Automation of oil leak detection using digital twins of the hydraulic system

Saving material and technical resources. Reducing uncontrolled oil losses and equipment downtime

2023 Project of the Year in the nomination "Best Domain Solution" Business Applications according to Global CIO

During the project implementation, the technology of a digital twin of the hydraulic system based on mathematical modeling was applied, allowing for a prompt response to oil leaks and the adoption of corrective actions. This will reduce the impact of the human factor and increase the operational efficiency of MRO (Maintenance, Repair, and Operations).

About the project

A complex of modern software and hardware tools designed to detect industrial oil leaks on coiler equipment and mechanisms of the mill's finishing group, determining their location and intensity in a continuous 24/7 mode.

Reduction of failures

of hydraulic and mechanical equipment by issuing warnings when leaks occur or when there is a lack of liquid lubricant flow to the friction units of mechanical equipment.

Ensuring predictive control of hydraulic fluid circulation

in hydraulic drive circuits to minimize hydraulic fluid losses in case of circuit integrity breach.

Ensuring online monitoring

of hydraulic and mechanical equipment by warning about the occurrence of leaks or the lack of liquid lubricant flow to the friction units of mechanical equipment.

Archiving information

on recorded leaks and maintaining oil records on the server.

Operating principle of the system

The volumetric balance and pressure drop methods belong to the group of parametric methods. They use information from flow and pressure sensors placed on the pipeline and do not require the installation of any additional equipment. These methods allow detecting the fact and location of leaks based on the analysis of changes in technological parameters.

Volumetric balance method

The main idea of the method is to monitor the fluid flow during the operation of the hydraulic unit. To register a leak, the monitored unit is equipped with two flow sensors based on the calorimetric measurement method.

Pressure drop method

The main idea of the method is to analyze pressure drop waves in the pipeline. To register pressure waves, the monitored point of the unit is equipped with two pressure sensors.

RESULTS

Results display

Visualization of results on the specialists' workstations.

Data storage

Ensuring the accumulation and storage of data for 12 months, with the possibility of extension.

Economic effect

Saving material and technical resources. Reducing uncontrolled oil losses and equipment downtime.

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Client

Location

In Sheet Rolling Shop 10 (LPTs-10), 10 workstations for maintenance and process personnel have been automated to provide timely information about the occurrence of oil leaks on hydraulic equipment.

Year

2023