1、 The necessity of monitoring shield tunneling machine oil

1. What is oil monitoring

Equipment status monitoring (also known as predictive maintenance) is an important component of modern equipment management systems. By monitoring various key status parameters of equipment, it determines and optimizes the maintenance and repair cycle of equipment, effectively improves equipment reliability, and reduces maintenance and repair costs. The status monitoring of key oil equipment is generally achieved through oil monitoring. By monitoring various characteristic parameters of industrial oil (such as pollution level, physical and chemical composition, viscosity, etc.), the wear status of the equipment, the pollution status of the oil, and its lubrication status are analyzed and judged, and the operating status and potential risks of the equipment are determined.

2. The necessity of monitoring shield tunneling machine oil

Shield tunneling machines have the characteristics of large size, low speed, heavy load, and high pressure, and the working environment is relatively harsh. Changes in production process parameters have a significant impact on equipment operating conditions, and these factors can cause an increase in equipment failure rates.

Due to its high cost, repairing a shield tunneling machine in the event of a major malfunction can incur significant maintenance costs and seriously affect the progress of the project, resulting in significant losses during construction.

Due to its large size, the shield tunneling machine is also completed by first disassembling and then assembling when entering the underground. When the shield machine is in operation, it is operated by the staff in the main control room, and all related equipment of the shield machine is controlled by buttons in the main control room. It is precisely based on this working mode that if the equipment malfunctions, the difficulty of maintenance will be very high.

There are also many oil using equipment in shield tunneling machines, such as gears, hydraulic systems, bearings, etc. The oil change method for these equipment is generally regular, which will result in a significant annual oil change cost. At the same time, there are also good oils that are replaced, and bad oils that continue to be used before the oil change cycle. Therefore, timely and effective oil monitoring of various lubrication points of shield tunneling machines is necessary to improve the reliability of key equipment such as shield tunneling machines.

2、 Expected benefits of shield tunneling machine oil monitoring

Carrying out equipment condition maintenance based on oil monitoring can effectively improve equipment reliability, reduce equipment accidents and shutdowns, improve equipment integrity, and create huge economic benefits for enterprises in reducing equipment usage costs, energy consumption, and improving equipment production efficiency.

1. Carrying out equipment oil monitoring can timely detect and eliminate lubrication hazards of equipment, actively maintain equipment, avoid abnormal wear of main friction components caused by poor lubrication, and reduce maintenance costs.

According to the general algorithm, the excavation life of a shield machine is approximately 8-10km. Assuming the cost of the shield machine is 48 million yuan, its major maintenance cost is about 5 million yuan, and the regular maintenance cost is about 10 million yuan, through oil monitoring, the number of major and frequent repairs can be reduced, the number of maintenance personnel can be reduced, and the cost can be reduced, which can directly reduce the maintenance cost of the enterprise by 5 million yuan.

2. Tracking and monitoring the wear and tear status of equipment and its changing trends provides scientific basis for equipment management personnel to develop temporary shutdown maintenance plans and major repair plans, realizing equipment condition maintenance. It can not only timely repair and deal with equipment failure hazards, but also effectively extend the major repair period of equipment, thereby obtaining economic benefits.

3. Due to the implementation of state maintenance, potential faults and hazards have been promptly addressed, avoiding shutdowns, production stoppages, and major accidents, achieving safe production.

4. Conducting regular oil monitoring can timely detect and eliminate lubrication hazards in equipment, achieve on-demand oil change of equipment, and thus achieve economic benefits by extending the oil change cycle of equipment and saving energy costs.

The main drive, screw machine, and pipe assembly machine of shield tunneling machines all have reducers, and their main lubricating and wear parts are gearboxes. They use gearbox oil 320 or 220, with an oil consumption of about 1000L. The prescribed oil change cycle is 2000-2500 hours, and it needs to be changed 2-3 times a year. Therefore, the cost of oil change is very high, and many gear oils are still in good condition when they need to be replaced. All indicators have not yet reached the time when they need to be replaced, which results in waste of oil. Through oil monitoring, the oil change cycle can be determined based on the quality of the oil, extending the oil change cycle and reducing oil consumption.

In addition to gear oil, the amount of hydraulic oil and lubricating grease used is also very large, so it is necessary to do a good job in oil monitoring, which can bring considerable economic benefits to enterprises.