inoperative) state of the object will remain.
Algorithm for technical diagnostics - a set of prescriptions that determine the sequence of actions during the diagnosis.
Diagnostic model - a formal description of the object, which is necessary for solving diagnostic problems The diagnostic model can be presented as a set of graphs, tables or standards in the diagnostic space.
There are various methods of technical diagnostics:
It is implemented using a magnifying glass, endoscope, and other simple devices. This method is used, as a rule, constantly, conducting external inspections of equipment during its preparation for work or in the process of technical inspections.
Vibroacoustic method implemented with various vibration measuring instruments. Vibration is evaluated by vibration displacement, vibration velocity or vibration acceleration. The technical condition assessment by this method is carried out by general level vibration in the frequency range 10 - 1000 Hz or by frequency analysis in the range 0 - 20000 Hz.
Implemented with. Pyrometers measure temperature in a non-contact way at each specific point, i.e. to obtain information about the temperature zero it is necessary to scan the object with this device. Thermal imagers allow you to determine the temperature field in a certain part of the surface of the diagnosed object, which increases the efficiency of detecting incipient defects.
Acoustic emission method based on the registration of high-frequency signals in metals and ceramics when microcracks occur. The frequency of the acoustic signal varies in the range of 5 - 600 kHz. The signal appears at the moment of microcracking. At the end of the crack development, it disappears. As a consequence, when using this method apply various methods of loading objects in the process of diagnostics.
The magnetic method is used to detect defects: microcracks, corrosion and breakages steel wires in ropes, stress concentration in metal structures. The concentration of stress is detected using special devices, which are based on the principles of Barkhaussen and Villari.
Partial discharge method It is used to detect defects in the insulation of high-voltage equipment (transformers, electrical machines). The physical basis of partial discharges is that local charges of different polarity are formed in the insulation of electrical equipment. A spark (discharge) arises with charges of different polarities. The frequency of these discharges varies in the range of 5 - 600 kHz, they have different power and duration.
There are various methods for registering partial discharges:
method of potentials (partial discharge probe Lemke-5);
acoustic (high-frequency sensors are used);
electromagnetic (partial discharge probe);
capacitive.
To detect defects in the insulation of station synchronous generators with hydrogen cooling and defects in transformers for a voltage of 3 - 330 kV, it is used gas chromatographic analysis... When various defects occur in transformers, various gases are released in the oil: methane, acetylene, hydrogen, etc. The proportion of these gases dissolved in the oil is extremely small, but nevertheless there are devices (chromatograms) with the help of which these gases are detected in transformer oil and the degree of development of certain defects is determined.
To measure the tangent of the dielectric loss angle in isolation in high-voltage electrical equipment (transformers, cables, electrical machines), a special device is used -. This parameter is measured at voltage supply from nominal to 1.25 nominal. With good technical condition of the insulation, the dielectric loss tangent should not change in this voltage range.
Graphs of changes in the tangent of the angle of dielectric losses: 1 - unsatisfactory; 2 - satisfactory; 3 - good technical condition of insulation
In addition, the following methods can be used for technical diagnostics of electric machine shafts, transformer housings: ultrasonic, ultrasonic thickness measurement, radiographic, capillary (color), eddy current, mechanical testing (hardness, tension, bending), X-ray flaw detection, metallographic analysis.
Gruntovich N.V.
Approved
Chief Engineer
LLC "Gazmenergodiagnostika"
A.V. Avdonin
12 February 2004
Technique for technical diagnostics of the electric drive of gas-pumping units of the organizations of OAO Gazprom
Signed
Head of Diagnostics Department
electrical machines V.V. Rytikov
1. GENERAL PROVISIONS ON TECHNICAL DIAGNOSIS OF ELECTRIC MOTORS OF GAS PUMPING UNITS
1.1. Purpose of the Method.
1.1.1. This Methodology should be guided by the diagnostic examination of the operated and commissioned electric motor. Electric motors that have worked out the minimum resource established by the standard must undergo a comprehensive survey, covering both main and auxiliary elements.
1.1.2. The technique provides for a diagnostic examination, which, as a rule, does not require the removal of the electric motor for repair and allows one to determine the degree of development and the danger of possible defects in the early stages.
1.1.3. The Methodology contains a list of diagnostic work and the maximum permissible values \u200b\u200bof the controlled characteristics. The technical condition of the electric motor is determined not only by comparing the results with standardized values, but also by the totality of the results of all tests, inspections and operating data. The results obtained in all cases should be compared with the results of measurements on the same type of equipment. However, the main thing is to compare the measured values \u200b\u200bof the parameters of the electric motor with their initial values \u200b\u200band assess the differences that take place according to the permissible changes specified in the Methodology. Parameter values \u200b\u200bexceeding the established limits (limit values) should be considered as a sign of the occurrence and development of damage (defects), which can lead to equipment failure.
1.1.4. As the initial values \u200b\u200bof the monitored characteristics when commissioning a new electric motor, the values \u200b\u200bspecified in the passport or factory test protocol are taken. When diagnosing electric motors during operation, the parameter values \u200b\u200bdetermined during the commissioning of a new electric motor are taken as initial values. The quality of the repairs carried out is assessed by comparing the results of the inspection after the repair with the data during the commissioning of a new electric motor, taken as initial data. After a major overhaul or refurbishment, as well as reconstruction carried out at a specialized repair enterprise, the values \u200b\u200bobtained after the completion of the repair (reconstruction) are taken as the initial values \u200b\u200bfor monitoring during the further operation of the electric motor.
2. TECHNICAL DIAGNOSIS OF ELECTRIC MOTORS OF GAS PUMPING UNITS
2.1. Indicators and characteristics of technical diagnostics.
2.1.1. Frequency of diagnosis. Technical diagnostics are carried out after the service life established by the normative and technical documentation has expired in order to assess the condition, establish the terms of further work and operating conditions, as well as after major repairs.
2.1.2. Duration of diagnosis. Diagnostic examination of the electric motor is carried out in the amount established by this Methodology.
2.2. Characteristics of the nomenclature of diagnostic parameters.
The diagnostic parameters listed below are the main ones in determining the technical condition of the electric motor, while the examination of auxiliary elements, the state of which is not a determining factor in assessing the technical condition of the electric motor and deciding on the possibility of its further operation, can, as a rule, be carried out in volumes and evaluated according to the criteria specified in the documents mentioned. Auxiliary elements are relatively cheap and, if they are faulty, can be replaced without much difficulty or, if possible, restored.
2.2.1. Nomenclature of parameters of the technical condition of the electric motor.
When carrying out diagnostics, such parameters of an electric motor are recorded as: insulation resistance of stator and rotor windings, absorption coefficient, resistance of stator and rotor windings, under-chair insulation resistance, vibration velocity, level of partial discharges, results of visual inspection, presence or absence of short circuits in active steel sheets.
2.2.2. Depth of search for the place of failure or malfunction:
With a low value of insulation resistance - the reason for the decrease or the place of insulation breakdown;
In the presence of closures of sheets of active steel - the location and nature of the closure;
With an increased value of vibration velocity - the cause of increased vibration;
If there is a high level of partial discharges, this is the reason for the increase in the level of discharges.
2.3. Rules for measuring diagnostic parameters.
2.3.1. Scope of work during the diagnostic examination of the electric motor:
1) Preliminary collection of information:
Analysis of operating experience, repairs and test results of an electric motor, clarification on this basis of engine elements that require special attention during inspection;
General inspection of the electric motor and its auxiliary elements.
2) Tests on a rotating machine:
Assessment of the vibration state based on the measurement and analysis of the vibration spectrum of the electric motor under load.
Simultaneously with the vibration tests, the data of the standard thermal control are recorded.
3) Work on a stopped machine:
Preliminary preparation (performed by the personnel of the customer's enterprise);
Measurement of resistance of stator, rotor and exciter windings to direct current;
Measurement of insulation resistance of stator and rotor windings and bearing insulation;
Visual and endoscopic examination of the stator and rotor;
High-voltage testing of stator windings with power frequency voltage with control of partial discharges;
Checking the condition and (if necessary) testing the stator core steel;
Visual and endoscopic examination of the pathogen.
4) Registration of examination results:
Drawing up a preliminary report;
Registration of an electric motor passport.
2.3.2. The collection and analysis of information about the history of the operation of the electric motor is necessary for a preliminary assessment of its technical condition. Engine data are entered in the appropriate sections of the diagnostic card (Appendix 1) and the motor passport. The following engine information should be used:
1) Design documentation for the engine:
Engine's type;
Factory number;
Year of manufacture;
Rotor serial number;
Stator serial number;
Phase connection;
Rated active power;
Rated apparent power;
Rotor rated current;
Stator rated current;
Rated speed;
The ratio of the rated value of the initial starting torque to the rated torque;
The ratio of the rated value of the initial starting current to the rated current;
The ratio of the nominal value of the maximum temporary torque to the nominal torque;
Efficiency;
Power factor;
Heat resistance class of stator insulation.
2) Factory measurements:
Insulation resistance of the stator winding relative to the motor housing and between phases at 20 ° C;
Phase resistance of the stator winding at constant current in a cold state at 20 ° C;
Average air gap (one-sided);
Resistance of the rotor winding at constant current in a cold state;
Insulation resistance of the rotor winding relative to the body at a temperature of 20 ° C;
Insulation resistance of the rotor winding relative to the housing at a temperature of 100 ° C.
3) Operational documentation and protocols of routine measurements and tests:
Commissioning year;
Acceptance test data (for items similar to factory measurements);
Statistics of measurements of insulation resistance and resistance of stator and rotor windings, carried out during repair and testing of the motor;
Date, type of test and result obtained;
Number of starts;
Engine operating time, including after major repairs.
4) Repair log:
Failures and emergency shutdowns, their causes;
Date, type of repair (preventive, capital, emergency recovery, etc.), a short list of the work performed;
Information about the replacement of individual elements.
5) Wiring diagram for connecting the motor.
2.3.3. Assessment of the vibration state of the electric motor.
The vertical and lateral vibration components measured on the bearings of electric motors coupled with mechanisms should not exceed the values \u200b\u200bspecified in the factory instructions. In the absence of such instructions, the maximum permissible vibration amplitude of bearings (according to Table 31 of Appendix 3.1 PTEEP) is 50 µm at a synchronous frequency of 3000 rpm.
2.3.4. Data of regular thermal control.
The readings of all standard temperature control devices are recorded.
In most cases, the temperature is controlled:
In the hottest part of the stator core (in each phase, one resistance thermocouple is placed on the bottom of the groove - "Steel" and between the layers of the winding - "Copper");
Cooling air at the fan inlet;
Hot air leaving the stator;
Liner in plain bearings.
Temperature control of the bearing shells is carried out by resistance thermocouples, which must be connected to a continuous automatic control device.
The temperature of the stator winding of class "B" in operation should not exceed 80 ° C.
2.3.5. The measurement of the resistance of the stator and rotor windings to direct current is performed by a digital microohmmeter with recording the temperature of the windings.
When making measurements, each resistance must be measured at least three times. The arithmetic mean of the measured values \u200b\u200bis taken as the true resistance value. In this case, the result of an individual measurement should not differ from the average by more than ± 0.5%.
When comparing resistance values, they should be brought to the same temperature (20 ° C). When measuring the resistances of each phase of the stator winding, the winding resistance values \u200b\u200bshould not differ from each other by more than 2%. The results of measuring the resistances of the same phases should not differ from the initial data by more than 2%.
When measuring the resistance of the rotor winding, the measured resistance value should not differ from the initial data by more than 2%.
2.3.6. Measurement of the insulation resistance of the stator windings, rotor and bearing insulation is carried out with a megohmmeter with a voltage of 2500/1000/500 V.
Insulation resistance measurement should be carried out for each winding. In this case, the rest of the windings must be electrically connected to the machine body. At the end of the measurements, the winding must be discharged by connecting it electrically to the grounded machine body. The duration of the connection of the winding with the body must be at least 3 minutes.
Megohmmeter voltage when measuring insulation resistance:
a) stator winding - 2500 V;
b) rotor winding - 500 V;
c) bearings - 1000 V.
The measurement of the insulation resistance of the motor under test is carried out in a practically cold state;
Allowable insulation resistance values \u200b\u200b(according to PTEEP):
a) the stator winding relative to the housing and between phases not less (at t \u003d 75 ° C):
10 MOhm for motor with U n \u003d 10 kV,
6 MOhm for motor with U n \u003d 6 kV;
The value of the absorption coefficient R 60 / R 15 at a temperature from 10 ° C to 30 ° C is not less than 1.2;
b) rotor winding relative to the body - not less than 0.2 MΩ.
c) bearings - not standardized.
When measuring the insulation resistance to determine the absorption coefficient (R 60 " / R 15 " ), the count is performed twice: 15 and 60 seconds after the start of measurements.
Comparison of insulation characteristics should be carried out at the same temperature or close to its values \u200b\u200b(discrepancy not more than 5 ° С). If this is not possible, the temperature recalculation must be carried out in accordance with the operating instructions. specific types electrical equipment.
2.3.7. Visual inspection of the electric motor is carried out in accordance with GOST 23479-79 and RD 34.10.130-96 using a flexible technical endoscope.
A visual inspection is carried out on an electric motor taken out for repair with the end caps and diffusers removed, without the rotor outlet.
Places subject to inspection and technical condition assessment:
Stator:
1. When examining the frontal parts near the exit of the sections from the grooves, the following are assessed:
Gaps between the frontal parts of the upper and lower half-section of one groove and the presence of abrasion of the insulation in the event of closing the gaps;
Extension of the interlayer gasket from the groove;
Cleanliness of the gaps between the frontal parts of the rods of adjacent grooves;
The degree of swelling of mica compound compounded insulation;
The degree of extrusion of the bitumen compound from the mica insulation;
The degree of leaching of the bitumen compound from mica insulation;
The condition of the frontal struts;
Curvature of the rods at the exit from the groove;
The state of the semiconducting coating, the presence of its damage and determination of the areas of damage.
2. When examining the frontal parts of the rods in the involute sections, the following are assessed:
The presence or absence of gaps between adjacent frontal parts;
The presence and depth of abrasion of insulation by spacers;
Squeezing out the bitumen compound in the places where spacers are installed, drips of dissolved bitumen;
The presence and degree of abrasion of insulation on interlayer calculations;
The presence and degree of abrasion of the insulation of the lower rods on the shroud rings;
The presence of dirt on the frontal parts;
Signs of insulation overheating (discoloration, presence of "icicles" of the bitumen compound).
3. When examining the frontal attachment system, the following are assessed:
Basket slack (gaps between brackets and retaining rings);
Loosening of the bracket mounting bolts;
Weakening of the cords of the lower frontal parts to the bandage rings;
Weakening or breakage of the cord ties of the upper frontal parts;
Drop-out or displacement of spacers;
Traces of vibration of the retaining rings relative to the brackets.
4. When examining the heads of the frontal parts, the following is assessed:
Color change of insulation.
5. When examining the end part of the core, the following are assessed:
Pressure plates, pressure fingers and riveted to the last segments of the outermost packs of active steel;
Contamination on the crowns of the teeth and along the pressure fingers;
Deformation of active steel segments in the channels of the outer packs;
Fluffing and chipping of tooth segments.
6. When inspecting the stator bore, the following are assessed:
End wedge offset;
The nature of the weakening of the groove wedges.
7. When inspecting the stator backrest, the following is assessed:
The presence of contamination;
Ferromagnetic dust along the prisms.
8. When examining the connecting bars, the following are assessed:
The presence of gaskets and pads;
Lace tying breaks;
Abrasion of insulation and pads in brackets;
Tire mobility;
Violation of the brackets;
Signs of increased heating;
Violation of the enamel layer covering the tire insulation.
Criteria for establishing the stator state:
Efficient - the examination revealed individual defects that do not interfere with further operation and are easily eliminated by the customer's enterprise, among such defects, in particular, it is possible to indicate: weakening of the fastening of the stator connecting buses, the presence of local contact of the connecting buses, signs of mobility of spacers, dustiness of the front parts the presence of foreign objects, slight damage to the insulation of the frontal parts and connecting buses.
Inoperative condition - the examination revealed one or more of the following defects that impede operation and need to be eliminated: the presence of serious violations of the insulation of the frontal parts or connecting buses, the sagging of the basket of the frontal parts, the presence of signs of swollen insulation, the loss of slot wedges, the presence of signs of sintering insulation in the interphase zones, poor knitting of the frontal parts.
Limit state - during examination, one of the following defects was found: violation of the integrity of the insulation by the edge of the pressure pin at the exit from the groove, signs of mobility of the groove wedges.
On the rotor:
1. When examining the groove part, the following are evaluated:
The external state of the groove wedges;
Signs of mobility of slot wedges;
Covering enamel condition;
Presence of local wedge melting.
2. When examining the winding frontal parts, the following are assessed:
Contamination of insulating parts;
Dustiness of the frontal parts;
The integrity of the coil insulation;
The degree of shortening of the turns;
The presence of foreign objects.
3. When inspecting the current leads to the slip rings and to the frontal parts of the winding, the following are assessed:
Cracks, tears, cuts, scratches on the top plate;
Condition of thread for live bolts.
4. When examining the end parts of the rotor:
Condition of fastening of balancing weights;
Condition of the surface of the rotor necks;
Signs of axial displacement of the rotor due to axial misalignment;
Signs of weakening of the fit of the elements on the rotor shaft.
Criteria for establishing the state of the rotor:
Serviceable - no defects were found during examination.
Efficient - the examination revealed individual defects that do not interfere with further operation and are easily eliminated by the customer's enterprise, among such defects, in particular, one can indicate: loosening of fastening, signs of mobility of slot wedges, contamination of insulating parts, severe dustiness of the frontal parts, the presence of foreign objects, poorly secured balance weights.
Inoperative state - the examination revealed one or more of the following defects that impede operation and need to be eliminated: the presence of local melting of wedges or a shroud ring, violation of the integrity of the coil insulation, axial displacement of the rotor, weakening of the fit of elements on the rotor shaft.
Limit state - during the examination, one of the following defects was found: fatigue cracks on the rotor neck, significant mobility of the rotor wedges, the presence of pits and discoloration on the rotor wedges.
By pathogen:
1. For brushless exciters:
Signs of loosening of the exciter on the shaft;
The state of soldering "cockerels";
Insulation condition of stator connecting bars.
2. For static pathogens:
Surface condition of slip rings;
The condition of the brushes.
Criteria for establishing the state of the pathogen:
Serviceable - no defects were found during examination.
Efficient - the examination revealed individual defects that do not interfere with further operation and are easily eliminated by the customer's enterprise, among such defects, in particular, one can indicate: weakening of the fastening of the pathogen landing on the shaft, violation of the insulation integrity of the connecting bus bars of the exciter stator, signs of violation of the soldering of the "cockerels" , violation of the brush-contact mechanism.
Inoperative condition - the examination revealed one or more of the following defects that impede operation and need to be eliminated: signs of destruction of the coils of the exciter stator "shoes".
Limit state - during the examination, one of the following defects was found: fatigue cracks on the contact pad.
2.3.8. Measurement of partial discharges (PD) in the insulation of stator winding sections.
1) The equipment for PD measurements consists of a sensor for measuring high-frequency PD pulses, a partial discharge recording device and a test setup (modular or compact), consisting of:
From a high-voltage stand - at least 1000 VA;
Test voltage regulator - appropriate power;
Measuring instruments - 50 A ammeter, static kilovoltmeter for direct measurement of test voltage;
Current cut-off relay (selected by the value of the current from the low side when the test voltage is applied);
A device that provides a visible break in the supply circuit.
During testing, the PD recorder operates in a single-channel mode. For each phase of the motor, a PD signal is recorded using an inductive sensor located on the cable connecting the test setup and the stator winding. For each phase, two tests are carried out, one with voltage applied from the zero terminal side and one - from the linear side.
According to the mechanism of formation, the following types of discharges are distinguished: internal PD (in the thickness of the insulation), slot discharges (discharges from the surface of the coil insulation to the wall of the slot), sliding discharges and corona of the frontal parts.
An approximate view of oscillograms of various types of discharges, the ratio of their comparative amplitude and position relative to the voltage sinusoid are shown in Fig. 1.
Figure: 1. Sample oscillograms different types discharges in the insulation of electrical machines
1 - sliding discharges; 2 - slot discharges; 3 - discharges in the internal cavities of the insulation;
4 - crown
2) Procedure for PD measurement.
3) The insulation resistance of the stator windings of the electric motor is measured and the absorption coefficient is calculated to make a decision on the possibility of carrying out high-voltage tests. A circuit is being assembled for testing the stator winding with an increased voltage of 50 Hz from an external source (Fig. 2).
Figure: 2. PD measurement circuit
R - partial discharge recording device, sensor - electromagnetic sensor
4) Voltage is applied to one of the phases of the stator winding, while the other phases are grounded. The test voltage rating is set as phase U fn voltage and can be lowered if a defect is suspected. If necessary, the phase of the winding can be tested in accordance with the current "Standards for testing electrical equipment".
For each phase, two measurements are carried out when voltage is applied - from the side of zero and line terminals.
5) At the end of the measurements in the first phase, the voltage is removed, applied to another phase, and the operations according to PP. 3) and 4) are repeated.
6) Upon completion of all measurements, the analysis of the measurement results is carried out, presented in the form of parametric diagrams of the following form (Fig. 3), in which the electric phase of the test voltage is deposited horizontally, and the pulse charge in pC is plotted vertically.
| Permissible discharge level< 0,05 | |
| Permissible discharge level< 0,3 | |
| Permissible discharge level 0.3 - 0.6 | |
| Permissible discharge level\u003e 0.6 |
Figure: 3. Permissible PD levels
At the end of all measurements, the analysis of the measurement results is carried out, presented in the form of parametric diagrams, in which the electric phase of the test voltage is plotted horizontally, and the pulse charge in pC is plotted vertically. The bit density is shown using a color scale.
CR assessment criteria:
In zone "3" (internal discharges) the following discharge levels are allowed:
- "red" zone (low level of discharges in PC) - discharge density - any;
- "yellow" zone (average level of discharges in pc) - the density of discharges should not exceed 0.6 · N/period;
- "green" zone (high level of discharges in PC) - the density of discharges should not exceed 0.3 · N/period,
where N - the number of discharges of this level at a given phase.
Exceeding the indicated values \u200b\u200bof the discharge density for the zones described above indicates the possible presence of an insulation defect (electrical or thermal aging, etc.). The conclusion about the possibility of operating the winding in this case is given taking into account the magnitude and density of the discharges outside the specified zones.
The presence of partial discharges with a density of more than 0.05 N/ period in zones 1 (creeping discharges), 2 (groove discharges) and 4 (corona discharges) indicates the presence of insulation defects. The conclusion about the possibility of operating the motor winding is given based on the magnitude and density of the discharges in the indicated zones and according to the results of visual inspection (corona rate).
2.3.9. Monitoring the state of insulation of sheets of active steel and identifying areas with increased local losses by the electromagnetic control method (EMC) (Fig. 4).
EMC of the stator core includes:
Measurements on packets of the induced annular magnetic flux voltage;
Carrying out measurements on all teeth of the stator bore;
Based on the measurements, identification of active steel teeth with increased additional losses, and localization of the fault location.
Figure: 4. Scheme of carrying out electromagnetic control of insulation of sheets of active steel
EMC is carried out when performing repairs with a rotor outlet.
The method is based on the location of the magnetic flux with the ring magnetization of the core with an induction of 0.02-0.05 T. Defective areas are identified by the distortion of the electromagnetic field in the area of \u200b\u200bsheet closing.
A specialized sheet closure detector is used for measurement.
2.4. Technical diagnostic tools.
2.4.1. The megohmmeter should be with 500/1000/2500 V supply voltage classes, measure the insulation resistance in the range from 50 kOhm to 100 GOhm.
2.4.2. The microohmmeter should provide resistance measurement in the range from 1 · 10 -3 to 1 Ohm incl.
2.4.3. The technical flexible endoscope is designed to inspect the internal cavities of the controlled products and objects in hard-to-reach places. The illuminator of the endoscope must provide illumination of the controlled surface of at least 1300 lux at a distance of 50 mm.
2.4.4. The partial discharge recorder is designed to register sliding and corona partial discharges; it must have a range of registered partial discharges of 85 Db.
2.4.5. Requirements for the vibration meter. The device must meet the general technical requirements for equipment for measuring vibration parameters in accordance with GOST 30296.
2.5. Technical requirements for performing diagnostic operations.
2.5.1. When carrying out diagnostics, it is necessary to comply with all the requirements and instructions of the PUE, the Rules for the technical operation of electrical installations of consumers, Intersectoral rules for labor protection (safety rules) during the operation of electrical installations.
2.6. Operating modes of the electric motor during diagnostics.
2.6.1. Visual inspection, measurement of the insulation resistance of the stator, rotor and under-chair insulation, measurement of the resistance of the stator and rotor windings, measurement of the level of partial discharges, testing of the stator active steel are carried out in the stop mode of the electric motor.
2.6.2. The vibration state of the electric motor is assessed when the electric motor is running.
2.7. Safety requirements for diagnostics.
2.7.1. When measuring PD, assessing the vibration state, conducting visual and endoscopic examinations, EMC, measures are taken that meet the requirements of the current "Interindustry rules for labor protection (safety rules) during the operation of electrical installations" and "Rules for the technical operation of electrical installations of consumers", in particular:
General safety requirements in the performance of work on technical diagnostics of electric motors in accordance with sections 1 and 2 of "Interindustry rules for labor protection (safety rules) during the operation of electrical installations";
The organization of the work of the seconded personnel is carried out in accordance with section 12 "Interindustry rules on labor protection (safety rules) during the operation of electrical installations";
Technical measures to ensure the safety of work with stress relief in accordance with section 3 "Interindustry rules for labor protection (safety rules) during the operation of electrical installations";
Safety measures when working with an electric motor in accordance with paragraphs. 4.4, 5.1, 5.4 "Interindustry rules on labor protection (safety rules) during the operation of electrical installations" and clause 3.6 "Rules for the technical operation of electrical installations of consumers".
2.8. Processing of results.
2.8.1. The technical data of the tested electric motor required for issuing an opinion (passport data, place of installation, test results, visual and endoscopic examinations) are entered into the diagnostic card (Appendix 1).
2.8.2. The complete results of the survey are presented in the form of a certificate of the technical condition of an approved electric motor (Appendix 2).
2.9. Issuance of an opinion.
2.9.1. At the end of each stage of work - work performed on the engine in operation and work performed during repairs with the rotor being removed, a protocol is drawn up on site with the results of measurements and tests, an assessment of the technical condition of the monitored units, recommendations for eliminating and preventing subsequently identified defects and the issuance of an opinion, diagnosis. At the same time, the results obtained are analyzed and compared with the previous ones.
List of references
1. Rules for the technical operation of electrical installations of consumers, approved by order of the Ministry of Energy of Russia dated January 13, 2003, No. 6.
2. Rules for electrical installations, 7th edition. - M .: Glavgosenergonadzor of Russia, 2002.
3. Regulations on the system of technical diagnostics of equipment and structures of the power facilities of OAO Gazprom STO RD Gazprom 39-1.10-083-2003. - M .: JSC "Gazprom", 2004.
4. Volumes and standards of electrical equipment testing. RD 34.45-51.300-97, 6th edition. - M .: Publishing house of NTs ENAS, 2001.
5. Intersectoral rules for labor protection during the operation of electrical installations. POT R M-016-2001, RD 153-34.0-03.150-00. - M .: Publishing house of ENAS, 2001.
6. GOST 26656-85 Technical diagnostics. Traceability. General requirements.
7. GOST 27518-87 Diagnostics of products. General requirements.
8. GOST 20911-89 Technical diagnostics. Terms and Definitions.
Appendix 1
Typical diagnostic card
| Electric motor type | Unit No. | LPUMG | |||
| KS | |||||
| Date of examination | |||||
| Passport data of the electric motor | Wiring diagram for connecting the electric motor | ||||
| Head No. | |||||
| Manufacturing date | |||||
| Power | Act., KW | Full, kVA | |||
| Stator | For example, kV | Current, A | |||
| Excitation | For example, B | Current, A | |||
| Rotation frequency | rpm | ||||
| cos j | |||||
| Efficiency | % | ||||
| Insulation class | |||||
| Phase connection | |||||
| Nominal. operating mode | |||||
| Electric motor hours, hour | from the beginning of operation | after the last overhaul | |||||||
| Stator winding phase resistance, Ohm | |||||||||
| ra | rv | rc | |||||||
| Insulation resistance of the stator winding phases, MOhm | |||||||||
| Ra | Rv | Rc | |||||||
| rp | |||||||||
| Rp | |||||||||
| Bearing insulation resistance, MOhm | |||||||||
| Rп | |||||||||
| Vibration speed on the bearings of the electric motor, mm / s | |||||||||
| Bearing 1 | Bearing 2 | ||||||||
| Direction | In the 10-300 Hz band | 50 Hz | 100 Hz | In the 10-300 Hz band | 50 Hz | 100 Hz | |||
| Vertik. | |||||||||
| Cross. | |||||||||
| Axial | |||||||||
| Visual and endoscopic examination results | |||||||||
Appendix 2
Typical technical condition certificate
|
OPEN JOINT STOCK COMPANY "GAZPROM" |
||
| "I approve" ___________________ "___" ______________ 200 |
"Agreed" ___________________ "___" ______________ 200 |
|
|
THE PASSPORT TECHNICAL CONDITION OF THE ELECTRIC MOTOR |
||
| A type | ||
| Head number | ||
| Installation location | ||
| (as of __________________) | ||
| ___________________
"___" ______________ 200 |
___________________
"___" ______________ 200 |
|
|
(ELECTRIC POWER EQUIPMENT) |
|
| Content | |
| Form No. 1. Registration of works | |
| Form No. 2. Documentation used for issuing a passport | |
| Form No. 3. Passport data of the engine | |
| Form No. 4. Data of factory measurements and acceptance tests | |
| Form No. 5. General form engine | |
| Form No. 6. Wiring diagram of motor connection | |
| Form No. 7. Information on the operation, testing and repair of the engine | |
| Form No. 8. High-voltage tests of stator winding insulation with partial discharge measurement | |
| Form No. 9. Visual inspection of the stator | |
| Form No. 10. Visual inspection of the rotor | |
| Part 3. Survey results | |
| Form No. 11. Defects detected | |
| Form No. 12. Recommendations for repair and further operation. | |
| Conclusion | |
|
PASSPORT OF TECHNICAL CONDITION OF ELECTRIC MOTOR (ELECTRIC POWER EQUIPMENT) |
|
| Part 1. Documentary information Form No. 3. Passport data of the engine |
|
| Index | Engine data |
| A type | |
| Factory number | |
| Station No. | |
| Manufacturing plant | |
| Year of manufacture | |
| Commissioning year | |
| Rotor serial number | |
| Stator serial number | |
| Phase connection | |
| Rated active power, kW | |
| Rated apparent power, kVA | |
| Rotor rated current, A | |
| Nominal stator current, A | |
| Rated speed, rpm | |
| The ratio of the nominal value of the initial starting torque to the nominal torque | |
| The ratio of the rated value of the initial starting current to the rated current | |
| The ratio of the nominal value of the maximum temporary torque to the nominal torque | |
| Efficiency,% | |
| Power factor, cos j | |
| Insulation heat resistance class | |
|
PASSPORT OF TECHNICAL CONDITION OF ELECTRIC MOTOR (ELECTRIC POWER EQUIPMENT) |
|||
| Part 1. Documentary information Form No. 4. Data of factory measurements and acceptance tests |
|||
| Indicators | Factory measurements | Acceptance tests | Established norm |
| Insulation resistance of the stator winding relative to the motor housing and between phases at 20 ° C, MOhm | R ³ 105 MOhm | ||
| Phase resistance of the stator winding at a constant current in a cold state at 20 ° C, Ohm | |||
| Average air gap (one-sided), mm | The difference is not more than 10% of the average | ||
| Resistance of the rotor winding at a constant current in a cold state, at 20 ° C, Ohm | The difference is not more than 2% from the factory data | ||
| Insulation resistance of the rotor winding relative to the body at a temperature of 20 ° C, MOhm | More than 0.2 MOhm | ||
| Insulation resistance of the rotor winding relative to the body at a temperature of 100 ° C, MOhm | ¾ | ¾ | ¾ |
| Note: Standards according to RD 34.45-51.300-97 "Scope and norms of electrical equipment tests". Ed. 6.M .: ENAS, 1997. * R ³ 10 4 · U n - is used to detect gross defects in the insulation of a single phase. U n - rated voltage of the stator winding (V). |
|||
|
PASSPORT OF TECHNICAL CONDITION OF ELECTRIC MOTOR (ELECTRIC POWER EQUIPMENT) |
|
| Part 2. Control measurements and inspection Form No. 8. High-voltage tests of stator winding insulation with partial discharge measurement |
|
| Examination date: Testing and measuring equipment: |
|
| PD histograms for stator winding phases (pC). | |
| 1. Phase "A" | |
| Conclusion: | Conclusion: |
| 2. Phase "B" | |
| a) from the side of zero terminals | b) from the side of the line terminals |
| Conclusion: | Conclusion: |
| 3. Phase "C" | |
| a) from the side of zero terminals | b) from the side of the line terminals |
| Conclusion: | Conclusion: |
|
PASSPORT OF TECHNICAL CONDITION OF ELECTRIC MOTOR (ELECTRIC POWER EQUIPMENT) |
|
| Part 2. Control measurements and inspection Form No. 9. Visual inspection of the stator |
|
| Examination date: | |
| Insulation resistance phase "A", MOhm, R15 / R60 | |
| Insulation resistance phase "B", MOhm, R15 / R60 | |
| Insulation resistance phase "C", MOhm, R15 / R60 | |
| Winding resistance phase "A", Ohm | |
| Winding resistance phase "B", Ohm | |
| Winding resistance phase "C", Ohm | |
| Stator inspection | |
| Possible defects | |
| a) stator bore | |
| Looseness of groove wedges (3 pieces in a row or movable by hand) | |
| The presence of products of contact corrosion of the stator core | |
| Mechanical damage to the boring | |
| Weakening, chipping of teeth | |
| Active steel repair marks | |
| Signs of overheating of active steel | |
| Dust, rust | |
| b) the frontal parts of the stator winding | |
| Insulation damage by edge of the pressure pin | |
| Looseness of fastening of the frontal parts, the presence of products of abrasion of insulation, deformation of the frontal arches | |
| Signs of heat aging in insulation, signs of overheating | |
| Frontal contamination | |
| Charring insulation | |
| Sagging of the "basket" of the frontal parts | |
| Violation of head rations, signs of overheating of rations | |
| The presence of foreign objects | |
| c) output and connection buses | |
| Loose tire fastening | |
| Aging of busbar insulation | |
| Signs of abrasion in busbar insulation | |
| e) support insulators | |
| Pollution | |
| Cracks | |
| f) other, relatively rare defects | |
|
PASSPORT OF TECHNICAL CONDITION OF ELECTRIC MOTOR (ELECTRIC POWER EQUIPMENT) |
|
| Part 2. Control measurements and inspection Form No. 10. Visual inspection of the rotor |
|
| Examination date: | |
| Inspection tools: | |
| Rotor winding insulation resistance, MOhm | |
| Rotor winding resistance, Ohm | |
| Possible defects | Inspection results |
| Motor rotor | |
| Defects of rotor shaft journals | |
| Shroud ring defects | |
| Signs of loose fit of parts on the rotor | |
| Loosening of the winding wedge in the grooves | |
| Damage to the busbars | |
| Damaged slip rings | |
| Damage to the bandage insulation | |
| Rotor barrel damage | |
| Loss of spacers in the rotor cavity | |
1. General provisions on technical diagnostics of electric motors of gas-pumping units
1.1. The purpose of the technique
2. Technical diagnostics of electric motors of gas-pumping units
2.1. Indicators and characteristics of technical diagnostics
2.2. Characteristics of the nomenclature of diagnostic parameters
2.3. Rules for measuring diagnostic parameters
2.4. Technical diagnostic tools
2.5. Technical requirements for performing diagnostic operations
2.6. Modes of operation of the electric motor during diagnostics
2.7. Safety requirements for diagnostics
2.8. Processing results
2.9. Issuance of an opinion
List of references
Appendix 1. Typical diagnostic card
Appendix 2. Typical technical condition certificate
Technical diagnostics is a process of analysis, conclusion and conclusions about the technical condition of equipment, in which the degree of serviceability of a technical device is determined, through a comparative analysis of the data obtained with the parameters established in the technical documentation. According to GOST 20911-89, technical diagnostics is the determination of the technical condition of objects.
Technical diagnostics - the area of \u200b\u200bknowledge, covering the theory, methods and means of determining the technical state of objects.
The tasks of technical diagnostics are:
- technical condition control;
- search for a place and determination of the causes of failure (malfunction, defect);
- forecasting the technical condition.
Monitoring of the technical condition is carried out in order to check the compliance of the values \u200b\u200bof the parameters of the diagnostic object with the requirements of technical documentation, and on this basis, one of the types of technical condition is determined at a given time. The types of the technical condition of the diagnostic object are: serviceable, serviceable, defective, inoperative.
Working condition: the state of the diagnostic object, in which it meets all the requirements of the normative and technical and (or) design (project) documentation.
Working condition: the state of the object being diagnosed, in which the values \u200b\u200bof all parameters characterizing the ability to perform the specified functions meet the requirements of the normative-technical and (or) design (project) documentation.
Prediction of the technical condition is the determination of the technical condition of the diagnostic object with a given probability for the coming time interval. The purpose of predicting the technical condition is to determine with a given probability the time interval (resource) during which the operable (serviceable) state of the diagnostic object will remain.
When is technical diagnostics carried out?
Technical diagnostics using non-destructive and destructive testing methods is carried out:
- during operation within the service life, in cases established by the operation manual,
- when conducting a technical examination to clarify the nature and size of the identified defects,
- upon the expiration of the estimated service life of the equipment under pressure or after the exhaustion of the estimated resource of safe operation within the framework of industrial safety examination in order to determine the possibility, parameters and conditions of further operation of this equipment.
- at the end of the service life set by the manufacturer for lifting structures and equipment under pressure that are not subject to registration in Rostekhnadzor, in order to determine the residual service life, parameters and conditions for further safe operation.
How is technical diagnosis carried out?
Technical diagnostics of technical devices includes the following activities:
- visual and measuring control;
- operational (functional) diagnostics to obtain information about the state, actual operating parameters, actual loading of a technical device in real operating conditions;
- determination of acting damaging factors, damage mechanisms and susceptibility of the material of the technical device to damage mechanisms;
- assessment of the quality of connections of elements of a technical device (if any);
- selection of non-destructive or destructive testing methods that most effectively detect defects resulting from the impact of established damage mechanisms (if any);
- non-destructive testing or destructive testing of metal and welded joints of a technical device (if any);
- assessment of the identified defects based on the results of visual and measuring control, methods of non-destructive or destructive testing;
- research of materials of technical device;
- calculation and analytical procedures for assessing and predicting the technical state of a technical device, including an analysis of operating modes and a study of the stress-strain state;
- residual resource (service life) assessment;
Based on the results of technical diagnostics, a technical report is drawn up with the attachment of non-destructive testing protocols.
Who conducts technical diagnostics?
Works on technical diagnostics using non-destructive and / or destructive testing methods are carried out by laboratories certified in accordance with the Certification Rules and the basic requirements for non-destructive testing laboratories (PB 03-44-02), approved by the decree of the Federal Mining and Industrial Supervision of Russia dated June 2, 2000 city \u200b\u200bnumber 29.
LLC "Khimnefteapparatura" has its own certified laboratory of non-destructive testing and technical diagnostics, Certificate No. 91А070223, equipped with necessary equipment, instruments and measuring instruments, verified in accordance with the established procedure, staffed by level II non-destructive testing specialists, certified in accordance with PB 03-440-02 with the right to perform types of control:
- visual measuring,
- ultrasonic flaw detection,
- ultrasonic thickness measurement,
- penetrant control (capillary),
- magnetic (magnetic particle) control,
- acoustic emission control.
All specialists are certified by the Rostekhnadzor Commission for Industrial Safety in their respective fields. The staff was trained and allowed to work at heights from lifts and towers. The division includes specialists in geodetic control who have undergone specialized training.
LLC "Khimnefteapparatura" carries out technical diagnostics:
- boilers;
- pipelines;
7. Diagnostics of the technical condition of equipment
7.1. Basic principles of technical diagnostics
Diagnostics- a branch of science that studies and establishes the signs of the state of the system, as well as methods, principles and means by which a conclusion is made about the nature and essence of system defects without disassembling it and the system resource is predicted.
Technical diagnosticsmachines represents a system of methods and means used to determine the technical condition of a machine without disassembling it. With the help of technical diagnostics, it is possible to determine the state of individual parts and assembly units of machines, to search for defects that caused a stop or abnormal operation of the machine.
Based on the data obtained during diagnostics on the nature of the destruction of parts and assembly units of the machine, depending on the time of its operation, technical diagnostics makes it possible to predict the technical condition of the machine for the next period of operation after diagnosis.
The set of diagnostic tools, an object and performers acting according to established algorithms is called {!LANG-70b235475c44eeecc269a104604c7cf5!}
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