Assarel-Medet Jsc Panagyurishte
APPENDIX No 1
ASSAREL-MEDET JSC – PANAGYURISHTE
Terms of reference
for assignment of services accomplishment
Concerning: Expansion of Intellinova System for Monitoring of the condition of the basic equipment (SPM) bearings in the Concentration Plant of ASSAREL – III-rd stage
- Current situation.
In 2009 in Concentration Plant ASSAREL wasfinished the first stage of the mounting and bringing into exploitation of “Intellinova System for Continuous Monitoring of the Rotating Parts” of SPM company. The System covers the following machines in the concentration plant:
●In Mill Workshop –the bearing of the driving shafts of ball mills МШЦ 4,5х6,0 and the slam pumps XR 350 to them;
●In Floatation Mill –floatation machines WEMKO 160 m3.
In 2012 in Concentration Plant ASSAREL was finished the second stage of the mounting and bringing into exploitation of “Intellinova System for Continuous Monitoring of the Rotating Parts” of SPM company. The System covers the following machines in the concentration plant:
●The bearings of the drums (driving, deflecting and tensioning), gear boxes and electric motors of the belt conveyors ПС-1 and ПС-2,МБ – 1, СТ – 1, Д – 6 and МБ – 2.
The mounted system works reliably. The continuous monitoring of the bearings allows summarizing of the obtained data and thereby making analysis and prognosis of the trends in the performance of a certain unit. The data is taken into consideration in preparing the plan –schedules for maintenance. Apart from this, the system shows problems with the bearings greasing, presence of loosen foundations and connecting bolts, pollutions, developing bearings problems as well as overloads leading to increase in the general vibrations of these machines. The early warning of developing problems allows the machines timely stop with the purpose of the necessary repair to be made (inadmissible increase in the operational temperatures of the bearings caused by problems with the greasing, intensive wear of the gear rings and pinions due to pollution or loosing and failure of thread joints).
- Volume of the service.
Accomplishment of the third stage of the equipment of rotating units, operating in ASSAREL Concentration Plant with a system for continuous monitoring of the bearings condition.
The expansion of the “Intellinova System for Continuous Monitoring of the Rotating Parts” of the SPM company to cover the bearings of the driving shafts of the mills MMC 7.0x2.3 from No1 to No5, the bearings to the impeller and the upper bearing to the belt pulley of 18 floatation machines Denver 1500 – 40 m3 IV row II-nd section, 12 floatation machines WEMKO – 40 m3, V row II-nd section, 14 floatation machines Denver 500 – 14m3 VI row II section, 5 floatation machines Denver 300 – 10m3 VI row II, the bearings of the tensioning drum of belt conveyor МБ2, bearings of the drums (driving and tensioning), gear box and electric motor of the belt conveyor ПВП – 1 and the bearings of the driving shafts of the regrind mills МШЦ 2,7х3,6 from No 1 to No 3.
- Technical conditions and requirements.
3.1Mills MMC 7.0x2.3 from No 1 to No 5 /located in Disintegration building/.
●Bearing to the coupling – 1 pc. VIB;
●Bearing to the free end – 1 pc. SPM.
Total for mills MMC 7.0x2.3:
●SPM sensor – 5 pcs.;
●VIB sensor – 5 pcs.
3.2Floatation machines Denver 1500 – 40 m3 IV row II section – 18 pieces /located in Floatation building /.
●Bearing to the impeller – 1 pc. SPM;
●Upper bearing to the belt pulley – 1 pc. VIB.
Total for floatation machines Denver 1500 – 40 m3:
●SPM sensor – 18 pcs.;
●VIB sensor – 18 pcs.
3.3Floatation machines WEMKO – 40 m3 V row II-nd section – 12 pcs. /located in Floatation building/:
●Bearing to the impeller – 1 pc. SPM;
●Upper bearing to the belt pulley – 1 pc. VIB.
Total for floatation machines WEMKO – 40 m3:
●SPM sensor – 12 pcs.;
●VIB sensor – 12 pcs.
3.4Floatation machines Denver 500 – 14 m3 VI row II-nd section – 14 pcs. /located in Floatation building/:
●Bearing to the impeller – 1 pc. SPM;
●Upper bearing to the belt pulley – 1 pc. VIB.
Total for floatation machines Denver 500 - 14 m3:
●SPM sensor – 14 pcs.;
●VIB sensor – 14 pcs.
3.5Floatation machines Denver 300 – 10 m3 VI row II-nd section – 5 pcs. /located in Floatation building/:
●Bearing to the impeller – 1 pc. SPM;
●Upper bearing to the belt pulley – 1 pc. VIB.
Total for floatation machines Denver 300 - 10 m3:
●SPM sensor – 5 pcs.;
●VIB sensor – 5 pcs.
3.6Belt conveyor МБ 2 /Located in Fine Crushing building/:
●Tensioning drum – right bearing – 1 pc. SPM;
●Tensioning drum – left bearing – 1 pc. SPM.
Total for belt conveyor МБ 2:
●SPM sensor – 2 pcs.
3.7Belt conveyor ПВП 1 /located in Fine Crushing building/:
●Tensioning drum – right bearing – 1 pc. SPM;
●Tensioning drum – left bearing – 1 pc. SPM;
●Driving drum – right bearing – 1 pc. SPM;
●Driving drum – left bearing – 1 pc. SPM;
●Deflecting drum – right bearing – 1 pc. SPM;
●Deflecting drum – left bearing – 1 pc. SPM;
●Gear box bearing pinion - 1pc. SPM, 1pc. VIB;
●Gear box shaft 2/bearing projecting shaft 1pc. VIB;
●Gear box bearing projecting shaft 1pc. SPM;
●Electric motor – bearing free end 1pc. SPM;
●Electric motor – bearing clutch 1 pc. SPM and 1pc. VIB.
Total for belt conveyor ПВП 1:
●SPM sensor – 10 pcs.;
●VIB sensor – 3 psc.
3.8Regrind mills МШЦ 2,7х3,6 from No1 to No3 /located in Floatation building/:
●Bearing to the coupling – 1 pc. VIB;
●Bearing to the free end – 1 pc. SPM.
Total for mills МШЦ 2,7х3,6:
●SPM sensor – 3 pcs.;
●VIB sensor – 3 psc.
Total for completion of the expansion of the system III-rd stage, are needed the following types and quantities of sensors:
●SPM sensor – 68 pcs.;
●VIB sensor – 59 psc.
3.9Type and execution of the delivery:
●Means of vibration and shock pulse method (SPM) for control of rolling bearings to be used at the accomplishment of the project;
●Phased implementation at the separate workshops to be proposed;
●The applied softwareto be multy-user and installed on theserver platformWindows Server2008 R2.As databases to be used MS SQL Server7, 2000, 2005 or 2008Express Edition.The databasesto betable andcolumn-oriented and accessibleby other applications. The applicationto becompletedwith OPC ServerandWEB Server.As an optionacomplex solutionincluding aprogram packagefor planningand management ofrepair worksand equipmentof the plantas a whole to be proposed.
●In presence of new software for Intellinova System, the existing software CondmasterNova 2010, license 2155 to be upgraded to the latest version.
3.10Scope of engineering:
●Study of the object and making a detailed design;
●Mounting of cabinets, local boards, field tools, cable laying, adjustment and putting in operation;
●Preparation/configuration of theappliedsoftware for the controllersand servers/operator stations;
●Training of the operational and serving staff;
●Conducting of 72-hour tests;
●Warranty and after warranty service for the equipment and the engineering.
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