To improve reliability of rotary equipment I hereby ORDER:
1. Engineering Supervision Department (Kazeev P.M.):
1.1. To arrange the acceptance test of all new rolling bearings on the vibration diagnostics stand COMPACS®-RPP making reports by engineers of the equipment diagnostics.
2. Materials Management Department (Tyulkin S.P.):
2.1. Arrange the acceptance test of all new rolling bearings on the vibration analysis stand COMPACS®-RPP in the repair department.
2.2. All rolling bearings, suitable for operation in all parameters, in accordance with the conclusion of engineers of the equipment diagnostics of Engineering Supervision Department, must be entered and given to the workshops in accordance with the applications.
2.3. All rolling bearings, not suitable for operation in one of the parameters, must be issued together with the claim of Department of Mechanical Engineering to the supplier.
3. Department of Mechanical Engineering (Karavayev O.I.) must prepare claims to the suppliers after detection of the defects of rolling bearings.
4. First Deputy General Director - Operation and Equipment Maintanence Director Struk Yu.V. shall be charged with monitoring the execution of this Order.
Authors: General Director, Rubinstein L.A., Chief Engineer Luriya V.B., First Deputy General Director - Operation and Equipment Maintanence Director Struk Yu.V / 2001
Scientific and Production Center "Diagnostics, Machinery Reliability and Complex Automatisation" DYNAMICS SPC is a business partner of the plant and has been expertizing the industrial safety of critical equipment since 1999. To solve these problems the Centre established a laboratory for Non-Destructive Testing and Technical Diagnostics, staffed with highly qualified specialists in industrial safety and non-destructive testing, advanced equipment of "Time Group", "Krautkrammer", "Diaton - RAC", systems and instruments for vibration analysis developed by DYNAMICS SPC. Besides classical NDT methods:
Metal hardness measuring,
they also apply advanced NDT methods for diagnostics such as vibration and acoustic emission.
The Centre performs work on tight schedule and with high quality through highly qualified specialists and modern equipment. Over the period of cooperation, the Centre diagnosed 29 units of process equipment and 200 rolling bearings with the help of non-destructive methods that allowed detecting equipment defects and providing repair, thus preventing possible emergencies. Service life of the operative equipment was extended on the basis of data and calculations, thus saving significant funds that would have been spent on the replacement of equipment that worked out its resource, specified by the manufacturer.
Totally during 1999 and 2000 the following works were performed and delivered to "Omsktekhuglerod" JSC:
Conclusions on the results of non-destructive testing - 82 pcs.
Stress calculation and remaining life operation - 28 pcs.
Expert reports on industrial safety - 28 pcs.
10 diagnostic reports for 200 bearings.
At the moment the agreement has been signed and tank stock in the shop № 4 is under diagnostics.
I consider it expedient and profitable further cooperation with DYNAMICS SPC, which approved itself as a reliable business partner that can quickly and efficiently solve complex technical problems.
Systems and technology have been developed under the egis of Federal Mining and Industrial Supervision of Russia since the early 90's. They are widely implemented at the Omsk, Angarsk, Achinsk, Volgograd refineries, Tobolsk petrochemical plant and other enterprises, and provide safety and significant labor, material and financial resource saving.
The systems are certified, registered in the State Register, and approved for use throughout Russia, have implosion protection of OExiallC class, adopted by Ministry of Fuel and Energy of Russia.
The System, technology and development staff in 1997 were awarded the Russian Federation Government Prize in scince and engineering and are equal to the best foreign patterns.
Authors: Head of Supervision Department for chemical, petrochemical and refining industry A.A. Shatalov / 1999
The reliability of process units of our company is very much dependent on the fault-free operation of pump-and-compressor equipment. Statistics shows that only in 1994-1996s there were more than 200 major accidents on petrochemical and oil-refining enterprises due to breakdown of the pumps for transportation of explosive products.
In recent years, we had a number of activities that greatly reduced the number of emergency breakdowns of pump-and-compressor equipment. The stock of existing pumps was updated, and repair technique improved. However, international some Russian plants experience recommended the implementation of stationary systems for machine equipment vibration analysis operation.
The analysis of existing stationary systems and experience of their operation at Omsk Refinery allowed to choose COMPACS® Stationary system for Computer Monitoring (computer monitoring for accidents prevention and equipment condition control). This system is designed by Omsk Scientific Production Centre "Dynamics", organized on the basis of an aerospace industry Research Institute.
All designs of this centre have been tested at the units of Omsk Refinery, equipped with 12 systems, that control 420 pieces of equipment. Our experts studied the application experience of stationary system for vibration analysis, implementation efficiency and its capabilities at the given plant. In 1998, Slavneft Yaroslavnefteorgsintez signed a contract with DYNAMICS SPC for design, production, installation and launching of the system COMPACS® at the unit AVT-4. The main works were made during the overhaul in October, and commissioning was completed in December of the preceding year. Personnel of the workshops №1, 11, 15 and 18 now face the task to master the system, study its strengths and weaknesses. COMPACS® system is designed for continuous monitoring of the technical condition of pumps and motors and warning about intolerable defects in the testing equipment. Vibration and temperature of pump and motor bearings are measured with the help of sensors and thermocouples installed on the pump and motor, motor load current is measured with the help of the current relay installed at the substation.
Through connecting cables and transforming remote modules signals from the sensors, thermocouples, current relays are passed to the diagnostic station, based on industrial computer and installed in the operator's room, for processing, display and storage. The diagnostic station not only monitors the condition of units on the parameters of vibration, temperature, and consumption current, but also provides automatic diagnostics of the units.
The results of the system operation are displayed on the screen, which provides various information with the help of appropriate "menu". The choice of a "menu" is a simple switching of number or hot keys of diagnostic station. This provides simple and convenient communication with the system for engineering technicians, engine operators, operators, electricians, repairmen, who use the information for their work.
Thus, COMPACS® system allows:
Duty personnel at any time to know the technical state of all units connected to the system.
To provide a verbal and visual alert of the staff about intolerable defects of the equipment.
Specialists, using vibration spectrum, to find hidden, quickly developing defects in order to take the necessary actions.
To use fully of the controlled equipment resource and repair it considering its technical condition.
To keep in the diagnostic station memory control data for several years and provide them reproducing in detail the equipment performance in emergency situation.
Objectively assess the quality of the maintenance at the first start of pump unit after the repair.
Chief mechanic and Chief power engineer services to reduce the vibration of the pumps and motors to the existing standards by eliminating the detected vibration sources – improper units fastening, bad foundations, piping vibration, etc.
If we can fully use the COMPACS® system potential, so due to pumps accident prevention, we will significantly increase the stability of the AVT-4 operation and completely eliminate downtime or its transfer into circulation due to these reasons.
It should be noted that even periodic vibration monitoring of pumps, which is performed for two years by a group of vibration diagnostics on AVT-4, has significantly improved their technical condition. During implementation of COMPACS® system, the specialists of DYNAMICS SPC were pleasantly surprised that only 10 percent of AVDU-4 pumps of unit operate in "Intolerable" mode, while in other plants, as a rule, the number of these pumps is up to 50 percent or more.
With the implementation of the new system, the number of repairs is increased, as it is necessary to eliminate defects of the pumps and motors operating with high vibration. But when improvement of the units is performed only according to their actual state, number of repairs will decrease. Accordingly, the amount of spare parts and materials will also decrease. So the cost of repairs will reduce to 20-30 percent.
Strict quality requirements, for pumps and motors maintenance imposed by the implemented system will require from the staff a higher level of accuracy and quality of work, the use of high-precision machining facilities, tools and instruments, as well as more advanced designs of pump assemblies and parts: face seals of new types for oil products with temperatures up to 400 degrees, plate couplings, bearings of modern types, etc.
COMPACS® system is rather expensive. Ruble collapse in August last year had affected its price as almost all component parts and assemblies were purchased abroad in currency. In December its price was increased approximately 2.5 times. So difficulties of financing operations have been exacerbated by the fact that major part of the expenses was financed from the repair funds. When it is necessary to cut expenses, affecting the net cost, purchase and implementation of a stationary system should be marked as "modernization" item of expenditure.
The experience of Omsk Refinery showed that COMPACS® system is paid off in one year. Under financing, this year we are planning to purchase and install stationary system at 1A-1M and AVDU-4 units and connect the remaining pumps to the diagnostic station.
The implementation of COMPACS® system is the way to the safe resource-saving operation of mechanical equipment and process units.
Since November 1995 COMPACS® systemprevented serious problems and emergency situations on pumping equipment and air coolers. It`s almost impossible to notice the defects detected by the system, but COMPACS® timely warned against developing defects, thus providing scheduled repairs of the equipment. There were no emergency breakdowns of the equipment except 2 cases when the system responded at the last moment (3-5min. before) and the staff had no time to react.
When the system was implemented, 70% of pumping equipment and air coolers were operated in the "red" zone (intolerable), as confirmed by the vibration analysis service. COMPACS® system allowed to coordinate more effectively the work of maintenance and repair service, electric shop service and technological personnel. Thereby almost all equipment was brought into operating state during 2 months.
During the period of 1996-1997s the number of pumps midlife repairs and overhauls was reduced 1.95 times in comparison with 1994-1995s. So in 1994 33 midlife repairs and overhauls were performed at unit L-35/11-1000 and in 1995-26 repairs, in 1996 -12 repairs, in 1997-17 repairs.
System failures were not observed, indication and diagnostics accuracy was confirmed by the vibration analysis service.
Authors: Head of the workshop 8/14 D.V. Morozov, Head of the unit L35/11-100 D.L. Shishov / 1998
The stationary system was installed on the phenolic oil purification unit 22 of LLC "LUKOIL-Volgogradneftepererabotka in April 1997 and showed that 25 pump units of NK6 type were defective and contained 16 malfunctions. 6 units had 3 motors and 5 pumps out of work, which contained 5 and 11 malfunctions respectively:
five machines required replacement of the bearings;
four machines required to be centered;
three machines required fastening improvement;
one motor had overheated bearing, and the other was overloaded.
All these malfunctions were constantly displayed on the monitor of the diagnostic station and during units repair the staff clearly saw the results of their work. Three months later, in July, the main mechanical causes for these units had been eliminated. In November, only one unit demanded the replacement of bearings, fastening improvement and centering, and three were a bit overloaded. At the end of January 1998 there were no units with mechanical causes, and only one of them was a bit overloaded.
Thus, during 9 months of stationary system operation the number of failed units was reduced 8 times and number of malfunctions - 15 times. The main factors that violated operation conditions of the units were detected and remedial measures were undertaken.
To improve the reliability of repaired pumps and motors, bearings installed in them previously inspect for quality on a special stand. Before pump assembly, the rotor with coupling is preliminarily balanced on the special stand. The measures for cooling systems improvement and rational choice and equipment load are developed.
The implementation of stationary systems allowed operating equipment with its maximum resources while saving its maintainability, that became possible due to warning system of the staff about dangerous development of the malfunction.
There were changes in repair structure, from general and midlife repairs to operating repairs and maintenance. Considering that the cost of units equipage with the system is approximately equal to the cost of the average repair (25-30 millions rubles), it can be said that the system has already paid off its keep with respect to repairs.
More than 30 emergency situation, connected with the loss of units efficiency due to alignment problems, fastening problems, bearings breakdowns were prevented during 9 months of the system operation. Effect is determined not only by reducing the number and labour intensity of repair, but also by reducing additional losses, first of all, downtime of the unit or its elements that is more than 100 million rubles per unit.
Thus, the economic effect of the system implementation is estimated at 120-150 million rubles per unit, i.e. not less than 3 billion rubles. Payback period is maximum 4-6 months.
Reliability management of the equipment has become visible and effective.
Since September 1995 the analysis of the pumping equipment operation in the CGFU workshop, controlled by COMPACS® system, has revealed a number of problems.
The following pumps were operated with the high level of vibration: H-1 / 1, H-1 / 2, H-1, H-1 / 4, H-2 / 2, H-M / 1, H-3 / 2, H-3 / 3, H-7 / 1, H-7 / 2, H-9 / 2, H-16 / 1, H-19.
An overload of standard values of vibration velocity, vibration acceleration and vibration displacement, typical for malfunctions detected by COMPACS® system, has occured.
Mechanical service "Butadiene" held activities for malfunction repair recommended by COMPACS® system.
Total cases of overload of vibration standard values were 47, among them seven times the malfunction was on the motor (H-3/1, H-3/2, H-3/3, H-2/1).
The most frequent malfunction of the pumps (according to the spectra analysis) is a unit misalignment and bearing assemblies malfunctions.
Pumps H-1/1, H-1/4, H-3/2 show the unstable operation and constantly misalign because of temperature differential at night and daytime. After centering the unit works properly half a day, then the defect appears again. This has been happening since mid-March.
The second repeated defect is bearings malfunction. Organization technological safety engineer in the maintenance foreman's presence checked up all bearings as a set of spare part, available in the shop CGFU, and found out seven units with deviation from specification for axial and radial clearance.
More common defects of electric motors are bearings malfunction. Rotor unbalance was detected on the pumps H-1/1, H-7/1, H-7/2, and corrected during scheduled maintenance.
During operation, COMPACS® system clearly reacted to the slightest changes of the vibration level. Strict control of vibration level allowed a significant reduction of mechanical seals breakdowns. So, during the period from September 1994 to March 1995 there were eight mechanical seals breakdowns, and during the same period a year later, from September 1995 to March 1996, there was only one mechanical seal breakdown.
The implementation of stationary systems of pump-and-compressor equipment vibration analysis COMPACS® has been carried out by the specialists of DYNAMICS SPC since 1989. During this period systems of vibration analysis have been implemented at 8 units of 4 plants (AVDU-10, AT-9, AVDU -7, AVDU-8 - plant № 1; 43-103 - plant №2; 36/1-1, 2 - plant №3; 35/11 - 1000 - plant №7). Installation and implementation of systems at units 36/1-3, 4 of plant №3 and the largest complex KT-1 of plant №2, have come to an end and will be comissioned in the nearest future.
COMPACS® systems measure vibration, temperature and power consumption and according to these parameters diagnose the state of main plant units - centrifugal pumps and drive motor compressors. About 100 pumps are monitored according to 200 measuring channels. After the commissioning of the complex KT-1, the number of controlled units will be 270, and that of measuring channels - 800.
The main result achieved after the implementation of systems - the exception of the sudden failures of the equipment and improvement of its operation reliability due to timely warning of personnel about the location, time and causes of faults, including bearing defects, shaft misalignment, balancing problems, unfastening of pumps and motors to the foundation and pipes – to the pump flanges.
The systems are also used to monitor the quality of pumps and motors after repair and installation.
An important function of the systems is to control the operators` work, who overload the pumps to get the process data, which is one of the causes of accidents. The system warns the operators by voice messages about the intolerable operating conditions of the unit. All the measured parameters are accumulated in the databases, displayed on a color monitor of the diagnostic station, designed on the basis on the AT-486DX computer, and recorded in various ways by the request of the staff.
COMPACS® systems have showed good results, keep high reliability, ease of use for the staff and according to technical characteristics are equal to the best foreign analogues. The cost of the system implementation is 5-10 times lower than the foreign ones, and are totally paid off during the first year of operation.
At present, it is decided to organize a diagnostic network for technical supervision, which provides a centralized acquisition, storage and recording of information about state, defects and repairs of pump-and-compressor equipment in order to optimize the stoch of pump-and-compressor equipment, its operation conditions, spare parts planning and achievement of minimum costs for equipment operation.