【Ten Years of Rapid Development in Chemical Processing Equipment】2664–2025: Lanzhou Petrochemical successfully developed China’s first intelligent diagnostic system for offline monitoring of equipment operation and maintenance

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Let’s give praise and encouragement to the achievements made in China’s chemical engineering technology and equipment; your participation in discussions is the greatest encouragement. **********************【Ten Years of Great Development in Chemical Engineering Equipment】Continuous updates and summaries are available; feel free to join the discussions: https://bbs.hcbbs.com/thread-3576046-1-1.html ***************** Lanzhou Petrochemical has successfully developed China’s first intelligent diagnostic system for offline monitoring. On September 9th, Zhang Wenjie and Wang Qiqi from Lanzhou Petrochemical’s Mechanical, Electrical, and Instrumentation Maintenance Center used handheld data collectors to gather information on the operation of pumps in a plant with an annual production capacity of 3 million tons. At this time, Du Yi, the deputy director of the production management department at the center, was also staring at the office computer in front of him, analyzing the information being sent back in real time. Since the beginning of this year, Lanzhou Petrochemical has addressed the \"pain points\" in the operation and maintenance of rotating equipment by using technological innovation as the driving force. It has successfully developed China’s first intelligent diagnosis system for offline monitoring data, thereby achieving a significant shift in equipment maintenance from being experience-driven to data-driven. “We are responsible for monitoring over 8,000 offline monitoring devices, which generate nearly 2,000 vibration spectrum and waveform datasets per day. In the past, data was processed manually, which was not only time-consuming and labor-intensive but also prone to missed or incorrect judgments. ”Zhang Zhongxin, deputy head of the Technical Services Department at Lanzhou Petrochemical Mechanical and Electrical Instrument Maintenance Center, said. To overcome this challenge, Lanzhou Petrochemical integrated the technologies of fault prediction and health management platforms in a thorough manner, combining accurately the on-site diagnostic expertise of frontline experts with the mechanisms behind equipment failures. After multiple rounds of refinement and testing, it developed China’s first intelligent diagnosis model capable of working with offline monitoring data. This model employs modular programming to deeply integrate and optimize 46 indicator operators and 16 common fault diagnoses, thereby meeting the requirements for detecting equipment faults accurately. It is capable of comprehensively diagnosing core faults such as imbalance and misalignment in centrifugal pumps and motors; furthermore, for the specific faults of rolling bearings, sub-models for diagnosing faults in the cage, rolling elements, and inner and outer rings are developed to enable targeted identification. Verified by data, the diagnostic accuracy of this model reaches 83.3%, significantly reducing the workload of manual diagnosis. Since August, this model has been successfully applied to 140 units in 3 million tons per year heavy catalyst regeneration plants; there have been a total of 11 fault alarms. Maintenance personnel carried out repairs based on the diagnostic findings, effectively preventing the faults from worsening. In the effort to establish an intelligent management system for the entire life cycle of equipment, the Mechanical, Electrical and Instrumentation Operation and Maintenance Center of Lanzhou Petrochemical developed data integration programs to address the issue of incompatible data between equipment management systems and equipment health management systems. These programs enabled vibration data from monitoring software to be seamlessly integrated into the equipment management system, and they also combined information on equipment records, past maintenance activities, and real-time monitoring data. As a result, a basic equipment database was created, containing details on 42,344 mechanical and electrical devices and over 100,000 pieces of information, thereby breaking down data silos. “By establishing an offline monitoring intelligent diagnosis model, we have achieved a deep integration of ‘digital technology’ and ‘professional expertise’, facilitating a shift in the operation and maintenance approach from reactive repairs to predictive maintenance, and upgrading decision-making from ‘experience-based judgments’ to ‘precise guidance’. ”Zhang Zhongxin is full of confidence. Lanzhou Petrochemical will continue to integrate online monitoring data, drive the iterative improvement of diagnostic models using AI technologies, enhance the intrinsic safety level of equipment, and create templates that can be used as references and replicated, thereby establishing a \"Lanzhou Petrochemical benchmark\" for the digital transformation of equipment management in the refining and petrochemical industry.