Quan Ly Bao Tri Nha May Cong Nghiep-Vinamain

BO TR CNG NGHIP VIT NAM Vinamain.
com ----- - & - -----
Qun l bo tr nh my cng nghip
KS. Nguyn Thanh Sn - Vinamain.com
MC LC
Bi 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Ni dung Trang 3 10 14 18 21 24 29 31 34 40 56 58 70 73
Lch s bo tr ca th gii, vai tr v thch thc Vi nt v bo dng cng nghip Vit Nam Mt s phng php bo tr ch yu c p dng cc nc chu u. nh ngha v phn loi Bo tr Mc tiu v li ch ca bo tr Tng qut v cc chin lc v gii php bo tr c im c bn ca 4 chin lc bo tr La chn gii php bo tr Bo tr phng nga (Preventive Maintenance) Bo tr d on (Predictive Maintenance) Bo tr tin phong (Proactive Maintenance) Kim nh da trn ri ro RBI M hnh qun l bo tr cc nh my cng nghip Cng tc bo tr, nhng tn ti v gii php nng cao hiu qu bo tr nh my cng nghip
Trang 2
BI 1: Lch s bo tr ca th gii, vai tr v thch thc

Bi ny trnh by v lch s bo tr ca th gii, nhng bc pht trin ca n (t thi s khai nguyn thy n thi i cng nghip ngy nay), vai tr v thch thc ca bo tr ngy nay l g?
S PHT TRIN CA BO TR Lch s bo tr Bo tr xut hin k t khi con ngi bit s dng cc loi dng c, c bit l t khi bnh xe c pht minh. Nhng ch hn mi lm nm qua bo tr mi c coi trng ng mc khi c s gia tng khng l v s lng v chng loi ca cc ti sn c nh nh my mc, thit b, nh xng trong sn xut cng nghip.
Trang 3
bt k ni no trn th gii ngi ta tnh trung bnh rng khong t 4 n 40 ln chi ph mua sm sn phm v thit b dng duy tr chng vn hnh t yu cu bng cc hot ng bo tr phng nga v phc hi trong sut tui i ca chng. Theo tp ch Control Magazine (October, 1996) cc nh sn xut trn ton th gii chi 69 t USD cho bo tr mi nm v con s ny s khng ngng gia tng.
Bo tr tri qua ba th h sau: Th h th nht: (Bt u t xa xa mi n u chin tranh th gii th II) Trong giai on ny cng nghip cha c pht trin. Vic ch to v sn xut c thc hin bng cc my mc cn n gin, thi gian ngng my t nh hng n sn xut, do cng vic bo tr cng rt n gin. Bo tr khng nh hng ln v cht lng v nng sut. V vy thc ngn nga cc thit b h hng cha c ph bin trong i ng qun l. Do khng cn thit phi c cc phng php bo tr hp l cho cc my mc. Bo tr lc by gi l sa cha cc my mc v thit b khi c h hng xy ra. Th h th hai: Mi th thay i trong sut thi k chin tranh th gii th II. Nhng p lc trong thi gian chin tranh lm tng nhu cu ca cc loi hng ha trong khi ngun nhn lc cung cp cho cng nghip li st gim ng k. Do c kh ha c pht trin mnh b p li ngun nhn lc b thiu ht. Vo nhng nm 1950, my mc cc loi c a vo sn xut nhiu hn v phc tp hn. Cng nghip bt u ph thuc vo chng.
Trang 4
Do s ph thuc ngy cng tng, thi gian ngng my c ngy cng c quan tm nhiu hn. i khi c mt cu hi c nu ra l "con ngi kim sot my mc hay my mc iu khin con ngi". Nu cng tc bo tr c thc hin tt trong nh my th con ngi s kim sot c my mc, ngc li my mc h hng s gy kh khn cho con ngi. V vy c kin cho rng nhng h hng ca thit b c th v nn c phng nga, trnh lm mt thi gian khi c nhng h hng hay tnh hung khn cp xy ra. T bt u xut hin khi nim bo tr phng nga m mc tiu ch yu l gi cho thit b lun hot ng trng thi n nh ch khng phi sa cha khi c h hng. Trong nhng nm 1960 gii php ny ch yu l i tu li thit b vo nhng khong thi gian nht nh. Chi ph bo tr cng bt u gia tng ng k so vi chi vn hnh khc. iu ny dn n vic pht trin nhng h thng kim sot v lp k hoch bo tr. Cui cng tng vn u t cho ti sn c nh gia tng ng k nn ngi ta bt u tm kim nhng gii php c th tng ti a tui th ca cc ti sn ny. Th h th ba: T gia nhng nm 1970, cng nghip th gii c nhng thay i ln lao. Nhng thay i ny i hi v mong i bo tr ngy cng nhiu hn.
Hnh 1 : Nhng mong i i vi bo tr ang ngy cng tng.
Trang 5
NHNG MONG I MI 1. Thi gian ngng my lun lun nh hng n nng lc sn xut ca thit b do lm gim sn lng, tng chi ph vn hnh v gy tr ngi cho dch v khch hng. Vo nhng nm 1960 v 1970 iu ny l mt mi quan tm ch yu trong mt s nghnh cng nghip ln nh ch to my, khai thc m v giao thng vn ti. Nhng hu qu ca thi gian ngng my li trm trng thm do cng nghip ch to th gii c xu hng thc hin cc h thng sn xut ng lc(just -in -time), trong lng tn kho nguyn vt liu, bn thnh phm gim rt nhiu nn ch nhng h hng nh ca mt thit b no cng lm ngng ton b mt nh my. Trong nhng nm gn y s pht trin ca c kh ha v t ng ha lm cho tin cy v kh nng sn sng tr thnh nhng yu t quan trng hng u trong cc ngnh cng nghip v dch v nh y t, x l d liu, vin thng, tin hc v xy dng. Vo thng 6/2000 ch mt gi mt in lm cho cc cng ty tin hc Silicon Valley (M) thit hi hn 100 triu la.
Hnh: Doanh nghip s dng s "sn xut ng lc" cho h thng sn xut.
2. T ng ha nhiu hn cng c ngha rng nhng h hng ngy cng nh hng ln hn n cc tiu chun cht lng v dch v. V d cc my mc h hng c th nh hng ng k n h thng iu ha nhit trong cc ta nh v s ng gi ca h thng giao thng vn ti v chng gy tr ngi cho kh nng t dung sai cho php trong ch to my.
Trang 6
3. Nhng h hng ngy cng gy cc hu qu v an ton v mi trng nghim trng trong khi nhng tiu chun cc lnh vc ny ang ngy cng tng nhanh chng. Ti nhiu nc trn th gii, c nhng cng ty, nh my ng ca v khng m bo cc tiu chun v an ton v mi trng. in hnh l nhng tai nn v r r mt s nh my in nguyn t lm nhiu ngi lo ngi. Mt s nc nh Thy in, c c k hoch ng ca ton b nhng nh my in nguyn t trn lnh th ca mnh trong nhng nm ti. 4. S ph thuc ca con ngi vo ti sn c nh, my mc, thit b ngy cng tng th ng thi chi ph vn hnh v s hu chng cng tng. thu hi ti a vn u t cho cc thit b, chng phi c duy tr hot ng vi hiu sut cao v c tui th cng lu cng tt. 5. Cui cng chnh chi ph bo tr cng ang tng ln, tnh theo gi tuyt i v tnh nh l mt thnh phn ca tng chi ph. Trong mt s ngnh cng nghip, chi ph bo tr cao th nh hoc thm ch cao nht trong cc chi ph vn hnh. Kt qu l trong vng 30 nm gn y, chi ph bo tr t ch khng c ai quan tm n ch vt ln ng u trong cc chi ph m ngi ta u tin kim sot. 6. Hin nay xu th cho rng:" hn 90% cc chi ph bo m cht lng, kh nng bo tr v tin cy trong cng nghip c dng phc hi li nhng sai st khuyt tt do thit k sn phm sau khi chng xy ra, trong khi ch gn 10% c chi lm ng sn phm ngay t u". Nhng n lc ca bo tr trong tng lai l phi o ngc xu th ny. NHNG NGHIN CU MI V BO TR Nhng nghin cu mi lm thay i quan nim c bn nht v tui i thit b v h hng. Hin nhin rng c mi quan h gia mc h hng v tui i ca thit b. Trc kia ngi ta ngh rng h hng l do thit b "gi" i. Trong th h th hai c thm quan nim cho rng giai on "lm nng my" ban u cng nh hng n h hng. Tuy nhin cc cng trnh nghin cu th h th ba chng t rng trong thc t khng phi ch c mt hoc hai m l su dng h hng. Nhng k thut mi ca bo tr
Trang 7
c s pht trin bng n v nhng khi nim v k thut bo tr mi. Hng trm k thut bo tr mi c trin khai vo sn xut trong hai mi nm qua v hin nay hng tun li xut hin mt vi k thut mi. Nhng pht trin mi ca bo tr bao gm : Cc cng c h tr quyt nh: nghin cu ri ro, phn tch dng v hu qu h hng. Nhng k thut bo tr mi: gim st tnh trng, vv Thit k thit b vi s quan tm c bit n tin cy v kh nng bo tr. Mt s nhn thc mi v mt t chc cng tc bo tr theo hng thc y s tham gia ca mi ngi, lm vic theo nhm v tnh linh hot khi thc hin.
Hnh 2: Nhng k thut bo tr ang thay i VAI TR CA BO TR NGY NAY Ngy nay bo tr ng mt vai tr rt quan trng trong mi hot ng sn xut, c th so snh nh mt i cu ha. m chy mt khi xy ra phi c dp tt cng tt trnh nhng thit hi ln. Tuy nhin, dp tt la khng phi l nhim v chnh ca i
Trang 8
cu ha m cng vic chnh ca h l phng nga khng cho m chy xy ra. Cho nn vai tr chnh ca bo tr l: Phng nga trnh cho my mc b hng. Cc i ha nng sut. Nh m bo hot ng ng yu cu v lin tc tng ng vi tui th ca my lu hn. Nh ch s kh nng sn sng ca my cao nht v thi gian ngng my bo tr nh nht. Nh ci tin lin tc qu trnh sn xut. Ti u ha hiu sut ca my: My mc vn hnh c hiu qu v n nh hn, chi ph vn hnh t hn, ng thi lm ra sn phm t cht lng hn. To ra mi trng lm vic an ton hn. Hin nay, bo tr ngy cng tr nn quan trng. nhng nc ang pht trin, c nhiu my mc c ang hot ng. Vn ph tng l yu t cn quan tm, bi v kh tm c ph tng thay th cho thit b, nu c tm thy th gi cng rt cao v phi tr bng ngoi t. Nu cng tc bo tr tt, hu qu ca nhng hng hc c phng th nhng vn ny phn no c gii quyt. NHNG THCH THC I VI BO TR K thut cng pht trin, my mc v thit b s cng a dng v phc tp hn. Nhng thch thc ch yu i vi nhng nh qun l bo tr hin i bao gm: La chn k thut bo tr thch hp nht. Phn bit cc loi qu trnh h hng.
Trang 9
p ng mi mong i ca ngi ch thit b, ngi s dng thit b v ca ton x hi. Thc hin cng tc bo tr c kt qu nht. Hot ng cng tc bo tr vi s h tr v hp tc tch cc ca mi ngi c lin quan. Theo gio trnh Qun L Bo Tr Cng nghip ca PGS. TS. Phm Ngc Tun "Bo tr phng nga m mc tiu ch yu l gi cho thit b lun hot ng trng thi n nh ch khng phi sa cha khi c h hng"
Trang 10
Bi 2: Vi nt v bo dng cng nghip Vit Nam

Bi vit ni v trnh bo dng cng nghip Vit Nam, trong nu ra 5 cp trong bo dng cng nghip.
"Theo tiu ch bo dng cng nghip gm nm cp bc ph bin trn th gii, th Vit Nam ang chp chng bc th hai v trnh bo dng cng nghip Vit Nam tt hu 40 n 50 nm so vi th gii. Thc s Nguyn Hng Long, chuyn gia trong lnh vc bo dng cng nghip thuc trung tm Sn xut Sch Vit Nam (VNCPC) cho bit: Nu nh nhng nm 60, cc nc chu u vt qua bo dng nh k v tin n bo dng da trn tnh trng ca thit b th hin nay, Vit Nam ch ang dng vic bo dng khi my hng v bo dng theo nh k. ng Long ni: c th ca bo dng Vit Nam l hnh thc bo dng c hi, ngha l khi my hng mt b phn, ngoi vic bo dng b phn b hng, th nhn lc s bo dng lun nhng b phn cn li.
Mt nghin cu mi y c tnh rng 50% my mc thit b ti cc cng ty sn xut cng nghip Vit Nam b hng hoc h hi nghim trng do khng c bo dng. V th, vn thiu bo dng cng nghip hin nay ang l mt thch thc i vi hiu qu v li nhun ca cc doanh nghip Vit Nam, tuy nhin gii quyt vn ny s mang li tim nng ln v tng li nhun v sc cnh tranh. Tuy c mt s doanh nghip c yu t u t nc ngoi p dng bo dng cng nghip rt tt, nh cc cng ty ca Nht: Honda, Toyotah p dng nhng chun ring
Trang 11
ca h, khng theo chun Vit Nam. Nhng so vi tnh trng chung ca bo dng cng nghip Vit Nam, th ch nh ming v p trn mt ci o rch, ng Long ni. ng Rudy Bunda, chuyn gia quc t tng c 30 nm kinh nghim trong bo dng cng nghip ti Hoa K v n hn 400 trung tm sn xut sch ca nhiu nc trn th gii, cho bit, bo dng cng nghip cng ging nh vic duy tr tnh trng sc khe ca con ngi hoc bo dng xe my, cn phi duy tr tnh trng tt ca my mc bng cch sa cha, lm sch, tra du m, hoc nng cp c h thng m khng lm nh hng n sn xut. 5 cp trong bo dng cng nghip: - Bo dng khi hng my - Bo dng phng nga bao gm bo dng nh k theo thi gian hoc da trn tnh trng thit b - Bo dng d bo trc khi my hng - Bo dng hiu sut - Bo dng hiu sut tng th. Nguyn nhn: Vit Nam tng l mt bi rc cng nghip Vit Nam tng c trnh bo dng cng nghip kh tt trong thi k bao cp, khi my mc thng nhp t cc nc XHCN vi nhng hng dn c th, r rng ca cc chuyn gia nc bn. Tuy nhin sau , thit b c nhp v t khp ni. C mt thi gian, nc ta tr thnh bi rc cng ngh vi rt nhiu thit b c c nhp t cc nc. V th, cc hng dn s dng v bo hnh thit b khc nhau, gy nhiu kh khn cho ngi qun l cng nh k thut bo dng. Thm na, trnh bo dng ca Vit Nam tt hu cn do cch tip cn cng nh suy ngh v bo dng Vit Nam.
Trang 12
nc ngoi, h coi bo dng v sn xut l hai mt ca mt vn . Mt bn l sn xut v bn kia l bo dng, hai mt gn cht vi nhau. Bo dng cng ng gp li nhun ca cng ty. Cn i vi Vit Nam, ging nh hai cnh tay, tay phi l sn xut, tay tri l bo dng, sn xut th ra tin cn bo dng th tn tin. V th ngi ta c gng chi ph ti thiu cho phn bo dng. Khi ng mt d n v bo dng cng nghip Trc thc trng trn, mt d n v bo dng cng nghip c khi ng sng nay, 11-5, ti trung tm Sn xut Sch Vit Nam (VNCPC) vi s h tr ca chng trnh hp tc Wallonie-Bruxelles (B). Hi tho gip nng cao nhn thc ca cc doanh nghip v t chc v cc li ch ca bo dng cng nghip. D n ko di mt nm s gii thiu vi cc cng ty Vit Nam nhng li ch tim nng m h c th t c thng qua vic p dng cc k thut bo dng cng nghip hin i. Mc tiu chnh ca d n l cung cp cc k nng v cng c cn thit h tr cc doanh nghip Vit Nam, cc nhn vin VNCPC v cc nh cung cp dch v khc ca Vit Nam nhm ci thin qun l bo dng v ti a ha u ra theo nng cao hiu sut, nng sut v li nhun. D n kt thc vo gia nm 2008 v s tin hnh mt lot cc kha o to v cc k thut bo dng cng nghip, v cc hot ng trnh din ti ba cng ty Vit Nam nhm khng nh li ch ca vic p dng bo dng cng nghip vo hon cnh ca Vit Nam. Tt c cc kha tp hun v cc d n trnh din s do VNCPC tin hnh vi s h tr ca cc chuyn gia bo dng cng nghip ca B. Tr gi ca d n l 150.000 euro bao gm chi ph thu chuyn gia, trang thit b o c s dng trong qu trnh o to ti Vit Nam, gi mt s chuyn gia sang hc ti B
Trang 13
ng Long cho bit, i tng ca d n l cc doanh nghip trong nc. S c khong 45 lp hc c t chc vi s tham gia ca khong 35-40 ngi mi lp, phc v cho khong 25-30 cng ty. Li ch ln nht ca d n l gip thay i nhn thc ca cc cng ty trong vic bo dng cng nghip. ri khi p dng, cc cng ty s tng li nhun, ci thin iu kin lm vic ca cng nhn cng nh gim nh hng ti mi trng. Pht biu ti bui hi tho, ng Christian Saelens, i din phi on Wallonie-Bruxelles (B) ti Vit Nam nhn mnh, Vit Nam hin nay, chi ph bo v mi trng rt nh so vi chi ph ca sn phm. V th, Vit Nam phi quan tm hn n bo v mi trng, a chi ph bo v mi trng vo sn phm.V mt trong nhng hot ng bo v mi trng chnh l bo dng cng nghip. Theo ng Long, Vit Nam nn c nhng d n tm quc gia v bo dng. ng Long tin tng, nu Vit Nam thc hin tt bo dng th GDP c th tng khng phi l 8% m l thm vi phn trm na." (Thanh Sn sa tm trn internet)
Trang 14
Bi 3: Mt s phng php bo tr thng thng c p dng cc nc u chu

Trong cng nghip hin i ngy nay, m bo hiu qu ti a cho sn xut, vn bo tr, bo dng my tr nn ngy cng quan trng. Phng php hin i trong bo tr my khng ch m bo cho cc c s sn xut c c phng tin lm vic ti u, m cn l nhn t chnh lm gim gi thnh sn xut. Trong nn kinh t th trng hin nay Vit Nam, nhu cu tng nng sut, gim gi thnh sn xut tr thnh thc t nng trong mi x nghip, nh my. Nhm gip bn c thng tin thm v vn ny, xin uc s lc gii thiu mt s phng php bo tr thng thng c p dng cc nc u chu nh c, Anh, Php v.v... 1. Sa cha, tn to sau khi my hng: (Breakdown maintenance) Phng php: - S dng my cho ti khi hng, ch c bo dng n gin nh tra, thay du, m v sa cha, tn to li my sau khi hng. - Thng p dng trong nhng c s sn xut nh. - V lu di, y l phng php bo tr tn km nht. u im: - Tn dng ti a thi gian s dng my. - Gim u t ban u, khng cn c xng bo tr. Nhc im: - Th ng, lch trnh sn xut khng c m bo. - Chi ph sa cha cao v nhn lc v ph tng thay th. - C th dn ti h hng ton b v phi thay th my mi. 2. Bo tr nh k: (Periodic shutdown maintenance) Phng php: - Da theo thng s k tht ca nh ch to thit b v tnh trng s dng. Thay th bt buc cc chi tit my theo lch trnh c nh. - y l phng php bo tr tiu chun, p dng trong cc x nghip c xng bo tr. - S dng software vi tnh qun tr bo tr: Computerized maintenance management
Trang 15
systems (CMMS). u im: - Ch ng v lch trnh sn xut. - an ton my tng i cao. Nhc im - Tn km: Ph tng cn tt vn phi thay th. - Gim thi gian s dng my. - C th c tnh trng my hng trc thi hn bo tr. 3. Bo tr theo tnh trng my (BTTTTM): (Condition based maintenance) Phng php: - Kim sot thng trc (on line), hoc nh k xc nh tnh trng my. Ch ln k hoch dng my x l dung sai (v d lch tm hay mt cn bng), hoc thay th v sa cha sau khi chun on chnh xc tnh trng my trc khi my hng. - S dng sofware qun tr bo tr CMMS. - C cc cng ty c lp chuyn trch v theo di v s l chng rung ng. u im: - m bo an ton my, nht l cho cc thit b quan trng. - Ch ng v m bo lch trnh sn xut. - Khai thc ti a cng sut v thi gian s dng my. - Tit kim: Ch sa cha hay thay ph tng ty theo tnh trng, gim chi ph nhn cng v vt t. - y l phng php ti u, thng c p dng trong cc nh my i hi tnh an ton my cao v hot ng lin tc 24/24h nh ho cht, in lc, xi mng v.v Nhc im: u t cao v thit b v kim sot an ton, phn tch, v s l rung ng nh chnh lch tm, cn bng ng. i hi c i ng cn b bo tr c trnh cao, hoc phi s dng cng ty chuyn trch bn ngoi Nhn xt: cc nc cng nghip pht trin, vi s cnh tranh khc lit v hch ton kinh t cht ch, th vic s dng vi hiu qu ti a trang thit b cng nh nhn lc l vn thc tin v lun c ci tin t ti mc tiu; Tng nng sut, gim gi thnh.
Trang 16
Gim chi ph bo tr l mt trong nhng bin php t ti mc tiu ny. Theo mt thng k Anh, nhng nh my p dng phng php BTTTTM gim c trung bnh 25% chi ph bo tr. Phng php BTTTTM tn ti t lu, nhng trc y, t c p dng trong cng nghip dn dng, bi v s phc tp kh khn trong vic chun on chnh xc tnh trng my. Cho n nhng nm gn y, nh s tin b vt bc trong cc lnh vc in t, vi tnh v o lng, ng thi vi s i hi tng nng sut, vic p dng phng php BTTTM ngy cng ph thng v ang tng bc thay th phng php bo tr nh k trong cc nh my. Kim sot, phn tch v x l rung trong BTTTTM (Safety monitoring, analysis and vibration treatment) 1.Tc hi ca rung ng: - C th ph hy my nu rung qu cao. - Tng nhanh hao mn, gim thi gian s dng my. - Gim cht lng sn phm. - Tiu th nng lng tng. Vic kim sot bo v, phn tch chun on v s l rung l khu quan trng nht ca BTTTTM, n cho php; - Bo v my chng s hy hoi; - Xc nh nguyn nhn gy rung ng; - X l cc nguyn nhn gy rung ng. 2.Kim sot bo v (Safety monitoring): Vi nhng dn my ln, quan trng hoc t tin, nhu cu bo v my l d nhin. S dng h thng kim sot thng trc, theo di rung ng my. Cn c vo bng tiu chun ISO v rung my v thng s k thut ca loi my, hai gii hn rung ng c chnh, gi trong h thng bo v: - Gii hn bo ng: Trong trng hp bt bnh thng, rung my vt qua gii hn bo ng, h thng bo v ra tn hiu bo ng. - Gii hn hu hi: Nu rung tip tc tng v vt qu gii hn hu hoi, h thng bo v s t ng dng my, trnh c hoc gim bt s hu hoi. Mt h thng trung tm c th cng lc kim sot v bo v nhiu c my khc nhau.
Trang 17
3.Phn tch, chun on (Vibration analysis): Vi nhng thit b o lng rung hin i nh velocity sensor, acceleration sensor i km vi cc chng trnh vi tnh chuyn dng, k thut vin c th xc nh chnh xc cc nguyn nhn gy rung nh: - Vng bi hoc gi vng bi hng, mn. - Bnh rng hp s, hp i tc b v, st hay qu mn. - Lch tm trc, mt cn bng, khong 80% rung ng gy ra bi hai nguyn nhn ny. - Cng hng rung ng vi b my, cu trc nn xng, vi cc my khc, hoc do s dng my i tn. Ty theo s quan trng ca c my v iu kin nhn s, m p dng phng php kim tra thng trc hay nh k. 4.X l rung ng: Tr nhng trng hp bt buc phi thay th ph tng mn, hng nh vng bi, bnh rng v.v c th x l rung ng m khng cn thay th cho nhng nguyn nhn sau: - Lch tm trc, mt cn bng: Hai nguyn nhn ny c th c x l d dng vi chnh xc cao bng my chuyn dng chnh lch tm laser, cn bng ng ti ch. - Cng hng rung ng do my i tn s ca ng c in: Tn s in (tc ng c) thay i cao hoc thp hn 50/60 Hz c th dn n tc my trng vi tn s cng hng ca cu trc. Xc nh v trnh lm vic tc ny. (Thanh Sn sa tm trn internet)
Trang 18
BI 4: nh ngha v phn loi Bo tr

1. CC NH NGHA V BO TR . Trong thi i hin nay, my mc v thit b ang ngy cng ng vai tr quan trng trong hu ht mi lnh vc : sn xut, kinh doanh v dch vV vy bo tr cc loi my mc thit b cng ngy cng quan tm nhiu hn. Bo tr l mt thut ng rt quen thuc, tuy nhin hiu r vai tr, chc nng v cc hot ng lin quan n bo tr li khng d dng. Ty theo quan im ca mi t chc, mi c quan m thut ng bo tr c nh ngha khc nhau. Sau y l mt s nh ngha tiu biu: nh ngha ca AFNOR (PHP) Bo tr l tp hp cc hot ng nhm duy tr hoc phc hi mt ti sn tnh trng nht nh hoc bo m mt dch v xc nh. ngha ca mt s khi nim t nh ngha ny l: Tp hp cc hot ng: Tp hp cc phng tin, cc bin php k thut thc hin cng tc bo tr. Duy tr: Phng nga cc h hng c th xy ra duy tr tnh trng hot ng ca ti sn. Phc hi: Sa cha hay phc hi tr li trng thi ban u ca ti sn. Ti sn: Bao gm tt c thit b, dng c sn xut, dch vu, Tnh trng nht nh hoc dch v xc nh: Cc mc tiu c xc nh v nh lng. nh ngha ca BS 3811 (ANH)- 1984: Bo tr l tp hp tt c cc hnh ng k thut v qun tr nhm gi cho thit b lun , hoc phc hi n v mt tnh trng trong n c th thc hin chc nng yu cu. Chc nng yu cu ny c th nh ngha nh l mt tnh trng xc nh no . nh ngha ca Total Productivity Development AB (Thy in):
Trang 19
Bo tr bao gm tt c cc hot ng c thc hin nhm gi cho thit b mt tnh trng nht nh hoc phc hi thit b v tnh trng ny. nh ngha ca Dimitri Kececioglu: Bo tr l bt k hnh ng no nhm duy tr cc thit b khng b h hng v mt tnh trng vn hnh t yu cu v mt tin cy v an ton; v nu chng b h hng th phc hi chng v tnh trng ny. 2. PHN LOI BO TR Cc loi chin lc, gii php, k thut v phng php ang ph bin hin nay c trnh by hnh sau
Trang 20
Theo gio trnh Qun L Bo Tr Cng nghip ca PGS. TS. Phm Ngc Tun
Trang 21
BI 5: MC TIU V LI CH CA BO TR
1. MC TIU CA BO TR th h th nht bo tr khng nh hng nhiu n hiu qu sn xut nn t c quan tm. Trong bo tr hin i, khng th tp trung qu nhiu vo vic sa cha thit b khi chng b h hng. Mi ln xy ra ngng my th r rng chin lc bo tr khng hiu qu. Qun l bo tr hin i l gi cho thit b lun hot ng n nh theo lch trnh m b phn sn xut ln k hoch. Thit b phi sn sng hot ng to ra cc sn phm t cht lng. Nh qun l bo tr v sn xut phi xc nh c ch s kh nng sn sng t ra ch tiu sn xut hp l nht. Mt s mc tiu ca bo tr : - Thc hin mt chng trnh k thut bo tr tng hp trong mua bn, k thut, nghin cu, pht trin, sn xut, kim sot cht lng, kim tra bao gi, vn chuyn lp t, vn hnh, dch v ti ch, thc hin cng vic khc phc bt c khi no v bt c ni u nu cn, a nhng c trng ca tin cy v kh nng bo tr ton din v ng n vo trong tt c cc hot ng ca cng ty. - Xc nh tin cy v kh nng bo tr ti u. - Thu nhn d liu thi gian vn hnh n khi h hng. - Thi gian kim tra chy r v thi gian lm nng my ti u. - Thi gian bo hnh ti u v chi ph tng ng. - Thi gian thay th phng nga ti u ca b phn quan trng. - Cc nhu cu ph tng ti u. - Thc hin phn tch cc dng, tc ng v kh nng ti hn ca h hng xc nh b phn nn tp trung thit k li. - Nghin cu hu qu cc h hng xc nh thit hi ca cc b phn.
Trang 22
- Nghin cu cc kiu h hng nhm cc tiu ha h hng. - Xc nh s phn b thi gian vn hnh n khi h hng tnh ton t l h hng. - Xc nh s phn b thi gian thit b h hng. - Gim s b phn trong thit k ca thit b. - Xc nh nhu cu d phng t mc tiu tin cy mong mun nu cc cc phng php khc u tht bi. - La chn vt liu tt hn v thch hp hn. - S dng cc phiu kim tra k thutbbo tr trong tt c cc giai on hot ng ca thit b. - Xy dng mt h thng bo co v h hng v bo tr thu thp nhng d liu v tin cy v kh nng bo tr cn thit. - Xc nh tnh trch nhim h hng do ai (v mt k thut, ch to, vn hnh..) - Hng dn ra quyt nh hot ng phc hi cc tiu ha cc h hng. 2. V D LI CH T CNG TC BO TR - Qua kt qu iu tra ngi ta nhn thy rng, trong mt nm nu tng ch s kh nng sn sng ca my mc thit b ln 1% th hiu qu kinh t mang li cho cc n v sn xut l rt ln: Nh my thp khong 10 t ng Nh my giy khong 11 t ng Nh my ha cht khong 1 t ng Nh my in khong 10 t ng Nh my xi mng khong 21 t ng
Trang 23
- Mt cng ty bao b nha ti TP. HCM gim c 310 gi ngng my ghp n trong mt nm v tit kim c hn 3 t ng. - Ti cng ty xi mng Pusan, Hn Quc, nh p dng h thng gim st tnh trng nn trnh c 80 gi ngng my mt nm v tit kim c 1,5 triu USD. - Mt nghin cu mi y ca chnh ph Anh tit l rng cng nghip ca nc ny tit kim c 1,3 t USD nh p dng bo tr phng nga - Hi qun Canada bo co: nh p dng chin lc bo tr trn c s tnh trng my nn cc h hng ca cc thit b trn mt i tu khu trc, 20 chic, gim c 45% v tit kim c chi ph 2 triu USD mi nm. - Nh theo di thng xuyn mt my x l kh Trung ng ngi ta nhn thy c rung ng mt rto my nn v so snh vi mt hin tng tng t trc y, t gip cho nh my rt ra kt lun rng rung ng l do s mt cn bng ca rto. Vy cn phi thay th r to , nhng nh my khng c ph tng thay th ngay lp tc. Nh hiu r tnh trng my m cc k s ca nh my kim sot c mc nghim trng ca s c bng cch gim ti t ln rto trong khi ch to mt r to mi. Nu khng pht hin sm v chnh xc iu chnh sn xut th khi my b h hng, ngng sn xut hon ton s gy thit hi c tnh 2 triu USD mi ngy. - Mt nh my lc du Php pht hin thy c mt trc ca my trn cht xc tc b o nhiu hn so vi trc y trong khi khi ng. Ngi ta nhn thy trc my ny c ma st vi v v nhng vng chn. Cht xc tc khi thot gn nhng vng chn s dn dn tch t bn trong v. Nh cng tc theo di tnh trng my thng xuyn m quyt nh loi b cht xc tc phun nc trong khi vn vn hnh my. Kt qu l rung ng tr li bnh thng. Bng cch gii quyt tnh trng mt cch trc tip, nh my trnh c thit hi c tnh khong 1 triu F mi ngy. Theo gio trnh Qun L Bo Tr Cng nghip ca PGS. TS. Phm Ngc Tun
Trang 24
BI 6: Tng qut v cc chin lc v gii php bo tr

Bo tr khng k hoch Chin lc bo tr ny c xem nh l "vn hnh cho n khi h hng". Ngha l khng h c bt k mt k hoch hay hot ng bo tr no trong khi thit b ang hot ng cho n khi h hng. Bo tr khng k hoch c hiu l: Cng tc bo tr c thc hin khng c k hoch hoc khng c thng tin trong lc thit b ang hot ng cho n khi h hng. Nu c mt h hng no xy ra th b s c sa cha hoc thay th.
Hai loi ph bin trong chin lc bo tr ny l: Bo tr phc hi Bo tr phc hi khng c k hoch l loi bo tr khng th lp c k hoch. Mt cng vic c xp vo loi bo tr phc hi khng k hoch khi m thi gian dng cho cng vic t hn 8 gi. Trong trng hp ny khng th lp k hoch lm vic mt cch hp l. Nhn lc, ph tng v cc ti liu k thut cn thit i vi cng vic bo tr ny khng th lp k hoch v chun b trc khi cng vic bt u m phi thc hin ng thi vi cng vic.
Trang 25
Bo tr phc hi khng k hoch l tt c cc hot ng bo tr c thc hin sau khi xy ra t xut mt h hng no phc hi thit b v tnh trng hot ng bnh thng nhm thc hin cc chc nng yu cu. Bo tr khn cp Bo tr khn cp l bo tr cn c thc hin ngay sau khi c h hng xy ra trnh nhng hu qu nghim trng tip theo. Trong thc t do thiu tnh linh hot v khng th kim sot chi ph c nn bo tr khn cp l phng n bt c d v t c chp nhn. Thay vo c th s dng cc gii php hiu qu v linh hot hn. Bo tr phc hi khng k hoch thng chi ph cao v cc ln ngng sn xut khng bit trc c, do s lm chi ph bo tr trc tip v chi ph bo tr gin tip cao. V vy bo tr khng k hoch ch thch hp trong nhng trng hp ngng my t xut ch gy ra thit hi ti thiu. i vi cc thit b quan trng trong cc dy chuyn sn xut, nhng v ngng my t xut tn tht ln cho nh my c bit l tn tht sn lng v doanh thu, do gii php bo tr ny cn phi c gim n mc ti thiu trong bt k mt t chc bo tr no. Bo tr c k hoch L bo tr c t chc v thc hin theo mt chng trnh c hoch nh v kim sot. Bo tr c k hoch bao gm: Bo phng nga Bo tr phng nga l hot ng bo tr c lp k hoch trc v thc hin theo mt trnh t nht nh ngn nga cc h hng xy ra hoc pht hin cc h hng trc khi chng pht trin ti mc lm ngng my v gin on sn xut. Nh thy t nh ngha, bo tr phng nga c chia thnh hai b phn khc nhau: bo tr c thc hin ngn nga cc h hng xy ra v bo tr phng nga
Trang 26
c thc hin pht hin cc h hng trc khi chng pht trin n mc lm ngng my hoc cc bt n trong sn xut. Bo tr phng nga trc tip Bo tr phng nga trc tip c thc hin nhm ngn nga h hng xy ra bng cch tc ng v ci thin mt cch trc tip trng thi vt l ca my mc v thit b. Nhng cng vic bo tr phng nga trc tip thng l thay th cc chi tit, ph tng, kim tra cc b phn, bi trn, thay du m, lau chi, lm sch my mc theo k hoch hoc chng trnh nh sn. Cc hot ng bo tr phng nga trc tip thng mang tnh nh k theo thi gian hot ng, theo s km di chuyn,nn cn c gi l bo tr nh k (Fixed Time Maintenance-FTC). Bo tr phng nga gin tip Bo tr phng nga gin tip c thc hin tm ra cc h hng ngay trong giai on ban u trc khi cc h hng c th xy ra. Trong gii php ny, cc cng vic bo tr khng tc ng n trng thi vt l ca thit b m thay vo l cc k thut gim st tnh trng nh gim st tnh trng khch quan v gim st tnh trng ch quan c p dng tm ra hoc d on cc h hng ca my mc, thit b nn cn c gi l bo tr trn c s tnh trng (CBM-Condition Based Maintenance) hay bo tr d on (Predictive Maintenance) hoc bo tr tin phong (Proactive Maintenance). Bo tr trn c s tnh trng my khc phc cc nhc im ca bo tr phng nga v bo tr nh k bng cch gim st lin tc tnh trng my xc nh chnh xc tnh trng v iu kin hot ng ca thit b mi thi im, ngi ta s dng nhng k thut gim st tnh trng. K thut gim st tnh trng Nu trong qu trnh hot ng, my mc v thit b c vn th thit b gim st tnh trng s cung cp cho ta thng tin xc nh xem l vn g v quan trng hn l
Trang 27
ci g gy ra vn . Nh vy chng ta c th lp qui trnh sa cha c hiu tng vn c th trc khi my mc b h hng. Gim st tnh trng c th chia thnh: Gim st tnh trng ch quan: L gim st c thc hin bng cc gic quan ca con ngi nh : nghe, nhn, s, nm, ngi nh gi tnh trng ca thit b. Gim st tnh trng khch quan: c thc hin khi m tnh trng ca thit b trong mt s trng hp khng th nhn bit c bng cc gic quan ca con ngi. N c thc hin thng qua vic o c v gim st bng nhiu thit b khc nhau, t nhng thit b n gin cho n thit b chn on hin i nht. Gim st tnh trng khch quan c th c thc hin bng hai cch: Gim st tnh trng khng lin tc: L gim st m trong mt ngi i quanh cc my v o cc thng s cn thit bng mt dng c cm tay. Cc s liu hin th c ghi li hoc lu tr trong dng c phn tch v sau. Phng php ny i hi mt ngi c tay ngh cao thc hin vic o lng bi v ngi phi c kin thc vn hnh dng c, c th din t thng tin t dng c v phn tch tnh hnh my hin ti l tt hay xu. Gim st tnh trng lin tc: c thc hin khi thi gian pht trin h hng qu ngn. Phng php ny cn t ngi hn nhng thit b t tin hn v bn thn thit b cng cn c bo tr. Trong h thng bo tr phng nga da trn gim st tnh trng thng 70% cc hot ng l ch quan v 30% l khch quan, l do l v c nhng h hng xy ra v khng th pht hin bng dng c. Bo tr ci tin: c tin hnh khi cn thay i thit b cng nh ci tin tnh trng bo tr. Mc tiu ca bo tr ci tin l thit k li mt s chi tit, b phn v ton b thit b.
Trang 28
Bo tr chnh xc: L hnh thc bo tr thu nhp cc d liu ca bo tr d on hiu chnh mi trng v cc thng s vn hnh ca my, t cc i ha nng sut, hiu sut v tui th ca my. Bo tr nng sut ton b (TPM-Total Productive Maint.): Lbo tr nng sut c thc hin bi tt c cc nhn vin thng qua cc nhm hot ng nh nhm tng ti a hiu sut s dng my mc thit b. TPM to ra nhng h thng ngn nga tn tht xy ra trong qu sn xut nhm t c mc tiu " khng tai nn, khng khuyt tt, khng h hng". TPM c p dng trong ton b phng ban v ton b cc thnh vin t ngi lnh o cao nht n nhng nhn vin trc tip sn xut Bo tr tp trung vo tin cy(RCM-Reliability Center Maint.): L mt qu trnh mang tnh h thng c p dng t c cc yu cu v bo tr v kh nng sn sng ca my mc, thit b nhm nh gi mt cch nh lng nhu cu thc hin hoc xem xt li cc cng vic v k hoch bo tr phng nga. Bo tr phc hi : Bo tr phc hi c k hoch l hot ng bo tr phc hi ph hp vi k hoch sn xut, cc ph tng ti liu k thut v nhn vin bo tr c chun b trc khi tin hnh cng vic. Trong gii php bo tr ny chi ph bo tr gin tip s thp hn v chi ph bo tr gin tip cng gim i so vi bo tr phc hi khng k hoch. Bo tr khn cp : D cc chin lc bo tr c p dng trong nh my c hon ho n u th nhng ln ngng my t xut cng khng th trnh khi v do gii php bo tr khn cp trong chin lc bo tr c k hoch ny vn l mt la chn cn thit. Theo gio trnh Qun L Bo Tr Cng nghip ca PGS. TS. Phm Ngc Tun
Trang 29
BI 7: c im c bn ca 4 chin lc bo tr
C 4 chin lc bo tr: - Chy cho n khi h hng (Run To Failure hay Breakdown Maintenance).
-
Bo tr ngn nga (Preventive Maintenance) Bo tr d on (Predictive Maintenance) Bo tr tin phong (Proactive Maintenance)
1. Chy cho n khi h hng (Run To Failure hay Breakdown Maintenance).

c im: Thit b b h hng nng hay b ph hy. Bo tr khng c k hoch Mt thu nhp t sn phm do ngng my
2. Bo tr ngn nga (Preventive Maintenance) c im:
- Tt hn Run To Failure
Ngng my c k hoch nhiu Bo tr khng cn thit H hng do bo dng khng hp l
3.Bo tr d on (Predictive Maintenance)

c im: Ti a tui th qua vic theo di tnh trng bt thng v pht hin cc li Gim ngng my khng k hoch bng cnh bo ngi s dng v s thay i tnh trng c kh/in. Ti u ha vn hnh
Cc phng php bo tr d on
Trang 30
Cc phng php da trn theo di theo tn sut Rung ng Du bi trn in th, dng in trc moto Nhit Lu lng Siu m
Theo di tnh trng lin tc (online) Kim tra offline Kim tra mch moto Kim tra Surge
4. Bo tr tin phong (Proactive Maintenance)

Xc nh cc h hng lp li Xc nh tm nguyn nhn gc r ca cc h hng Sa cha phc hi nguyn nhn gc r loi b cc h hng cng nguyn nhn trong tng li. KS. Nguyn Thanh Sn
Trang 31
BI 8: La chn gii php bo tr
Khng nn chp nhn v phi trnh ngng my khng k hoch. Mi ngi trong t chc t ngi qun l cao nht n cng nhn ang lm vic ti nh my u phi bit chnh sch bo tr. Ngi sn xut v ngi bo tr phi c th phn tch nhng vn bo tr ny sinh. Nu mt sai st xut hin, ngi vn hnh, ngi bo tr hay bt k ngi no khc phi bit t cu hi:" c th trnh sai st ny xy ra mt ln na bng cch sa i, thit k li hoc bt k gii php bo tr no khc khng?". C th la chn gii php bo tr bng cch nu mt lot cu hi v tr li theo trnh t sau y: C th thit k li trnh h hng hay khng? Nu khng th thit k li th bc k tip trong chin lc bo tr l phi c gng ko di tui th ca chi tit thit b. C th ko di tui th ca chi tit hay khng? Nu khng th ko di tui tho ca chi tit th bc k tip l phi c gng p dng gim st tnh trng thit b trong sut thi gian vn hnh sm tm ra nhng sai st trong thi k pht trin h hng v c th lp k hoch sa cha gim hu qu h hng. C th p dng gim st tnh trng thit b trong qu trnh vn hnh khng?
Trang 32
i khi gim st tnh trng khng th thc hin c trong qu trnh vn hnh. C th gim st tnh trng thit b trong khi ngng my c k hoch khng? Nu khng th p dng gim st tnh trng thit b do khng c h hng no pht trin th phi ngh n thay th nh k. C th p dng thay th nh k c khng? Nu kh xc nh c khong thi gian gia nhng ln h hng xy ra th h hng l ngu nhin v phi ngh tip n gii php d phng C th p dng d phng c khng? Nu khng c gii php bo tr no nu trn c p dng th gii php d phng phi c xem xt trc khi quyt nh i n gii php bo tr khi b ngng my. Gii php ny phi xem xt cn thn v mt kinh t. Vn hnh n khi h hng Ch cho php s dng gii php bo tr ny khi cc gii php bo tr khc khng th p dng c. V d khi h hng mang tnh ngu nhin v khng c thi gian pht trin h hng. Tuy nhin thng th phi xem xt hu qu kinh t pht sinh. i khi gii php bo tr ny l kinh t nht do gi thit b thp v khng tc ng n tn tht sn xut. V d phn loi cc cng vic bo tr di y l bo tr phng nga trc tip (TT), bo tr phng nga gin tip (GT) hay bo tr phc hi (PH). STT Cng vic 1 2 3 4 5 6 Bi trn cc bi trong mt ci bm Thay du nht trong hp gim tc hng nm Kim tra cc mt tip xc ca khi ng t mi 6 thng Kim tra p lc kh nn trong mt bnh xe hi mi tun Bm hi vo bnh xe sau khi kim tra Kim tra mt khp ni mm xem cc m cao su c b X X X X X GT TT PH X
Trang 33
mn khng 7 8 9 10 11 Thay th m cao su sau khi kim tra Ra xe hi Lng nghe m thanh t hp s mi ngy o cng dng in ca mt ng c o nhit ti mt mi ni ni in ca mt my trn hng thng 12 13 14 15 16 17 18 19 Lm sch mt cnh qut do b rung ng nhiu Thay th dy ai than ca my nn kh Kim tra mt chuyn i nhit Sn trn nh o nhit trn ng c in hng tun Thay th cn p thng ca mt xe ti o rung ng ca my thi hai tun mt ln Tho bm ly tm mi 3 nm thay bi, trc v cc chi tit b mn 20 21 22 V du m my tin 2 tun 1 ln Thay du trong ng c izen Phn tch du bi trn trong mt ng c ca mt h thng X my pht in 23 24 25 26 27 18 29 30 Thay bng ti sau 1000gi lm vic Lm v sinh sn nh xng sau mi th by Kim tra mc du qua th knh mi ngy Tm kim h hng mt bo mch ca my tnh Thay th n bo trn bng iu khin iu chnh t bo quang in ng ca t ng Thay th mt bi b mn Thay th m trong bi X X X X X X X X X X X X X X X X X X X X X X X
Theo gio trnh Qun L Bo Tr Cng nghip ca PGS. TS. Phm Ngc Tun
Trang 34
BI 9: BO TR PHNG NGA (PREVENTIVE MAINTENANCE)

Bo tr phng nga hay bo tr ngn nga l bt c mt hot ng no c thc hin ko di tui th ca thit b v trnh nhng h hng trc thi hn. V d: kim tra thit b, bi trn iu chnh my v kim tra d on (bo tr d on) v bo tr nh k, thng l thay th chi tit. K thut gim st tnh trng Gim st tnh trng l mt qu trnh xc nh tnh trng ca my mc ang lc hot ng hay lc ngng hot ng. Nu mt vn no c pht hin th thit b gim st tnh trng s cung cp cho ta thng tin xc nh xem l vn g v quan trng hn, ci g gy ra vn . Nh vy chng ta c th lp lch trnh bo tr c hiu qu tng vn c th trc khi my b h hng. - Mt nghin cu gn y ca chnh ph Anh cho thy rng: "Nn cng nghip tit kim khong 1,3 t la mi nm", nh p dng chin lc CBM. Ngi ta xc nh rng c tng 5% kh nng sn sng ca my th c th tng 30% nng sut. Hi qun Canada bo co rng ton b chi ph bo tr ca mt i 20 chic tu khu trc gim c 45% (trung bnh mi tu tit kim c 100.000 la mi nm) nh p dng CBM. - Mt nghin cu khc Anh trn mt tu ch du cho thy kt qu trong vng 12 thng k t khi bt u p dng chng trnh gim st tnh trng gim 37% chi ph trong cng tc bo tr. Trong ngnh cng nghip ha du y, chi ph bo tr cng h xung khong 9-10 la/HP/nm nh thay i chin lc bo tr t hot ng cho n khi h hng sang bo tr trn c s tnh trng. Theo thng k ca nhiu nc cho thy rng khi chng trnh gim st c thc hin th c mi 1 la chi ph s tit kim c 5 la ni chung v t 10 n 22 la ni ring trong ngnh nha.
Trang 35
- Chi ph bo tr trc tip trong cc ngnh cng nghip khc nhau trung bnh l 4% ca cc ti sn c nh, thay i t 2,6% i vi ngnh cng nghip du m n 8,6% i vi ngnh cng nghip luyn thp. Nu cng thm c lng khong 4% chi ph tn tht sn xut do ngng my, th tng cng 8% gi tr ti sn c nh b mt i mi nm. V vy mt iu chc chn rng mt chin lc bo tr ti u c p dng trong cng nghip s c th tit kim c mt khon tin rt ln. - Chin lc bo tr ti u l phi tip cn n chin lc bo tr trn c s tnh trng my, cng vic gim st tnh trng c dng xc nh tnh trng ca my mc v nh vy c th dng my bo tr trc khi h hng xy ra. - Khi cc h hng xy ra dn dn s lm thay i cc c tnh vt l ca chi tit. V vy cn phi thu thp v phn tch cc thng s k thut ca my mc, thit b c th d on cc h hng ca chi tit, b phn trc khi chng xy ra. Nhng thng s ny c gi l thng s d on v hnh thnh trn c s bo tr d on, cng cn c gi l bo tr phng nga d on (predictive preventive maintenance), hoc bo tr tin phong (proactive maintenance) hay thng hn l bo tr trn c s tnh trng. Nhng thng s ny cung cp thng tin v tnh trng ca my mc d on c cc h hng giai on u v t c th lp k hoch bo tr ng n. - iu ny gip lm ti thiu tn tht v nng sut, gim chi ph u t, chi ph bo tr trc tip v cho php cc chc nng ca bo tr c tin hnh mt cch c hiu qu. Tuy nhin, t kt qu tt nht th phi bit la chn thch hp cc my mc, thit b p dng CBM v p dng cc phng php gim st tt nht cho cc my chn. Chn my theo tn tht nng sut Cc my gy nn tn tht nng sut cao thng l cc loi my : ang hot ng lin tc. Lin quan vi mt qu trnh sn xut. C thit b lp t song song hay d phng nh nht. C kh nng d tr sn phm trung gian ti thiu.
Trang 36
C lin quan vi chc nng chuyn giao hay vn chuyn sn phm mang tnh quyt nh. Chn my trn c s an ton Ngoi cc kha cnh kinh t, nhng my no c lin quan n an ton cng cn c gim st. Mc an ton ny c th pht sinh do:

My pht n. Cc vt liu nguy him vng ra v h hng. My dng cho vn chuyn nhn s.
Nn chn nhng b phn no gim st trong cc my c chn Nu khng c kinh nghim v cc dng h hng ca mt my, v nu cc my ny nh hng nghim trng n qu trnh sn sut th cn phi gim st tnh trng ca tt c cc b phn ch yu ang chuyn ng, v thm ch mt hay hai b phn ang ng yn, trong mt vi trng hp, cc b phn cn gim st s c hiu qu nht thng l :

C tnh quan trng v tin cy ca thit b Thc hin mt ch lm vic cao C thi gian bo tr thay th hoc sa cha di
Nhng b phn c tui th thp hn nhng b phn cn li Tng quan v cc phng php gim st Mc tiu ca gim st tnh trng l nhn bit tnh trng ca mt my sao cho c th c bo tr an ton v kinh t. Nhn bit tnh trng ca my c th hai cp :

Nhn bit c tn ti mt vn no . Xc nh vn l g ?
Nhng k thut gim st n gin nht thng l gim st ch quan tnh trng ca thit b bng cc gic quan nh sau :
Trang 37

Nhn: dng gim st l thng, khe h, khi, thay i mu sc. Ngi: nhn bit cc hin tng qu nhit hoc r r. Nghe: gim st ting n khng bnh thng. S: gim st rung ng, nhit khng bnh thng. Tng hp cc gic quan: c dng c lng hiu sut my mc.
Vic xc nh s tn ti ca mt vn no trong my mc, thit b ci tin nh s dng nhng dng c ch th s n gin. Nhng dng c ny loi tr cc sai lm do kin c nhn v c th so snh vi cc d liu khi cc my hot ng trng thi bnh thng do cc nh sn xut my a ra v cng c th so snh vi cc ch s trc y ca cng mt dng c o. Cc dng c n gin ny thng thch hp cho hu ht cc my mc, thit b v c th cung cp nhng ch s nhn bit tnh trng cng nh mt vn no ang tn ti trong my mc, thit b, v d : p k, nhit k, ampe k, tc k hay cc n hoc chung bo ng c t mt ch nht nh cng c th gip nhn bit c mt vn ang tn ti. Bn phng php c bn ca gim st tnh trng
Gim st bng mt
Cc b phn my mc c kim tra bng mt xc nh tnh trng ca chng.
Gim st hiu nng
Tnh trng ca mt chi tit hoc mt my c th c nh gi bng cch o lng cch thc thc hin cng vic c d nh.
Gim st rung ng
Tnh trng ca mt chi tit ang hot ng trong mt my c nh gi qua bin v bn cht ca rung ng m chng sinh ra.
Gim st ht
Trang 38
Tnh trng ca b mt chi tit ph thuc vo ti trng v c lin quan n chuyn ng, c nh gi t cc mnh v do mn gy ra, thng thng nhng chi tit ny c bi trn bng du do vic thu thp v phn tch mnh v do mn c thc hin thng qua kho st du bi trn. La chn cc phng php gim st My c s c c th l do mt hay nhiu chi tit h hng nghim trng gy nn. V vy phi tm ra cc chi tit sp h hng c th gy ra ngng my. Kt qu l cn phi c cc phng php, thit b gim st tnh trng ng tin cy nhm tm ra triu chng h hng ca cc chi tit ring r c thi gian nhn bit trc cc chi tit sp h hng cng di cng tt. Cc khuynh hng trong gim st tnh trng Ngoi cc phng php gim st tnh trng nh bit, ngy nay v trong tng lai gim st tnh trng s c cc khuynh hng pht trin xa hn p ng ngy cng cao ca cc yu cu k thut, mt vi phng php c th c bit n nh sau :
Phn tch ph rung ng : chn on cc h hng c tht trn mt my ngay trc khi dng my.
Phn tch mnh vn do mn : Mt trong nhng phng php l o t l mnh vn trong bnh cha du bi trn ca ng c.
Gim st hiu nng : Ngy nay phng php ny l mt lnh vc gim st tnh trng c trin vng ln nht. Trong thc t phng php gim st ny lin h n vic kho st cc chc nng l g m mt b phn ca h thng yu cu.
Pht trin tr tu nhn to: cung cp cc dng c v tm ra cc k thut gim st c tnh chuyn mn cao, lun trong mt tnh trng sn sng pht hin nhng triu chng h hng trc khi chng gy nn ngng my.
Nhng vn cn quan tm cc nc ang pht trin
Trang 39
D khi nim gim st trn c s tnh trng c ph bin cc nc ang pht trin v li ch ca k thut ny cng c chng minh nhng nhng kh khn v tr ngi trc mt l:
S dng cha ng cc dng c dng trong k thut gim st tnh trng, cng vic o to ngi s dng cha tt, nhng dng c ny c bo tr khng ng cch.
Hu ht cc nh sn xut dng c nc ngoi ch c nhng i l bn dng c cc nc ny. Kh nng s dng cc dch v k thut v cc tin ch dch v cn rt km. iu ny gy kh khn cho cc nc ang pht trin trong vic bt kp cng ngh CBM.
Nhng li ch ca gim st tnh trng Trong sn xut thi gian ngng my c th gy thit hi hng triu ng mi gi. Kinh nghim cho thy rng, nhng nh my p dng mt chng trnh gim st tnh trng th c th :

Ko di tui th trc Cc i ha nng sut ca my Cc tiu ho thi gian ngng my khng theo lch trnh Ko di mt cch an ton khong thi gian i tu Ci thin thi gian sa cha Tng tui th ca my Nng cao cht lng sn phm Tit kim mt lng ng k chi ph bo tr Gim gi thnh sn phm Tng mc an ton ca nh my.
Trang 40
BI 10: BO TR D ON (PREDICTIVE MAINTENANCE)

I. BO TR D ON Cc k thut bo tr d on (PdM) gip xc nh cc tnh trng thit b ang hot ng c th d on khi no cng vic bo tr nn c thc hin. Phng php ny gip tit kim chi ph hn phng php bo tr ngn nga da trn thi gian, bi v cc cng vic bo dng ch c thc hin khi c cnh bo. Cng ging nh phng tr phng nga, bo tr d on c rt nhiu nh ngha. i vi mt s ngi lao ng, bo tr d on l theo di rung ng ca cc thit b ng trong mt c gng pht hin cc h hng ngay t khi n mi pht trin ngn nga h hng ln. i vi nhng ngi khc, l theo di cc hnh nh hng ngoi ca c cu chuyn mch in, m t in, v cc trang thit b in khc pht hin h hng ang pht trin.
K thut kim tra nhit bng nh hng ngoi h thng in L thuyt c bn ca bo tr d on l duy tr thng xuyn theo di cc tnh trng c kh thc t, hiu qu vn hnh, v cc ch s ca cc iu kin vn hnh ca h thng my v cc h thng x l s cung cp cc d liu cn thit bo m ti a gia cc gian sa cha v gim thiu s ln v chi ph ca ngng my ngoi k hoch. Tng quan v bo tr d on Bo tr d on hay bo tr da trn tnh trng thit b, n lc nh gi tnh trng ca cc thit b theo nh k hoc gim st lin tc tnh trng (online) cc hot ng ca thit b. Cc mc tiu chnh ca bo tr d on l thc hin bo tr ti mt thi im d kin khi cc hot ng bo tr hu ht c hiu qu chi ph v trc khi cc thit b mt i s vn hnh ti u. Bo tr d on tri ngc vi cc hot ng bo tr trn c s m thi gian vn hnh (bo tr nh k), khi m mt phn thit b cn c bo tr hay khng cn. Bo tr da trn thi gian s dng nhiu lao ng, khng c hiu qu trong vic xc nh cc h hng m ang pht trin gia cc ln kim tra, v khng c hiu qu chi ph.
The PDM Cycle Trang 41
Nhng thnh phn "d on" ca bo tr d on xut pht t mc tiu d on nhng xu hng trong tng lai ca tnh trng cc thit b. Phng php ny s dng cc nguyn tc kim sot thng k qu trnh xc nh ti thi im no trong tng lai cc hot ng bo tr s l thch hp. Hu ht cc hot ng kim tra ca bo tr d on c thc hin trong khi l thit b ang vn hnh, do gim thiu gin on hot ng bnh thng ca h thng. Thc hin bo tr d on c th gip cho vic tit kim ng k chi ph v tin cy cao hn ca h thng. Bo tr tp trung vo tin cy, hay Reliability-Centered Maintenance-RCM, nhn mnh vic s dng cc k thut bo tr d on (PdM) kt hp cng vi cc k thut bo tr ngn nga truyn thng. Khi trin khai thc hin ng, RCM cung cp cho cc cng ty mt cng c t c chi ph bo tr trn ti sn cho cc mc hiu qu v ri ro l thp nht. II. CC K THUT CHO BO TR D ON
Trang 42
nh gi tnh trng cc thit b, bo tr d on s dng cc k thut kim tra khng ph hy nh l hng ngoi, m thanh, theo di in ha, phn tch rung ng, o mc ting n, phn tch du, v cc phng php kim tra online khc. 1- PHN TCH RUNG NG Tt c cc thit b ng u to ra rung ng hay tn hiu m phn nh tnh trng lm vic ca n. iu ny c lin quan ti tc , kiu lm vic chuyn ng quay, chuyn ng tnh tin hay tuyn tnh. Phn tch rung ng c kh nng p dng cho tt c cc thit b c kh, thng l cc thit b c tc quay trn 600 vng/pht. Phn tch rung ng l cng c hu ch cho bo tr d on, chn on h hng v nhiu tc dng khc. C nhiu k thut bo tr d on c s dng theo di v phn tch cc h thng thit b, my mc quan trng trong mt nh my. Nhng k thut ny bao gm phn tch rung ng, siu m, th nhit, phn tch mi mn, bi trn, theo di qu trnh, kim tra bng mt v cc k thut phn tch khng ph hy. Trong cc k thut ny, phn tch rung ng l mt k thut bo tr d on hiu qu nht c s dng trong cc chng trnh qun l bo tr. Bo tr d on tr thnh b phn ng nht vic theo di cc c tnh rung ng ca cc thit b ng theo di cc h hng pht sinh ngay t ban u v chn ng cc h hng pht trin ti nguy him. Tuy nhin, phn tch rung ng khng cung cp cc d liu yu cu phn tch thit b in, cc khu vc mt nhit, tnh trng du bi trn v cc thng s khc gip nh gi h hng trong mt chng trnh bo tr. Mt chng trnh bo tr d on ton b nh my phi bao gm nhiu k thut, mi ci c thit k xc nh mt vn ring cho thit b ca nh my. Theo di v phn tch rung ng l cng c chn on quan trng i vi thit b to ra sn phm. Khi c s dng hp l, n s gip cho cc h thng thit b ca nh lm vic tt vi hiu sut ti u.
Kiu h hng Phng php theo di Trang 43 Mt cn bng ng
Mt ng tm trc Bt thng vng bi Bt thng bc trt
Bt thng hp gim tc S lng chi tit c im
Khng thay p sut O i nu c h hng nh Khng thay Lu lng O i nu c h hng nh Nhit Cht lng du O O O p ng chm O S dng phng lab Hiu qu Rung ng O O O O O O trong tm nguyn nhn gc r Ngoi ra, phn tch rung ng cn c s dng nh gi lu lng cht lng chy qua ng v bn thng theo di r r v thc hin cc cng vic kim tra khng ph hy tng tin cy cho cc thit b quan trng nh my.
Trang 44
Tm li: Phn tch rung ng hiu qu cao i vi cc thit b tc cao v c th tn km nht trong cc thnh phn ca mt chng trnh bo tr d on. Phn tch rung ng khi thc hin ng cch cho php ngi s dng dng nh gi cc tnh trng thit b v trnh cc h hng ln. Cc th h mi nht ca phn tch rung ng bao gm nhiu kh nng v c t ng ha cc chc nng ca n hn trc. Nhiu thit b phn tch c th hin th ton b cc rung ng trong ba trc ta ng thi, cung cp mt s ghi nhn nhanh chuyn g ang xy ra vi mt my. Nhng mc d vi kh nng nh th, thm ch cc thit b c tinh vi th no th s thnh cng ca vic d on cc h hng ang pht trin vn ph thuc vo s am hiu ca cc nhn vin vn hnh v s p dng nhng iu cn bn v phn tch rung ng. Phn mm qun l gim st my System1- Gii php qun l tnh trng my quay
System 1 - Gii php cho qun l gim st cho cc loi my quay trng yu trong mt nh my: turbine, my pht, my nn, bm cp nc l hi, bm nc lm mt, v.v. H thng gim st lin tc v bo v thit b ca Bently Nevada c ci t v s dng nhiu nht trn th gii, gii php gim st v bo v ti u ca Bently Nevada tr thnh mt phn thit yu ca chin lc qun l ti sn l cc thit b quay quan trng trong cc nh my in, du kh, ho du, gin khoan... nh turbine, bm cp nc l hi, bm cp nc lm mt...
Trang 45
Bently Nevada m u trong mt ngnh cng nghip cn mi m bng thit b gim st v bo v thit b trc tuyn vi sn phm c gii thiu u tin l my thm d vo nhng nm u thp k 60. T , Bently Nevada tr thnh nh tin phong trong cc ngnh cng nghip vi vic m rng sn xut nhng cng c cng ngh cao, phn mm v cc dch v khc nhm cung cp cc thng tin v thit b v cc ti sn khc m bo nh my hot ng lin tc v hiu qu. C th ni rng Bently Nevada khng c i th cnh tranh v cht lng v lun c coi l hng dn u khng ch s lng h thng bo v thit b c thit lp trn ton th gii m cn trong tt c cc sn phm v dch v khc. Nhng gii php ca Bently Nevada lun em li s an ton, hiu qu, cc thit b ng tin cy, v hn th Bently Nevada lun lm hi lng khch hng vi nhng li ch kinh t m h mong mun. L mt thnh vin ca tp on GE Power Systems, Bently Nevada ang nng cao cht lng phc v vi vic thc hin theo cc phng php v cng c "Six sigma" ca GE. Thit b phn tch tnh trng my CSI 2130 ca Emerson Cc phng qun l bo tr ngy nay i hi phi t nhn vin v ngn sch t hn so vi trc y. Vi iu kin t ngi m phi gii quyt cng vic nhiu hn, cc nhn vin bo tr khng th c s c gng lin tc dt ui theo cc h hng lin tip. H cn phi xc nh nhanh chng v chnh xc cc li h hng tm ra cc nguyn nhn gc r gy ra h hng my. Mt gii php cng ngh hiu qu phi s dng n gin, gim thi gian o to v cung cp cc thng tin nhanh u tin cc hot ng bo dng. Emerson pht trin thit b phn tch tnh trng ca my - CIS 2130 p ng yu cu ny. The CSI 2130 ngoi vic thu thp d liu m cn c kh nng sau:

Phn tch rung ng nng cao -Advanced Vibration Analysis Phn tch knh cho - Cross-Channel Analysis Phn tch d liu tc thi - Transient Analysis Cn bng ng - Dynamic Balancing Cn tm laser Theo di mt
Trang 46
2-PHN TCH M THANH V SNG NG SUT Phn tch m thanh c th c thc hin trn mt sng m sonic hay cp siu m Ultrasonic. Cc k thut siu m mi cho theo php di tnh trng m lm cho n c th "nghe" ma st v ng sut trong thit b ng, m c th d on s h hng sm hn cc k thut truyn hng. Cng ngh Ultrasonic l nhy vi m thanh tn s cao c m tai ca con ngi khng th nghe v phn bit chng t m thanh tn s thp v rung ng c kh. S ma st trong my v sng ng sut to ra cc m thanh ring bit trong gii hn trn sng siu m. Nhng thay i trong ma st trong my v sng ng sut c th gip pht hin nhiu tnh trng h hng sm hn cc cng ngh khc nh phn tch rung ng hoc phn tch du bi trn. Vi vic o v phn tch siu m ph hp, c th phn bit t mi mn bnh thng hay bt thng, ph hy c hc, iu kin mt cn bng, v bi trn km da trn mt quan h trc tip gia cc thit b v cc tnh trng vn hnh. Cc thit b theo di m thanh (Sonic) l t tn km, nhng n cng c s dng t hn cc cng ngh siu m (Ultrasonic). Cng ngh m thanh rt hu ch ch cho cc thit b c kh, trong khi siu m c th pht hin cc vn ca thit b in v thm na l linh hot v ng tin cy trong pht hin cc vn c kh. Kim tra bng siu m
Trang 47
Thit b nghe vng bi Ultraprobe 201M Grease Caddy
Vic bi trn ng nh hng n tui th vng bi. i vi vng bi bi trn bng m th vic bi trn ng loi m, bi trn l iu quyt nh n tui th vng bi, nu thiu m bi trn hay bm m vo qu nhiu th u dn n qu nhit vng bi. Vy lm sao c th bit bn bm m hay lm sao bit bm n lc no th ngng, nu bm nh k th c th gy lng ph m do bn u bit m cn hay khng. Nhng lo lng ca bn c mt thit b h tr c lc l Ultraprobe 201M Grease Caddy. Thit b ny c tc dng g: - Nghe m thanh vng bi v xc nh thi im bn cn tra m v khng cn tra m - Gip bn nhn ra khi no ngng bm m vo - Gip pht hin h hng sm ca vng bi Li ch mang li: - Ko di tui th thit b - Ngn nga vic bi trn qu mc
Trang 48
- Tit kim chi ph vn hnh v bo dng - Nng cao hiu qu bo tr Cch lm vic ca thit b: Khi lng m bi trn thp, ma st vng bi s tng ln to ra sng siu m. My c th gn trn hu ht cc sng bn m. my s chuyn cc m thanh tn s cao sang m thanh m cn nhi c th nghe c. My c th loi b cc m thanh nhiu t mi trng ngoi. Thit b d siu m CTRL Dng sn phm CTRL vn dng nhng c tnh ca sng siu m nhm tit kim nng lng, ci tin sn xut, m bo an ton v qun l cht lng. L cng ngh c s dng nhm pht hin r r p sut v chn khng; kim tra tnh trng cc b phn my mc; pht hin cc r r hay h hng ca cc van v by hi trong h thng cng nh pht hin tia la in v hin tng phng h quang. Sng ny c to ra t s ma st hay rung ng. Khi cc bi hay bnh rng trong h thng hot ng (xoay), chng to ra ma st v do xut hin du hiu sng siu m truyn i. Cc thit b nh bm hay my nn cng to ra sng siu m. Trn thc t, tt c cc thit b my mc c kh u to ra sng siu m. S r r p sut v chn khng cng l mt trong nhng nguyn nhn gy ra sng siu m. Khi kh gas thot ra ngoi qua mt vt nt hoc l thng, kh ny s di chuyn t ni c p sut cao n ni c p sut thp, cc phn t s chuyn ng nhanh hn v va chm vi cng ln hn, do to ra sng siu m. Tng t vy, s pht tia la in hay phng h quang cng to sng siu m khi cc ht mang in thot t k h ra ngoi, bn ra xung quanh hay ion ha khng kh. ng dng: c NASA, qun i M v cc nh my, cc c quan kim nh s dng Dng CTRL cho vic pht hin cc r r; chn on cc vng bi v bi trn hp l, kh; chn on s pht nhit pht tia la in; Cc h thng c kh-cc h thng p sut, chn khng - Vng bi - S r kh my nn - Hp s - S r ng phn phi lng vo v ra - By hi - S r hi; Kim tra cc ni hi - Valves - Cc t in
Trang 49
- My nn - S r chn khng Cc h thng in-Cc h thng v bnh cha khng p sut - Truyn in - Cc bnh, bn cha - Cc h thng pht in v nh la - Cc ng ng - Switches, Coils, Spark Plugs & Wiring - Door & Window Gaskets Cc h thng thy lc - Cylinder Head Gaskets - Check & Control Valves - Actuator & Stop Valves - Internal Cylinder leaks
thit b d siu m UL101
s pht tia la in hay phng h quang cng to sng siu m khi cc ht mang in thot t k h ra ngoi, bn ra xung quanh hay ion ha khng kh
Bt d phng in ca mot in ca SKF (Electrical Discharge Detector Pen)
Trang 50
Bt o phng in l dng c cm tay n gin pht hin s phng in trong vng bi ca ng c in. S phng in l do in th trc ng c truyn xung t qua vng bi to ra s n mn do phng in, lm thoi ha cht bi trn v kt qu l lm ph hng vng bi. Cc ng c in hayb h hng vng bi do s phng in l cc ng c s dng b iu khin thay i tn s (VFD). Kt hp vi chng trnh bo tr d on bt o phng in c th sm pht hin cc vng bi d b hng nhanh v gip ngn nga nhng trng hp phi ngng my t xut. Xem nh cht bi trn b thoi ha v vt ln do s phng in qua vng bi
Trang 51
Gii thiu thit b o b dy v thit b tnh cm tay Dakota MX (Ultrasonic Thickness Gauge) L thit b cm tay dng o b dy v thit b tnh nh ng ng, bn b, ni hi v.v...bng sng siu m nhm kim tra s n mn thn v cc thit b. Khong o cho php t 0.63 n 500mm. Thit b ny h tr cho cng tc bo tr phng nga, m bo s an ton, tin cy khi lm vic. Xem thm ti: www.dakotainst.com
3- PHN TCH DU BI TRN

Trang 52
Phn tch du l mt chng trnh lu di, ni c lin quan, c th cui cng d on tt hn bt k cng ngh no. C th mt mt nm cho cc chng trnh ny t c mc phc tp v hiu qu. K thut phn tch thc hin trn mu du c th c chia ra hai loi: phn tch du c s dng v phn tch cc phn t mi mn nhim trong du bi trn. phn tch du c s dng s xc nh tnh trng ca du , s xc nh cht lng ca du, v kim tra c tip tc s dng na hay khng. Phn tch cc phn t mi mn nhim trong du bi trn s xc nh tnh trng c kh ca cc thnh phn my c bi trn, bn c th nhn bit cc thnh phn ca cc vt liu rn hin din v nh gi loi ht mi mn, kch c, mt phn b, hnh dng v cu trc. Theo di v phn tch hng ngoi c phm vi ng dng rng (t thit b tc thp n cao), v n c th c hiu qu cho cc h hng v in v c kh; hin nay n c xem l mt trong s cc cng ngh c hiu qu chi ph. Kt hp phn tch rung ng v phn tch du trong chng trnh bo tr da trn tnh trng thit b Lu nay ngi ta nhn ra rng, bo tr da trn tnh trng thit b (condition-based maitenance) l phng php mang li hiu qu nht, nht l hiu qu v chi ph, trong vic ti a tui th ca cc my cng nghip. Phn tch rung ng v phn tch mnh vn kim loi do mi mn ln trong du bi trn l hai thnh phn ch yu ca bt c chng trnh theo di tnh trng thit b thnh cng v c th c s dng nh l cng c bo tr d on v bo tr tin phong xc nh s mi mn v chn on cc h hng xy ra bn trong my. Khi cc k thut ny c tin hnh c lp th ch mt phn trong cc li h hng ca my c chn on. Tuy nhin cc kinh nghim thc t ch ra rng s kt hp ca hai k thut ny li trong mt chng trnh theo di tnh trng thit b s cung cp cc lng thng tin ln hn v ng tin cy hn, mang li li ch ng k v kinh t cho sn xut cng nghip. Phn tch rung ng ni ring ang ngy cng tr thnh ph bin nh l mt quy trnh bo tr d on v nh l mt cng c h tr ra cc quyt nh bo tr my. Nh l mt quy tc chung, my khi h hng s c cc dng cnh bo m cho thy bi mt mc rung ng tng cao. Bng vic o v phn tch rung ng my, c th xc nh c cch thc
Trang 53
v mc h hng v t c th d on cc h hng ca my. Tn hiu rung ng tng overall t mt my c tng hp t nhiu thnh phn v kt cu my c kt ni vi nhau. Tuy nhin cc h hng my to ra c tnh rung ng cc tn s khc nhau m c lin h n cc tnh trng h hng xc nh. Bng vic phn tch biu dng ph spectrum v biu quan h ca tn s theo thi gian v s dng cc k thut x l tn hiu th c th xc nh c cc tn s khi h hng v tn s t nhin hay tn s ring ca cc thnh phn kt cu my khc nhau.
Thu thp d liu rung ng my
Biu rung ng dng ph spectrum v dng sng waveform hu ch trong chn on h hng my So vi phn tch rung ng, phn tch du v ht bn c nhng thun li ng k khi m n cung cp trc tip v sm cc thng tin v cc kiu mi mn v tnh trng ca my. Trn thc t, nhiu trng hp chng minh phn tch du l mt cng c hng u cho bit tnh trng mi mn bn trong my. Ngoi ra phn tch du c thun li trong vic theo di tnh trng ca cc my tc thp (di 5 vng/pht), m thng cho kh hoc khng th p dng k thut phn tch rung ng. Tuy nhin, k thut phn tch mnh vn kim loi do mi mn trong du khng th hon ton hiu qu trong tt c cc kiu h
Trang 54
hng ca cc c cu c kh. Chnh v l do m c hai k thut phn tch du v phn tch rung ng u cn thit v l thnh phn sng cn ca mt chng trnh bo tr hiu qu. C hai k thut phn tch ht vun kim loi trong cht bi trn v phn tch rung ng c t hp vi nhau lin quan n cc yu cu phn tch ca chng v i hi ca ngi c chuyn mn v kinh nghim. Cc chuyn gia trong hai lnh vc phn tch ny thng tch bit thnh hai mng. Do s kt hp hiu qu ca hai k thut theo di tnh trng c th l thch thc trong mi trng lm vic, c bit l trong nghnh cng nghip nh khoan thm d ngoi bin, khai thc m v cc nghnh khc. Trong nhng nm gn y, cc nghin cu hng ti mc tiu ny ang c tin hnh nhng kt qu cn rt hn ch. Tuy nhin, nhng thun li ca s ci tin cng ngh, bao gm k thut phn tch my tnh tin b v tr tu nhn to to ra s lc quan v trin vng ca vt qua kh khn pht trin mt phng php thng nht mi trong theo di tnh trng my. 4- Gii php gim st tnh trng Swantech "Ma st lun lun hin din trong bt k my mc," Ralph Genesi, Ch tch v Gim c iu hnh ca Swantech gii thch "cng ngh phn tch ng sut sng siu m (SWAN Stress Wave Analysis) ca chng ti xc nh lng ny ma st v theo di n thay i theo thi gian vi cc iu kin ti khc nhau" V d, gii php gim st tnh trng Swantech, pht hin cc h hng nh giai on sm nht, gip c lp cc thnh phn xc nh trong cc thnh phn lin quan. H thng s tnh ton mc h hng, tc tin trin ln k hoch sa cha ph hp. "Swantech l ln u tin kt hp cng ngh cm bin siu m vo trong mt gi phn mm theo di tnh trng," ng cho bit thm. "Nhng d liu khng c phn tch bi mt k s tin cy xc nh c h hng, m phn mm s t ng phn tch v a ra cc xut cc nguyn nhn c kh nng." Tch hp vi bo tr: h thng v cc cm bin thng minh ang tr nn ngy cng tinh vi, gi r hn v ph bin nhiu hn trong cc nh my. Thn thin vi ngi s dng l cc cng c la chn thay th m i hi cc k nng chuyn mn cn thit vn hnh. D liu gi y c th c thu thp, phn tch v biu din trong mt nh dng trong thi gian thc. Tuy nhin, tnh a dng ca cc phng php theo di tnh trng v cc thit b gim st c th to ra gnh nng.
Trang 55
tin hnh cc nhim v bo tr Predictive, cc nh cung cp gim st tnh trng ang pht trin giao din h thng qun l ti sn cho doanh nghip, to ra cc work order, yu cu vt t tn kho v yu cu lin quan n qu trnh c th c kch hot t ng. Cng ngh gim st tnh trng Swantech ang c kt hp vo trong cc gii php Invensys Asset Performance Management (APM). Tch hp vi phn mm qun l bo tr Invensys' Avantis s c tin hnh. Swantech cng ang c tch hp vi Indus Asset Suite. Ks. Nguyn Thanh Sn
Trang 56
BI 11: BO TR TIN PHONG (PROACTIVE MAINTENANCE)

Bo tr Tin phong l g? Bo tr Tin phong l thc hin mt chin lc duy tr n nh tin cy ca my mc hoc thit b. N tp trung vo cc hnh ng nhm mc ch khc phc cc nguyn nhn h hng gc r, cc triu chng h hng ang tin trin , cc li hay tnh trng mi mn trong my. Thc hin mt bo tr tin phong in hnh bao gm ba bc sau: * (1) thit lp mt s mc tiu hoc tiu chun lin quan n mt nguyn nhn gc xc nh (v d nh mc tiu lm sch cho mt cht bi trn), * (2) thc hin mt chng trnh bo tr kim sot nguyn nhn gc r trong mt cp mc tiu (v d nh nh k ly ra hoc loi b vic nhim bn). * (3) gim st thng xuyn ca cc nguyn nhn gc r bng cch s dng mt k thut o lng (v d nh m ht bn) xc nh cp hin nay l g trong mc tiu. Theo cc nh qun l bo tr cc ngnh cng nghip ln trn ton th gii, y l lc vt b tng c v bo tr my mc. Xu hng tit kim chi ph c hng v mt chng trnh bo tr m mc tiu l tm v loi b cc nguyn nhn gc r gy h hng my. Ti sao? Bi v cc phng php bo tr tin phong cc ngnh cng nghip hin nay tit kim hng ngn, thm ch hng triu la trn bo tr my hng nm. i thng vo gc ca h hng Chin lc bo tr Bo tr tin phong Theo di v khc phc cc nguyn nhn gc r gy h hng. Bo tr d on Theo di rung ng, nhit, alignment, phn t mi mn trong du Bo tr ngn nga Thay mi chi tit nh k Khai thng hay phu thut cy ghp Bo tr khi h hng Chi ph cao
Trang 57
Cc k thut
C th con ngi
Theo di Cholesterol v huyt p bng kim sot ch n
Pht hi bnh tim s dng o in tim or siu m
au tim hay t qu
Bi 12: RBI (Risk Based Inspection) l g? s cn thit ca RBI software trong cng tc bo tr
Theo s trn, c th ni RBI l mt trong 4 h thng khng th thiu ca chin lc bo tr RCM/PMO. RBI, CBM, FMEA v RCA l d liu u vo ca RCM/PMO v RCM/PMO phn hi cc kt qu ca ca 4 h thng trn vo chng trnh bo tr PM/PdM trn CMMS nhm thc thi v tng cng hiu qu ca chng trnh bo tr nh my. Ghi ch: RCM (Reliability Centered Maintenance) PMO (Planned Maintenance Optimization) CBM (Condition Based Maintenanace) RCA (Root Cause Analysis) FMEA (Failure Mode and Effect Analysis) RBI (Risk Base Inspection) RBI (Risk Base Inspection): l mt phng php da trn s ri ro kim tra nh gi thit b trong nghnh cng nghip du kh da theo da trn tiu chun API 580/581 ca vin du kh Hoa k. Phng php ny nhm loi b s kim tra bo dng thit b da trn s gi chy, m ch kim tra khi cn thit, gim s ln ngng my kim tra, thi gian chy s lu hn, gip nng cao tin cy v kh nng sn ca sng ca thit b do c lp k hoch v thc hin cng vic khi tht s cn thit. RBI s dng cho thit b tnh v van an ton da theo mc quan trng ca thit b trong h thng. Hin nay cng tc kim tra bo dng cc thit b tnh ca nh my ch yu da trn s gi chy my, iu ny gy lng ph do s ln kim tra nhiu, khi li cha c cch
Trang 58
qun l h s v kim sot tnh trng cc thit b ny mt cch chnh xc v khoa hc. Trong khi ri ro chy n ngy cng tng ca thit b theo thi gian, e da s vn hnh an ton v hiu qu ca nh my. Chng ta cha c mt cng c h tr xp loi mc gy ri ro cho tng hng mc thit b, cung cp mt k hoch kim tra da trn c s: Nhn dng c ch gy n mn, hng hc tim tng trn mi thit b.* a ra k thut kim tra ph hp nhm pht hin ra cc h hng* khuyt tt. Mt chng trnh kim tra thch hp da trn mc ri ro ca tng* thit b.
Phn mm qun l kim tra BAYKBI-S (Knowledge Based Inspection System h thng kim tra da trn kin thc v kinh nghim) do cng ty Bayer Technology Services xy dng, nhm to ra cc li im trong vic chun on, nh gi v a ra khuyn co trong cng tc kim tra-bo dng- sa cha cho cc nh my ha cht-ha du. Hin nay phn mm c cc cng ty ha cht v ha du Hoa k, Chu u, Nht bn, Malaysia, Trung quc,.. a vo p dng kim sot, chun on tnh trng thit b cng ngh cho Nh my ca h. Phn mm RBI, s xp hng mc ri ro ca tng thit b trn mt ma trn li 5x5 (gm 3 mu c bn: xanh, vng v vi mc cnh bo ri ro tng dn), nhn ra s t thit b, ng ng trong Nh my tim tng mc % ri ro cao v a ra cc nh gi, khuyn co c bit cho nhng thit b ny nh tng tn sut kim tra bo dng hay chn phng php kim tra ph hp nht. Mt khc, phn mm cng xp loi cc thit b c % mc ri ro thp, trn c s a ra k hoch yu cu kim tra t hn hoc c
Trang 59
th ko di chu k kim tra cho cc thit b ny. Qua gim vic dng nh my khn cp do hng hc thit b tnh, ng ng cng nh rt ngn thi gian dng Nh my theo k hoch. Nh th phn mm khc phc mt s nhc im cho cng tc ln k hoch kim tra-bo dng truyn thng trong vic xc nh phng php kim tra, chu k bo dng c th vi tng thit b khng ph hp, i khi khng hiu qu, to pht sinh cc chi ph, pht sinh nhn lc v thi gian khng cn thit. Phn mm c th giao tip vi phn mm qun l bo dng CMMS m Nh my ang a vo p dng nhm truy nhp d liu v mt s phn mm kim sot thit b khc. Ks. Nguyn Thanh Sn
Trang 60
BI 13: M hnh qun l bo tr cc nh my cng nghip

Bi ny ti xin mo mui trnh by vi nt v m hnh qun l bo tr cc nh my cng nghip ln m ti bit nh phn bn, ha cht, lc du v nhit in.
nh: nh my ti khu CN Ph M huyn Tn Thnh - B Ra Vng Tu 1. M hnh b phn bo dng trc thuc nh my Trc y v hin ti m hnh qun l bo tr nc ta ch yu l bao gm 2 b phn b phn vn hnh v b phn bo dng. Trong b phn bo dng chia ra lm 3 nhnh chnh: sa cha c kh (bao gm xng gia cng ch to v sa cha ngoi hin trng), sa cha in v BD thit b iu khin o lng. B phn bo dng c iu hnh qun l chung bi phng k thut nh my. Phng k thut nh my c trch nhim qun l chung v mi vn lin quan n cng tc k thut, ch tr iu phi mi cng tc v vic ln k hoch BD (bao gm k hoch BD K v BD i tu trong cc t sa cha ln ngng nh my, ln k hoch mua sm vt t v thu nh thu trong v ngoi nc thc hin cc cng vic bo dng m nh my khng c kh nng thc hin. Phng k thut gim st n c cc xng bo dng thc hin cc cng vic trong k hoch ban hnh bi phng k thut v cc cng vic t xut pht sinh trong qu trnh chy my do cc xng vn hnh yu cu. Ph gim c bo dng l ngi thay mt gim c nh my trc tip chu trch nhim qun l v gim st cc cng tc bo dng ca phng k thut v khi bo dng. u im: - Nhn lc bo dng lun trong tnh trng sn sng p ng. - H hiu r cng vic v c kinh nghim gii quyt cc cng vic thc t ca nh my. - V mt ngn hn chi ph cho khi bo dng thp hn khi thu bn ngoi. - Gii quyt c cng n vic lm cho nhiu ngi.
Trang 61
Nhc im ca m hnh ny: - Tn km chi ph trong vic qun l, thu cn b qun l. - Tn chi ph o to nhn lc hng nm cho khi bo dng. - Tn km chi ph u t ban u cho vic xy nh xng, mua sm thit b, my cng c, phc v cho cng tc bo dng. - Tn nhn cng, v sao? V nh my phi nui ton b cc nhn vin BD lc nhiu vic (nh im l lc ngng ton b nh my i tu) cng nh t vic (khi nh my ang vn hnh). Trong khi cng vic nhiu lc th cn nhiu th SC nhng c lc ch cn s lng va phi. - Tn nhiu chi ph mua sm v bo qun vt t, v sao? V m bo lun m bo vt t d phng thit yu thay th khi cn th nh my phi mua rt nhiu vt t vi nhiu chng loi c kh, in v o lng - iu khin. Chi ph cho vic mua v bo qun vt t d phng l rt ln. y l vn au u cho cc nh qun l bo tr ca cc nh my ln khi m phi cn i trong vic mua sm vt t. M hnh ny u th t m nhc im th nhiu. M hnh th 2 s khc phc cc nhc im ca m hnh th nht. 2. M hnh thu dch v bo tr bn ngoi y l m hnh ph bin cc nc pht trin. Nh my ca h ch c phng k thut chu trch nhim trong vic ln k hoch bo dng cn thc hin cng vic h thu hon ton n v bn ngoi l cc cng ty chuyn v cc dch v bo dng. iu ny s gip h gim cc chi ph trong nhc im m hnh 1. u im: - Khng tn km chi ph trong vic qun l, thu cn b qun l. - Khng tn chi ph o to nhn lc hng nm cho khi bo dng. - Khng tn km chi ph u t ban u cho vic xy nh xng, mua sm thit b, my cng c, phc v cho cng tc bo dng. - Ch thu mn nhn cng khi cn thit. - Gim chi ph cho vic mua sm v bo qun vt t d phng thng thng. Vt t s do cc n v bo dng bn ngoi mua v thay th khi cn. Nh my ch cn mua d phng cc vt t c th ring v quan trng ca nh my. Nhc im: - Ch ph bn thu ngoi tnh v ngn hn th cao hn
Trang 62
- Nhiu khi th ng trong vic nhn cng - Cht lng bo dng ph thuc vo kh nng ca nh thu trong v ngoi nc
3. M hnh trung ha 2 m hnh trn V m hnh qun l ging m hnh 1 nhng quy m nh hn. B phn bo dng nh nh hn v trang thit b phc v cho cng vic bo dng nh k n gin v nhng sa cha nh n gin. Cn ch yu thu n v ngoi lm (ging m hnh 2). 4. La chn m hnh no cho nh my ca bn? Vic la chn m hnh no tt nht cho vic qun l bo tr nh my bn cn da trn cc li ch sau: - Li ch kinh t: sao cho ch ph cho cng tc bo tr l thp nht - Tnh hiu qu ca cng tc bo dng: m hnh no mang li cht lng v hiu qu cao nht. Cho nn lm sao trung ha 2 li ch trn l iu cn xem xt. Trn y l 3 m hnh qun l bo dng cc nh my cng nghip Vit Nam theo hiu bit c hn ca ti. Nu cc bn c kin hay hn th xin c s ch gio i cht ti c th m rng tm mt nh.
Ngy 21-02-2009 Vit bi KSCK Nguyn Thanh Sn.
Trang 63
Bi 13: Nhng tn ti v gii php nng cao hiu qu bo tr nh my cng nghip

1.Cc tn ti nh gi chung v cng tc bo tr: - Cht lng sa cha cha cao: cn gp nhiu li ch quan ca con ngi, tay ngh k thut cn hn ch. - Cha chnh thc ra c cc gii php v chin lc bo tr p dng cho nh my. - Cng tc bo tr cn nhiu lng ph: c bit trong BD K v con ngi - Cng tc bo tr cha thc s c s tham gia ca mi ngi: c bit l nhn vin vn hnh. Cng tc bo dng nh k: - Kt qu cng tc bo tr cn nhiu hn ch: nng cao cht lng ca cng tc lp k hoch v trin khai thc hin. - Cht lng bo tr cha cao: cn nhiu sai st trong cng vic - Cha tnh n hiu qu chi ph: k hoch lp ra khng da trn gi chy my. - Cha phi hp tt gia cc bn lin quan: b phn lp k hoch, thc hin, nhn vin gim st. - Cha c s quan tm st sao ca mi ngi (trc tip v gin tip).
Cc hot ng sa cha phc hi, t xut v khn cp
- Hiu qu cha cao: ch yu l thay mi chi tit, - Cng tc iu tra s c nhm tm nguyn nhn gc r cn p dng hiu qu trong cng tc bo tr. - Cn a ra cc gii php cho cc h hng ngu nhin (ca cc thit b in v iu khin). 2. Cc gii php nng cao hiu qu bo tr
Trang 64
nh gi chung v cng tc bo tr: - Cht lng sa cha cha cao: cn gp nhiu li ch quan ca con ngi, tay ngh k thut cn hn ch. Vn ny ch c th hn ch bng cc quy trnh hng dn c th cho cc cng vic c th nh: trnh t tho lp, kim tra tng bc (check list) v chy th v.vnhm kim sot cht lng cng vic. Trc v sau khi tin hnh cng vic cn c cc bui hp nh gi v rt kinh nghim. o to nng cao tay ngh cho cng nhn v trnh gim st cng vic cho k s. Ghi li nht k sa cha c th phc v cho vic tm nguyn nhn h hng, t l h hng, nh gi cht lng v hiu qu bo tr - Cha chnh thc ra c cc gii php v chin lc bo tr p dng cho nh my. Cn thit phi a ra cc chin lc v gii php bo tr g m nh my phi thc hin v mang tnh h thng, da vo mi c cc nh hng mc tiu v cc thc thc c th v nh mi c s thay i v ci tin cho ph hp. - Cng tc bo tr cn nhiu lng ph, cha c thc s tham gia ca mi ngi: c bit l nhn vin vn hnh Lng ph trong bo dng nh k s ni r hn di. Xin ni r v lng ph con ngi, lng ph thi gian: l bo tr cn c s tham gia ca vn hnh. Vn hnh t trc ti gi ch bit c vn hnh, ngoi ng m van, x l cng ngh v ghi li thng s cng ngh. Thi gian rnh ca vn hnh l kh ln, nu my chy m th h cng rnh, rt d to s nhm chn trong cng vic. Vn hnh cn tham gia vo cc cng vic nh b sung du, thay lc, xit r online, theo di tnh trng ngoi quan v.vy l cc cng vic khng i hi k nng cao.
Trang 65
Lng ph v thi gian: gim thi gian ch i giy php cng vic (c bit l trong thi gian ngng my). Cn c s lp k hoch tt hn nh c th c lp v lm sn giy php t ca m sng ra lm ngay. Cng tc bo dng nh k: - Tn sut bo tr cn da trn s gi chy my - Ngi lp k hoch phi phi hp ngi gim st cng vic thay i k hoch cho ph hp. - Xng BD v cng ngh phi c phn hi v ni dung k hoch v tn sut - Cc xng bo dng phi lp k hoch iu phi tt nhn lc cho BD K v cc cng vic t xut. - C cc bui hp nh gi, tng kt v rt kinh nghim xc nh cc tn ng v hng khc phc. - o to nng cao kh nng gim st cng vic, cch sp sp cc cng vic theo th t u tin cho k s gim st cng vic. - S dng cc phn mm qum l bo tr nh CMMS, RBM Trin khai vic p dng RCA, FMEA nhm ti u ha vic lp k hoch: p dng k thut phn tch cc dng h hng nguyn nhn v cch khc phc cho cc thit b quan trng.
Cc hot ng sa cha phc hi, t xut v khn cp
- Cn lm tt cng tc iu tra s c nhm tm nguyn nhn gc r v cn sa i cho ph hp vi yu cu p dng hiu qu trong cng tc bo tr. Ngoi ra s dng cc k thut tm ra nguyn nhn gc r ca cc h hng nh phn mm chn on h hng System 1, thit b phn tch du
- Cn s dng hiu qu cc k thut bo tr d on vo bo tr nhm gim cc h hng c th bit trc.
- Nhiu thit b n giai on h hng lin quan ti tui th, c bit cc thit b tnh, tim n nhiu ri ro nn cn c qu trnh o c phn tch tnh trng sa cha phc hi ng lc. - Cn a ra cc gii php cho cc h hng ngu nhin (ca cc thit b in
Trang 66
v iu khin n giai on gi ci) nh: i vi cc thit b critical cn c cc gii php nng cao tin cy nh thit k li, c thit b d phng, v.v
Vit bi KSCK Nguyn Thanh Sn
Trang 67

Quan Ly Bao Tri Nha May Cong Nghiep-Vinamain

Uploaded by

Copyright:

Available Formats

You might also like

Quan Ly Bao Tri Nha May Cong Nghiep-Vinamain

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Quan Ly Bao Tri Nha May Cong Nghiep-Vinamain

Uploaded by

Copyright:

Available Formats

BO TR CNG NGHIP VIT NAM Vinamain.

com ----- - & - -----

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

BI 1: Lch s bo tr ca th gii, vai tr v thch thc

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Hnh 1 : Nhng mong i i vi bo tr ang ngy cng tng.

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Bi 2: Vi nt v bo dng cng nghip Vit Nam

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Bi 3: Mt s phng php bo tr thng thng c p dng cc nc u chu

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

BI 4: nh ngha v phn loi Bo tr

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

BI 6: Tng qut v cc chin lc v gii php bo tr

Qun l bo tr nh my cng nghip

KS. Nguyn Thanh Sn - Vinamain.com

Qun l bo tr nh my cng nghip