Processing Accuracy Problems in the User System in the Thermal Central of Skikda to Increase the Work of Drilling Machines

Transcription

1 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:14 No:06 54 Processing Accuracy Problems in the User System in the Thermal Central of Skikda to Increase the Work of Drilling Machines * Sami Mehennaoui (1), Lakhdar Khochemane (), Said Boutata (3) (1) () (3) Mechanical Engineering Department, University of Skikda, El Hadaiek Road, B. O. 6, 1000 Skikda, Algeria * address: sami.mehennaoui@gmail.com Abstract The principal aim of this paper is to Determine the reasons for the low reliability of the user system in thermal central of Skikda Algeria- that led to problems in the work of drilling machines which depends largely on electrical power. the first cause of the poor reliability of the system studied in Skikda is the aging of equipment, as it depends on the working conditions and the technical competence of intervention teams. The importance of this research is to prove that the aging of equipment is the first cause of poor reliability of the system studied in Skikda central and thus address the problem. Index Term Vibration Analysis, Feed Pump, Alternator, Poor Reliability, Aging Equipment, Wear, Drilling Machines. I. INTRODUCTION In 1951, Weibull has published an article concerning continuous probability law, The Weibull law is a special case of generalized extreme law as well as the Gumbel or Frechet laws [1]. The Maintenance is one of three technical business functions, between engineering and production. For long time considered as a source of cost and often limited to the maintenance of equipment, it now finds its rightful place as a source of profit. A well-organized maintenance avoids indirect costs related to waste, stops unforeseen machinery, excessive use of subcontracting. The objectives of production and maintenance are common. The predictive maintenance is based on vibration analysis, oil analysis and thermographic analysis with these three we may have a condition-based maintenance (predictive) very effective. We will demonstrate the methods and tools used in the central SONALGAZ of Skikda, and give the plans of all the monthly checks technicians for vibration analysis and oil analysis [6]. To assess the functional competence of our system, we chose ten items that share in two similar groups, each group contains five elements: -An alternator. - A main circulation pump (M.C.P) - Food pump. - A box of turbine oil. -A boiler. Each element of these five is of strategic importance [5]. Finally, we determine the reasons for the low reliability of the user system in thermal central of Skikda, and we proposed solutions. II. DIGITAL COMPUTING A feature of the reliability is the MTBF «Mean time between failures», the MTBF corresponds to the mathematical expectation of the random variable T, failure occurrence date. Availability is the probability that the device is serviceable, availability depends on the reliability and maintenance, according to the relation: Increase availability is a classic target of maintenance services, a device, started for the first time, inevitably falls down out of order at a time T: Complementary probability: (1) ( ) ( ) () ( ) ( ) (3) ( ) ( ) (4) ( ) ( ) (5) T: is a random variable with distribution function F (t), F (t i ): is the probability that the device is out of order at time t i, R (t i ): is the probability of correct operation at time t i. ( ) ( ) ( ) (6) The development of these data will be performed by the following equations [4]: ( )

2 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:14 No:06 55 ( ) ( ) ( ) TABLE II Mechanical results MTTR = (8) λ R F(%) MTBF(h) MTTR(h) D(%) All results are shown in the tables below: TABLE I Electrical result Electrical results Alt Alt pcp *10 ⁴ λ R F(%) MTBF(h ) MTTR(h ) D(%) pcp Alt *10 ⁵ aliment *10 ¹⁰ aliment *10 ¹⁰ Alt *10 ³ pcp pcp *10 ¹⁰ *10 ¹³ aliment1 Chaudr *10 ⁶ aliment Chaudr *10 ⁴ Chaudr Chaudr Fig. 1. Mounting system

3 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:14 No:06 56 TABLE III Boiler results TABLE IV Instrumentation λ R F(%) MTBF(h ) MTTR(h ) Alt 1 D(%) λ R F(%) MTBF(h) MT TR( h) D(%) Alt Alt pcp1 pc p Alt pcp pcp alime nt1 ali ment *1 0 ⁵.36*1 0 ³ aliment aliment C. a huile 1 C. a huile Chaudr Chaudr Chau dr1 Chau dr *1 0 ⁷ 9.9*10 ⁸ The tables below represent all electrical mechanical, instrumental failures and boiler during one year for the five elements. A. Alternator TABLE V Failures duration of Alternator CLASSE_INTER DESCRIPTION DURREE INST Alternator1 5h MECA Alternator1 7h ELEC Alternator1 h ELEC Alternator1 1h ELEC Alternator1 4h ELEC Alternator1 1h ELEC Alternator1 h ELEC Alternator1 1h MECA Alternator1 1h ELEC Alternator1 8h ELEC Alternator1 3h ELEC Alternator1 h ELEC Alternator1 1h ELEC Alternator1 3h ELEC Alternator1 h

4 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:14 No:06 57 B. Pump (MCP) TABLE VI Failures duration of Pump (MPC)) CLASSE_INTER DESCRIPTION DUREE ELEC Pump MCP1 48h CHAUDR Pump MCP1 8h MECA Pump MCP1 5h CHAUDR Pump MCP1 8h MECA Pump MCP1 4h MECA Pump MCP1 5h CHAUDR Pump MCP1 4h ELEC Pump MCP1 1h MECA Pump MCP1 5h MECA Pump MCP1 4h MECA Pump MCP1 4h INST Pump MCP1 h INST Pump MCP1 1h MECA Pump MCP1 4h MECA Pump MCP1 5h MECA Pump MCP1 4h C. FOOD PUMP D. Turbine body oil TABLE IX Failures duration of Turbine body oil CLASSE_INTER DESCRIPTION DUREE MECA oil turb1 3h INST oil turb1 1h MECA oil turb1 1h MECA oil turb1 1h MECA oil turb1 3h MECA oil turb1 h MECA oil turb1 h MECA oil turb1 5h MECA oil turb1 4h MECA oil turb1 1h MECA oil turb1 80h MECA oil turb1 5h MECA oil turb1 h MECA oil turb1 1h MECA oil turb1 4h MECA oil turb1 5h INST oil turb1 1h TABLE VII Failures duration of Food Pump CLASSE_INTER DESCRIPTION DUREE CHAUDR Food Pump N 1 7h MECA Food Pump N 1 13h MECA Food Pump N 1 4h MECA Food Pump N 1 15h MECA Food Pump N 1 30h MECA Food Pump N 1 3h MECA Food Pump N 1 18h MECA Food Pump N 1 15h CHAUDR Food Pump N 1 01h CHAUDR Food Pump N 1 8h CHAUDR Food Pump N 1 5h E. Boiler TABLE X Failures duration of Boiler CLASSE_INTER DESCRIPTION DUREE INST Boiler N 1 1h CHAUDR Boiler N 1 5h MECA Boiler N 1 1h MECA Boiler N 1 5h ELEC Boiler N 1 0h MECA Boiler N 1 h MECA Boiler N 1 h MECA Boiler N 1 1h CHAUDR Boiler N 1 8h MECA Boiler N 1 4h MECA Boiler N 1 3h CHAUDR Boiler N 1 7h CHAUDR Boiler N 1 6h CHAUDR Boiler N 1 7h CHAUDR Boiler N 1 5h

5 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:14 No:06 58 The graphs show the variation in the reliability and likelihood of failure of components with time: Fig. 5. Reliability and Probability of Failure of the MCP Pump Fig.. Reliability and Probability of Failure of the Alternator1 Fig. 3. Reliability and Probability of Failure of the Alternator Fig. 6. Reliability and Probability of Failure of the Food Pump1 Fig. 4. Reliability and Probability of Failure of the MCP1 Pump Fig. 7. Reliability and Probability of Failure of the Food Pump

6 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:14 No:06 59 Fig. 8. Reliability and Probability of Failure of the Turbine body oil1 Fig. 11. Reliability and Probability of Failure of the Boiler Fig. 9. Reliability and Probability of Failure of the Turbine body oil Fig. 1. Reliability and Probability of Electrical Failure of G1&G Fig. 10. Reliability and Probability of Failure of the Boiler1 Fig. 13. Reliability and Probability of Mechanical Failure of G1&G

7 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:14 No:06 60 Fig. 14. Reliability and Probability of Total Failure of G1&G Fig. 15. Reliability and Probability of Total Electrical Failure Fig. 16. Reliability and Probability of Total Failure of the System III. COMMENTS ON CHARTS The first thing we see is that all the elements, and the system in general goes to the state of aging over time, this implies that the reliability of the system will decrease and cause an increase in the probability of failure. We observe in all the figures that the curve graphs representing reliability increases when the rate of the failure λ takes small values. Fig.: The alternator 1 is available: electric side: 464 hours, mechanical side: 79 hours for the boiler side is available all year, and instrumental side: 5589 hours. For the total operation, it is available for 370 hours where at this moment the reliability is equal to the probability of failure, after this point the system is likely to be failing more than reliable. Fig.3: Alternator is available: electric side: 93 hours, mechanical side: 776 hours, boiler and instrumental side is available all year. For the total operation, it is available for 475 hours before it could be faulty. Fig.4: The main circulation pump 1 (MCP): Electric Side: 793 hours, mechanical side: 616 hours, boiler side: 1857 hours and the instrumental side: 793 hours. For the total operation, only 34 hours before it could be faulty. Fig.5: The main circulation pump (MCP): Electric Side available all year mechanical side: 1816 hours, 5588 hours boiler and instrumental (overlay) side. For the total operation, only 1088 hours before it could be faulty. Fig.6: Food Pump 1: Electric Side: 0 down, mechanical side: 60 hours, boiler side: 54 hours and the instrumental side: 794 hours. For the total operation, only 160 hours before it could be faulty. Fig.7: Food Pump : Electric Side: 887 hours, mechanical side: 58 hours, boiler side: 90 hours and the instrumental side: 5589 hours. For the total operation, only 178 hours before it could be faulty. Fig.8: Turbine body oil 1: electrical side: 0 failures, mechanical rating: 49 hours, boiler rating: 0 failures and the instrumental dimension: 186 hours. For the total operation, only 0 hours before it could be faulty. Fig.9: Turbine body oil : There are mechanical failures, so the total availability equal mechanical availability (188 hours). Fig.10: The boiler 1: electrical side: 96 hours, mechanical side: 46 hours, boiler side: 367 hours and the instrumental side: 5588 hours. For the total operation, only 160 hours before it could be faulty. Fig.11: The Boiler : Electric Side: 99 hours, mechanical side: 796 hours, boiler side: 344 hours and the instrumental side: 0 failures. For the total operation, only 188 hours before it could be faulty. Now for the fig.1-15 we will demonstrate the reliability and the probability of failure of each group: Fig.1 shows the reliability of the electrical side: G1 is available (77 hours), G is available too (399 hours).

8 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:14 No:06 61 Fig.13 shows the reliability of the mechanical side: G1 is available (8.48 hours), G is available too (87.4 hours). Fig.14 shows the total reliability of each group: G1 is available (43.89 hours), G is available (53.56 hours). In Fig.15 we show the total power reliability, mechanical, instrumental and boiler, and the total system reliability. And finally Fig.16 gives us an availability of hours [6]. IV. ANALYSIS OF WORK After all this study, we observe that the failures of mechanical side and boiler side represent the quasi-majority of failures, for each group or for the entire system as seen in the figures. Fig. 19. distributions and percentages of failures in the system V. CONCLUSION According to the study that we did, we find that the first cause of poor reliability of the system studied in Skikda central is the aging of equipment, it also depends on the conditions of work and the technical competence of intervention teams. Wherefore, in order to Treatment problems of necessary energy to run well drilling machines, we must change the equipment used in the central and bring new equipment as the efficiency of drilling machines [3]. Fig. 17. distributions and percentages of failures in group 1 Fig. 18. distributions and percentages of failures in group REFERENCES [1] Weibull W. A statistical distribution functions of wide applicability. J Appl Mech-Trans ASME, 1951; 18. [] Lewis E E. Introduction to Reliability Engineering. John Wiley and Sons, New York, [3] Khochemane L. Optimization of parameters of drilling machine with wheels,.university of Badji Mokhtar Annaba, 007. [4] Zine B, Benamara A, Study of the reliability of a drilling tool. University of boumerdes, 007. [5] Sadrati Hichem. Fault detection of pump by using vibration analysis. Skikda University, 007. [6] Mehennaoui Sami. Early detection of defects of a centrifugal pump by vibration analysis. Skikda University, 01. Mehennaoui Sami is a teacher at Department of Mechanical Engineering, PhD in Mechanical Engineering: Mechatronics option, enrolled at the University of 0/ August /1955 Skikda, he has got a state certificate engineer in industrial maintenance in 009, and a magister degree in 011 from Skikda university, he has also worked for a year as a Research Associate at the Research Unit for Industrial Technology URTI/CSC, Annaba. He has published a lot of research papers in reputed national and international journals and conferences. Lakhdar Khochemane is a Conference Master Class (A) since 006, teacher at the University of 0/ August /1955 Skikda, Department of Mechanical Engineering. He has State doctoral in drilling machinery. Said Boutata is an engineer in mechanics; he has got a state certificate engineer in 008 from Department of Mechanical Engineering (Skikda University).