The stationary computer monitoring system for accidents prevention and condition control COMPACS® for the first time in the world was implemented in 2005 at the wheel-rolling mill (WRM) of WRC PSU of "VSW" JSC.
The system COMPACS®-WRM, installed on the wheel rolling mill, provides the WRM technical condition monitoring of the rotating equipment - by 22 channels of vibration, 4 - temperature, 2 – rotating frequency; and of the static equipment - by 3 channels of fluid pressure in the WRM hydraulic system as well as an additional channel for the wheel billet temperature control.
The system is included in the enterprise diagnostic network Compacs-Net®, through which the information about the WRM condition goes to the WRC specialists: PSU mechanists, WRM PSU technologists, as well as the technical diagnostics laboratory of "VSW" JSC.
Real-time condition monitoring provides a timely WRM withdrawal in the repair and significantly reduces its period.
The latest example of an adequate operation of this system is the detection of the bearing defect of the lower motor, installed after overhaul, at the time of its scrolling at idle. The system identified the defect of the outer bearing cage, on the basis of which it was decided to replace that electric motor.
Thus, a possible emergency situation and a 6-hour downtime of the rolling line were prevented and the repair was held by the actual technical condition in real time, so more than 700 wheels were additionally produced.
The implementing of the system in the "VSW" WRM allowed to transit to the maintenance and repair of equipment by the actual technical condition in real time. According to officially published data, in the first six months of operation the system has prevented more than 30 WRM downtimes and paid off more than tenfold, having provided a direct economic effect of more than 50 million rubles. The payback period was less than one week.
Behold the NODE
Using the new opportunities of the after-repair control the Volga Railway is able to take orders from the adjacent lines.
In the Volga Railway railcar depot Anisovka the comprehensive diagnostic system COMPACS®-EXPRESS-TR3 has been implemented.
So far the only one in the network system, intended for AC trains, has already studied the first overhauled suburban electric trains.
"The three sections of the electric train ED9M, which passed TR3, were brought into the specially equipped ways where the equipment operation was fully simulated in real time as if the stock moved by rails. It took COMPACS®-EXPRESS-TR3 a few minutes to reveal deficiencies. In the motor car – an underestimated time to lift a trolley, and in the trailing car – a disconnected power to the automatic locking doors. Mechanics immediately began to correct the deficiencies,"- says the head of the railcar depot Anisovka Sergei Kazanov.
COMPACS®-EXPRESS-TR3 allows to check all the electric systems of the train.
A monitor displays data concerning the operation of the machinist’s crane, pneumatic pipelines and air diffusers, brake cylinders, spare tank and compressor, wheel motor units, pneumatic door drives and pantograph.
"It is easy to detect the circuits in the compressor, heaters, contactors of the motor and trailer cars, to discover the brake system leakage," - says the railcar depot Anisovka technician Sergey Buyanov.
The new system not only speeds up an indispensable after-repair testing of the rolling stock, but also allows to output the train on the line without any defects.
"Previously, the workers had to check approximately the quality of the electric trains, examining the crucial nodes and parts. Presently this is the matter of the equipment concern. It admitted to eliminate the human factor, thereby ensuring 100% quality of repair", - says Sergey Buyanov.
"However, due to this system the road is able to take repair orders for electric trains from other routes," - said Sergey Kazanov.
On November 2 the specialists of DYNAMICS SPC completed the system COMPACS® implementation in the rotating equipment of the isomerization unit. On November 17 a group of the SPC experts will initiate the machinery acoustic emission (the research of the metal destruction by means of special sensors which "hear" the molecular disruption and reflect the crack opening resource).
After approval of documents with the Russian Federal Service for Technical Supervision, all the rotating equipment of the isomerization unit will be operated by its actual technical condition. That will concern the static equipment (three reactors) as well. Before November 29 the experts of the Achinsk Refinery and the representatives of DYNAMICS SPC will conduct the research and prepare the report. The document will be sent to the Russian Federal Service for Technical Supervision to approve the transmission of all the machinery equipment to the operation by its actual technical condition.
The arrangements are held within the framework of the large-scale program, which on the first stage provides the machinery transition of the Achinsk Refinery workshops №1, №3/5, №6, №8, №16 and №17 to the operation by its actual condition. On the second stage (since 2011) we plan to connect our static units with the automated system.
As a whole, the program solves the problem of improving the reliability of the equipment operation through the transition to a two-year run-to-failure. The automated system should pay off in 4,5 months, and the economic effect of its use is estimated at 400 million rubles a year.
From 1995 to the present time our company cooperates with DYNAMICS SPC in the sphere of safe resource-saving operation of equipment. During this time, the basic machinery of technological systems (units 35-11/1000, 11/4 (AVDU-6), GK-3, 21/10-3M, L-24/6) is transmitted into the operation according to the actual technical condition on the basis of ACS SRSM™ COMPACS®.
To date, 439 units of pump-compressor equipment are under the control of the equipment condition monitoring systems COMPACS®, and in November-December 2006, under the constant technical condition monitoring 22 pumping units, 6 smoke exhausters, 2 air-coolers unit and 3 piston compressors were installed in the unit L-24/6. The technical condition of the unit L-24/6 rotating equipment is controlled by the system COMPACS® by 309 vibration parameters, 33 current consumption parameters and 3 rotating frequency parameters.
Simultaneously with the implementation of COMPACS® was conducted the implementation of the diagnostic network Compacs-Net®, which allowed to combine the diagnostic systems data and transmit the objective information concerning the equipment condition from the monitoring services to all stakeholders of the enterprise (Chief mechanic department, Chief power engineer department, technologists, technical supervision) to automate the planning processes and organization of equipment maintenance and repair.
ACS SRSM™ COMPACS® made transparent the processes of change in the technical condition of the controlled units and the staff technical discipline, thus enabling a timely and consistently carrying out of maintenance and repairs in real time to prevent failures and technogenic situations.
The system is easy to operate and is fully paid off in the first six months of work, as evidenced by a recent case of the failure prevention by the system COMPACS®.
In December 2006 while the commissioning of the system COMPACS® in the unit L-24/6 we managed to prevent the charging pump H-1 failure. This unit was connected to the system COMPACS® and its vibration activity during 2 days was within normal limits. 14.12.2006 at 12:01 the level of the controlled vibration parameters on the bearing pump supports abruptly increased. The unit was shut down, which prevented its further destruction and violation of the technological process, because the transition to the standby unit was carried out in time. When disassembling the stopped unit we found that the reason of the abruptly increased vibration on the bearing pump supports was a crack in the casing, through which the cooling jacket water got into the bearing.
Thus, the system COMPACS® before its entering into the commercial operation at the unit L-24/6 prevented the charging pump failure, the possible unit shutdown and in our opinion completely paid off at the stage of implementation.
The implementation of ACS SRSM™ COMPACS® in our enterprise has given a significant economic effect. Specific economic impact for a one diagnosed unit is more than 40 000 USD per year.
In connection with the above stated, in 2007 we plan to implement the system at the units 37/3 and 39/7 of the Achinsk Refinery Oil plant and the introduction of the third stage in the unit GK-3.
In March 2006 the depot Ramenskoye commissioned the system of comprehensive diagnostics of electric multiple units ER-2 series COMPACS®-EXPRESS-2 (DYNAMICS SPC), which consists of seven subsystems:
vibration analysis of the wheel motor units of a motor coach,
diagnostics of the electric compressed-air braking system of an electrical section,
diagnostics of the pantograph technical condition,
insulation diagnostics of the power circuits of an electrical section,
diagnostics of control circuits of an electrical section,
diagnostics of power circuits of an electrical section,
diagnostics of auxiliary circuits of an electrical section.
While the TR-3 permanent repair all the electrical section units are removed, disassembled and repaired, regardless of their current technical condition. When the repair is over, the units are installed back on the electrical sections, but the proper operation and high reliability of the repaired equipment are not guaranteed due to the human factor. The system COMPACS®-EXPRESS-2 operation allows to reveal in a short time the malfunctions, caused by the human factor or improperly repaired equipment, so we can quickly eliminate the detected equipment failure.
The operation of the system of comprehensive diagnostics for electric multiple units ER-2 series COMPACS®-EXPRESS-2 reduces the time for faults detection, locates their place and improves greatly the quality of the rolling stock repair.
Authors: Chief Engineer A.V. Kudryashov, Head of technical department V.A. Parovatkina / 2006
During the operation of the system COMPACS®-EXPRESS from November 2003 to November 2006, it proved itself as a modern system for diagnostics of the wheel reduction gear units of electric trains.
The use of the vibration monitoring system COMPACS®-EXPRESS in the depot Ramenskoye confirmed the high technical and economic efficiency, the reliability of defective WRGU determining and the absence of their omissions with defects in the operation.
The undoubted advantages of COMPACS®-EXPRESS are:
prompt diagnosis-making by dint of parallel measurements of vibration from all sensors;
archiving of test results for the entire period;
test report printing with the automatic diagnostics results;
switching of WMU traction motor from the diagnostic system panel;
automatic control of rotation frequency and taking of vibration signals from the sensors;
opportunity to listen to the vibration signals from the sensors;
reduction of energy costs and increase of the WMU diagnostics station capacity compared with hand-held devices.
The WMU diagnostics data in the depot Ramenskoye for the period from November 2003 to November 2006:
the number of diagnosed WMU – 4533;
the number of defects on the line – 1;
the number of rejected WMU – 62.
One case of defect was admitted by the instantaneous destruction of the inner ring of the bearing axle-box because of the lateral impact load.
Authors: Chief Engineer A.V. Kudryashov, Head of technical department V.A. Parovatkina / 2006
During this time the staff, involved in the vibration analysis of the wheel reduction gear units, appreciated the operational features of the complex.
Its distinctive features include:
simple motor cars diagnostics in the workshop;
high-speed data extraction, defined by simultaneous survey of six major assemblies;
results receiving in the process of measurement, which allows to interfere the process and take the necessary measures to eliminate defects;
high confirmability of the results.
As a remark, we would like you to provide an opportunity to use a computer for more flexible methods of information processing and presenting, using the common program products MicroSoft Office (Excel, Word) in the operational system Windows.
Authors: Head of the locomotive depot A.A. Sharapov / 2006
Since 1999 till the present time the Achinsk Refinery has been operating the stand COMPACS®-RPP, providing a 100% acceptance tests of supplied to the plant bearings. During the stand operation there were no failures of a diagnostic station and a drive mechanism. The stand COMPACS®-RPP is easy to operate, the bearing diagnostics is carried out in a short time with a high percentage of guaranteed reliability.
The main advantage of COMPACS®-RPP is ensuring an accurate and easily understood information about the inspected bearing condition, which allows to decide timely upon its use in order to reduce the probability of failures development.
Within a few years 1300-1500 bearings have passed acceptance tests and diagnostics. In the period from 1999 to 2002 the number of defected products was 15-20%. The main reason was the low quality of production. Currently, the identification of sub-standard products is 4-5,5% of the total number of those which passed the acceptance test. The main reason for the defects reduction is the increase of requirements on the stage of ordering and the transition to the bearings SKF.
The issues of ensuring the stable equipment operation are actual for the Moscow Refinery, which was the main argument in favor of cooperation with DYNAMICS SPC and the implementation of the bearings vibration analysis system COMPACS®-RPP.
The bearings vibration analysis system COMPACSС®-RPP has been operated at our enterprise since November of 2002 and the system for diagnostics and dynamic balancing of cradle-mounted pump rotors COMPACSС®-RPM – since December of 2004. All the works on the stages of implementation and operation are our successful experience of collaboration with DYNAMICS SPC.
The system COMPACS®-RPP is applied for the acceptance test of all types of bearings coming to the plant and excludes the omission of low-quality bearings from suppliers.
For the time of its fault free operation the system COMPACS®-RPP has inspected more than 15000 rolling bearings of various types of domestic and foreign production.
The system COMPACS®-RPM 7506 allowed to organize the control of bearing supports after the repair, which reduced the number of repeated repairs and decreased the amount of failures of the plant pumping equipment.
DYNAMICS SPC systems have a number of advantages:
stable operation of systems;
the simplicity of operation and maintenance;
they do not require from the staff the theoretical knowledge on vibration, diagnostics and balancing;
automatic diagnostics of test equipment (bearings, pump supports) and hardware systems;
automatic archiving of diagnostics results, which allows to restore the test reports.