Issues connected with uninterrupted operation provision and search for means of improvement of resource–saving technologies are vital for Tobolsk-Neftekhim, LLC. That has become a main reason for cooperation with DYNAMICS SPC and implementation of the COMPACS® vibration analysis and condition monitoring system for pump units.
Since 1998, one of the largest shops of the Tobolsk-Neftekhim, LLC’s - DBO-10 – has 36 the most important pump units equipped with the COMPACS® system providing constant control of their technical state.
In 2012, 13 more pump units were added to them. Currently, the units’ state is constantly supervised through 108 vibration channels and 36 current strength measurement channels.
If the state of supervised units is worsening along with an increase of the nominal vibration parameter values the COMPACS® system issues verbal and text warnings and recommendations for the staff to solve the problem and the most probable cause of the unit’s state worsening.
The successful application of the COMPACS® system can be explained by its following advantages:
during its operation the automatic monitoring of the pump units’ state is carried out;
it does an electronic archiving of the monitoring data - trends of parameters, signals, logs of machinery state, which helps to carry out search, view and printing of necessary data;
unit state is displayed on the screen in easy for comprehension tree-coloured array;
the system has an in-built expert system giving prompting messages about the most probable reasons of the units’ state worsening, helping the staff to conduct the operating procedure saving the units’ service life by their accident-free operation.
Due to mentioned above, as well as the Compacs-Net® diagnostic network set in the enterprise which allows the specialists and managers in charge of safe operation of the machinery to get the information on the pumps’ state from their own workplaces, if they are connected to the intraplant network. Consequently, the enterprise staff reduces the pump units’ downtime caused by unscheduled repairs, and ensures timely and full production.
Authors: DBO-10 shop manager Armantovich A.N., mechanic of the United Client Services Kokan K.L. / 2015
The COMPACS®-RPP system with drives 1602 and 1607 was implemented at the "PAVLODARENERGO", JSC in 2013. Since that, all bearings supplied for HPP-2, HPP-3 and Ekibastuzsky HPP undergo the acceptance test.
For the past 2 years of operation it has tested over 4500 bearings. Bearings which have not passed the acceptance test should be returned to the supplier for the replacement.
Expert system of bearing defects diagnostics is based on the analysis of spectrum waveform of the vibration signal and detects the specific malfunctions of bearings: defects of the inner and outer bearing races, defects of rolling elements and separator defects.
The database of bearings includes data on the number of the bearing, its inner and outer diameter, number of rolling bodies, their diameter and contact angle. The software provides an opportunity of data correction according to the bearing parameters using the operator’s keyboard. Calculation of bearing frequencies considering the rotation frequency during the bearing testing is automatic.
The system’s advantages are the following:
high operational speed rates;
industrial verson, ensuring high reliability;
fully automatic operation process, operator should just place the bearing and activate diagnostics process.
Usage of the COMPACS®-RPP system allows to prevent mounting of low-quality rolling bearings during the repair works, and, consequently, increase the reliability and prolong the machinery operation life.
Authors: Head of ICS A.Yu. Boychukov, Deputy Head of the ICS A. A. Kutyavin, Leading Hazardous Production Engineer at the ICS S. V. Kuklin / 2015
The system for vibration analysis of rolling bearings COMPACS®-RPP has been operating in our company since 2006, and our work on the stages of its implementation and operation were our first and very successful experience of working with DYNAMICS SPC.
The COMPACS®-RPP system operates successfully due to its following advantages:
the system automatically operates the diagnostic bench during the control process;
electronic archiving of data, which allows searching, displaying and printing the test report;
system technology is implemented to increase machinery life by sorting bearing into three categories according to its quality with the following recommended frequency of rotation: not more than 1000 rpm (low speed frequencies), not more than 1500 rpm (medium-speed frequencies) and up to 3000 rpm and more (high-speed frequencies);
condition of the bearing is displayed on the monitor in clear ergonomic colors, similar to traffic lights.
The usage of the system led to elimination of the risk of low-quality bearing commissioning and, as consequence, increased the reliability and operational life of the machinery.
Provision of safe steady operation of equipment and searching for a better resource-saving technology for Sibur-Neftekhim, JSC are very important issues. That was the main reason for working with DYNAMICS SPC and implementation of the system for vibration analysis of rolling bearings COMPACS®-RPP.
Authors: The chief mechanic V.N. Kochuev, the executive chief of NDT and VA Laboratory Nasonov A.A. / 2015
The bench system for bearings vibration analysis COMPACS®-RPP with drive 1602 and drive 1607, with landing diameter of bearings from 40 to 300 mm, produced by DYNAMICS SPC, Omsk, which has been operating at Rostov NPP from 2009 to the present, providing acceptance test of bearings of domestic and foreign production. During operation of the COMPACS®-RPP bench system 6739 bearings were subjected to the vibration analysis.
Expert system for detection of bearings defects is built on the analysis of the spectrum waveform of the vibration signal and indicates the specific defects of bearings: inner and outer bearing race defect, rolling elements defect or cage defect. Bearings which have not passed the acceptance test return to the supplier for the replacement.
During the operation of the bearing bench, there were no faults of the diagnostic station or the drive mechanism. The COMPACS®-RPP system is easy to operate, bearing diagnostics is carried out in the shortest possible time with high percentage of guaranteed confidence.
The main advantage of the system is provision of reliable and easily-comprehendible information about the state of the bearing which allow the personnel to make timely decision about its usage in order to decrease the probability of accident development, and, also, to provide high operation speed rates. It is fully automatic and requires minimum skills from the personnel: the operator needs only to place the bearing and start the diagnostic process.
Using of the system does not allow commissioning of poor-quality bearings and, consequently, improves the reliability and increases the life of the machines.
The system for vibration analysis of rolling bearings COMPACS®-RPP has been operating at "Tomskneftekhim", LLC since 2007. The bearings supplied for repair needs of "Tomskneftekhim", LLC are subjected to acceptance testing. Number of tested bearings exceeds 7.5 thousand items per year. Bearings that fail the inspection test, return to the supplier for replacement.
The advantages of the system are the following:
easy operation and service;
low requirements for qualification of staff: no need of theoretical knowledge in vibration;
automatic diagnostics of both test equipment (bearings) and hardware system, the operator only needs to set the bearings, and start the process of diagnostics;
automatic archiving of diagnostic results, which allows to restore the test reports;
industrial design, ensuring high reliability.
Usage of the system has allowed to eliminate commissioning of low-quality bearings and, as a consequence, increase the reliability and extend operational life of existing equipment all around the enterprise.
Also we would like to express gratitude to the specialists of SPC Dynamics for efficiency and quality of work on checkup, diagnosis and repair of the COMPACS®-RPP diagnostic system.
Authors: Head of Technical Customer Service Division - Plodisty S.L. / 2015
Since 1996 systems for the diagnostics and condition monitoring of machinery have been implemented at the LUKOIL-Volgograd Refinery, JSC. Today the enterprise totally uses the technology of safe and recourse-saving operation and maintenance, including:
The stationary diagnostics and monitoring systems for accidents prevention and machinery condition control COMPACS® at refinery units: DCU, CDU, CCR, FCC and others. At the moment under the COMPACS® monitoring there are 515 machines and 2 coke drums.
The repair quality check systems: acceptance testing and diagnostics of bearings - the COMPACS®-RPP system; diagnostics and balancing of console pump rotors with their own bearings - the COMPACS®-RPM; the system for the electric motor quality and repair check - COMPACS®-RPE.
The portable diagnostic system Compacs®-micro, designed for diagnostic of quasistatic equipment.
As a result of the COMPACS® systems implementation at the refinery the number of pump and compressor units emergency breakdowns has dropped significantly, as well as complicity of its repairs. The production and quality of repair works have improved, operational processes at the technological units became transparent more stable.
The COMPACS® system implementation at the LUKOIL-Volgograd Refinery, JSC allows to save a considerable amount of money due to actual exclusion of accidents caused by pump and compressor machines, and, as a consequence, downtime of technological units, reduction of repair cost, decrease of repair’s difficulty from overhauls and medium repairs to current repairs
The comprehensive diagnostics of electric train units system COMPACS®-EXPRESS-TR3 was implemented at the Anisovka depot in August, 2008 for train TR-3 repair quality assessment.
For the period of the operation the system proved itself to be modern and convenient instrument, which considerably eases quality assessment and setting-up of the systems and equipment of the electric trains both after repair and routine diagnostics when malfunctions occur during the train operation.
The COMPACS®-EXPRESS-TR3 system’s advantages are:
full coverage of EMU-train units of alternating and direct current;
high level of automation which considerably decrease duration of the train setting-up after repair, increasing repair quality and minimizing human factor;
full coverage of the diagnosed assemblies considerably increasing the control of the reliability of the most important parts of electric trains and allowing to detect not only clear faults but hidden defects;
high reliability of diagnostic results;
easy provision of the diagnostic data in the form of reports for all electric train subunits and units in general, and online data collection.
The main result of the system operation is an increase of electric train operation reliability due to the increase in repair and maintenance quality.
Today, the operating system provides EMU-train equipment diagnostics and ensures minimum expenses for operation and repair of the rolling stock, and also is an important instrument for safety and uninterruptedness of railway transport operation.
Authors: Deputy chief engineer of the Anisovka depot S.V.Fabrichny / 2015
The COMPACS® stationary systems were implemented at the Reftinskaya GRES in 2011-2012. On 10 power-units the COMPACS® system provides automatic real-time condition monitoring of 20 smoke-exhauster, 78 hot-blast fans, 20 blow-fans and 8 booster pumps. The systems are connected to 488 vibration sensors, one per bearing assembly, and 130 current sensors.
The implementation of the COMPACS® systems at the auxiliary equipment of the Reftinskaya GRES has allowed to detect malfunctions in time and issue prescriptions for the personnel about the unit’s problems beforehand. During the operation the systems showed high rates of reliability in condition diagnostics. Due to the integration of the COMPACS® system into the data and technological network the personnel can supervise the equipment’s condition in real time from their workplaces in real time. The system makes sudden failures of a unit observable and gradual.
The systems have convenient and clear interface which allows the personnel easily supervise changes in equipment’s condition. In the foreseeable future it is planned to install extra vibration sensors for the vibration level control in three directions, in accordance with operational rules, and a rotation frequency sensor.
To enlarge the abilities of the COMPACS® expert system it is necessary to form the report on the factors which influenced the expert messages.
In the ANALYSIS mode it is necessary to show a grid of the bearing defects on the signal spectrum, as well as of reverse, network and other harmonics.
Since the COMPACS® system is able to receive and process current signals, its next step in development can be the diagnostics of electric motors by the current spectrum.
Authors: The production director - the chief engineer of the Reftinskaya GRES branch - P. A. Bebenin, chief of SSTP branch of the Reftinskaya GRES D. V. Bystrov, vibration analysis and vibration adjustment experts P. V. Kuznetsov and S.E. Rykunov / 2015
At the "Gazprom dobycha Orenburg" LLC the COMPACS®-RPP system was implemented in 2005. Bearings supplied for replacement purposes of "Gazprom dobycha Orenburg", LLC undergo the acceptance test. Average number of bearings, undergoing the acceptance test, is 8000 per year. System of bearing defects diagnostics is based on the analysis of spectrum envelope of the vibration signal and point at specific malfunctions of bearings: the inner and outer bearing races, rolling elements and separator.
The database of bearings includes data on the number of the bearing, its inner and outer diameter, number of rolling bodies, their diameter and contact angle. The software provides an opportunity of data correction according to the bearing parameters using the operator’s keyboard. Calculation of bearing frequencies considering the rotation frequency during the bearing testing is automatic. The system can save the data obtained by the results of bearing testings in a special archive.
Bearings which have not passed the acceptance test should be returned to the supplier for the replacement. There is the practice of used bearings rolling for diagnostics its technical condition and decision if re-installing to the processing equipment is possible.
The advantages of the system are the following:
High operational speed rates.
Low requirements to the personnel skills.
Industrial verson, ensuring high reliability.
Fully automatic operation process, operator should just place the bearing and activate diagnostics process.
Usage of the COMPACS®-RPP system allows to prevent commissioning of low-quality rolling bearings, consequently, increase the reliability, enlarge the operational resource of equipment.
The COMPACS®-RPP system with drives 1602, 1607 and 1608 at the Verkhnetagilskaya Thermal Power Plant of INTER RAO - Electric Power Plants, OJSC was implemented in June, 2014. The system provides acceptance testing of all supplied rolling bearings with inner diameter from 7 to 300 mm.
The database of bearings includes data on the number of the bearing, its inner and outer diameter, number of rolling bodies, their diameter and contact angle. The software provides an opportunity of data correction according to the bearing parameters using the operator’s keyboard. Calculation of bearing frequencies considering the rotation frequency during the bearing testing is automatic. The automatic expert diagnostic system for bearing defects diagnostics is based on the vibration signal-wave envelope spectrum analysis and shows the exact defects of the bearings. The system can save the data obtained by the results of bearing testings in a special archive.
Bearings which have not passed the acceptance testing should be returned to the supplier for the replacement.
The system’s advantages are the following:
Simplicity in usage, fully automated system work process, the operator needs only to place the bearing and start the diagnostics;
High operational speed rates, diagnostic time is not more than 3 minutes;
Low requirements to the personnel skills.
Usage of the COMPACS®-RPP system at the Verkhnetagilskaya Thermal Power Plant allows to prevent mounting of low-quality rolling bearings during the repair works on the dynamic equipment, and, consequently, increase the reliability, enlarge the operational resource of equipment and reduce repair expenses.
Authors: Chief engineer of Verkhnetagilskaya Thermal Power Plant A.A.Chuvashev / 2015