The issues of ensuring the stable operation of equipment and finding the ways to improve the resource-saving technologies are relevant for "LUKOIL-Ukhta Refinery", LLC, that was the main argument in favor of cooperation with DYNAMICS SPC and implementation of the COMPACS®-RPP system for vibration analysis of rolling bearings.
The COMPACS®-RPP system for vibration analysis of rolling bearings was implemented in our company in 2008, and all works during its introduction and pilot operation was our first and very successful experience of joint work with DYNAMICS SPC.
During this period, 2111 bearings were diagnosed by the system. The quantity and quality of diagnosed bearings are presented in table 1.
Qty of bearings
Qty of bearings, exceeded unacceptable values
% Ratio of bearings, exceeded unacceptable values
The greatest number of bearings – 704 was diagnosed in 2010: 39,77 % of them exceeded the unacceptable values.
Figure 1 presents a histogram of the number of diagnosed bearings by years.
Figure 1 - Histogram of the number of diagnosed bearings by years
Figure 2 presents a histogram of the % ratio of bearings that exceeded unacceptable values by years.
Figure 2 - Histogram of the % ratio of bearings that exceeded the unacceptable values by years
The histograms show that the trend of defective bearings, supplied to "LUKOIL-Ukhta Refinery", LLC, is reducing.
Using the COMPACS®-RPP system in 2008, 28% of the bearings, which was tested to be of a low quality, wasn`t installed in the units of critical equipment and was returned to the suppliers. The bearings, which have passed the acceptance test on the COMPACS®-RPP system, are having a long-time and reliable service in the equipment, confirmed the necessity of this system for "LUKOIL-Ukhta Refinery", LLC.
During the XXII Olympics and XI Paralympic Games 2014 in Sochi 23 EMU-trains of ED4M series, equipped with an on-board monitoring system COMPACS®-EXPRESS-З, meant for real-time health monitoring of EMU-trains equipment and allows to detect the emergence and development of faults in time, displaying the information on the screen of the diagnostic controller in the form of messages of the expert system in the engineer`s cab, were operated in the following areas: Tuapse - Sochi, Sochi - Olympic Park, Sochi - Krasnaya Polyana, Sochi Airport. Also, all information about the bearing assemblies condition, pneumatic brake system and EMU-trains electric circuits in operation is generated and archived in the form of condition reports of each car and EMU-trains in general.
Thus, on the 8th of February, 2014, the on-board monitoring system COMPACS®-EXPRESS-3 revealed the late operation of the pressure regulator in the 043601 car on the ED4M-0436 EMU-train, information about this fault was displayed on the diagnostic controller screen in the form of expert system messages "CHECK_PR".
On the 26th of February, 2014, on the ED4M-0436 EMU-train the on-board monitoring system COMPACS®-EXPRESS-3 revealed, that the electrodynamic braking scheme hasn’t been assembled on motor cars 043606 and 043608, i.e. the braking substitution has occurred. This information was displayed on the diagnostic controller screen in the form of expert system messages "CHECK_POW_CIRC_EDB".
On the 4th of March, 2014, on the ED4M-0435 EMU-train the on-board monitoring system COMPACS®-EXPRESS-3 revealed an increased vibration level on the 1st and the 2nd wheel pairs on the left of the 043505 car, corresponding to the defect availability on the tread of the wheel pair tire. The information about this discrepancy was displayed on the diagnostic controller screen in the form of expert system messages "CHECK_WP".
The information about revealed failures is reported immediately to the personnel in charge.
According to the results of the operation, the on-board monitoring system confirmed its high efficiency, ensuring timely fault diagnosing with the issuing of recommendations, displayed on the diagnostic controller screen, to the service personnel, and thereby providing the improvement of safety and reliability of the transportation process, maintaining a high level of technical readiness of the rolling stock.
Authors: Deputy Chief of the Belorechenskaya depot in the field of maintenance I.L. Lyalyushkin / 2014
At the time of XXII Olympic winter games in Sochi 23 EMU-trains of ED4M series, equipped with the on-board monitoring system COMPACS®-EXPRESS-З were operated in the following areas: Tuapse - Sochi, Sochi - Olympic Park, Sochi Airport. During this time the system has proved itself as a reliable and effective instrument, allowing to reliably track changes of the most important assemblies and EMU-trains units health in real time: assemblies of mechanical part (bearings of axle assemblies and traction electric engines, reducer gear, coupling, wheel pair tread), electrical equipment of power and auxiliary circuits (traction electric motors, groups of pre-braking resistors, transducer, generators, compressors and others), compressed-air braking system equipment, control circuits of the traction and auxiliary electrical equipment.
Thus, on the 19th of February, 2014, the on-board system for monitoring COMPACS®-EXPRESS-3 revealed the failure of transducer on the 044007 car of ED4M-0440 train, the information about which was displayed on the screen of the diagnostic controller in the form of expert system messages "CHECK_ TRANSDUCER_CIRCUIT (BREAKAGE)".
On the 19th of February 2014, on the ED4M-0440 train the on-board system for monitoring COMPACS®-EXPRESS-3 revealed the increased level of vibration at the first wheel pair of the 044001car, which corresponds to the defect occurrence on the tread of the wheel pair tire, the information about this defect was displayed on the screen of the diagnostic controller in the form of expert system messages "CHECK_WP".
On-board monitoring systems are a reliable source of information about the rolling stock equipment condition and means of ensuring the safety of suburban passenger services on the North-Caucasian railway.
Authors: Deputy Chief of the Belorechenskaya depot in the field of repair K.V. Gavrilov / 2014
At the "Gazprom Dobycha Orenburg", LLC the system for vibration analysis of rolling bearings COMPACS®-RPP by the DYNAMICS SPC is operating since 2005. The bearings which are supplied for the repair needs of "Gazprom Dobycha Orenburg" are subjected to the acceptance testing. The number of tested bearings exceeds 12 thousand per year. Bearings which have not passed the acceptance test are returned to the supplier for replacement.
The system has the following advantages:
high operation speed;
low requirements to the personnel skill;
industrial version provides high reliability;
fully automatic operation, the only thing to do manually is to install the bearing and start the diagnostic process.
The usage of the system helped to eliminate the commissioning of the low-quality bearings, and, consequently improve the reliability and increase the resource of the operated equipment of the whole gas-and-chemical complex.
The COMPACS® system was implemented on the ELOU AVT-5 unit of "Kuibyshev Refinery" JSC in 2012. The first implementation of the system was on the basic, the most important units.
During the COMPACS® system operation, series of repairs was carried out based on system readings, which confirmed the effectiveness of equipment condition monitoring by the vibration parameters. The introduction of pump-and-compressor equipment monitoring systems has provided the condition observability of each piece of equipment in real time not only to the process unit, but also remotely through the Compacs-Net®, has allowed to react to the equipment health changes in proper time, connected as with the occurrence of malfunctions of different assemblies and details, so with violations of the technological operating mode.
Moreover, in 2013 the system’s second phase was implemented. The extension allowed to cover more comprehensive dynamic equipment park on the unit. At the moment, 93 equipment pump unit, 4 blowers and 4 smoke exhausters are operating under the supervision of the COMPACS® system.
Also, on the ELOU AVT-5 unit, the information transfer about the health of the units to the APCS (Automatic Process Control System) based on the COMPACS®-OPC technology was realised, that along with the diagnostic network Compacs-Net® extends opportunities of the system.
The Sankt-Petersburg-Baltiysky depot for more than five years successfully operates a comprehensive system for diagnostics of EMU-trains sections COMPACS®-EXPRESS-TR3. During the operation, the system repeatedly demonstrated its strong points. For example, among other advantages of the system for diagnostics of the wheel-motor blocks, which distinguish it from other diagnostic complexes used in depot, one can emphasize the ensuring of automatic wheel pair acceleration to the specified speed and maintain it at a constant level throughout the process of diagnostics, and measuring of vibration parameters in six places simultaneously.
The general advantages of the system are: fully automatic diagnostics with reference to specific problems and forming of the conclusion about the possibility of further operation of the assembly, subsystem and electrical section in general. The test results are archived and cannot be changed, but are available for analysis at any time. A high level of diagnostic procedures automation almost completely eliminates the influence of “human factor” on the diagnosis results.
Subsystem of wheel-motor blocks diagnosing makes minimal demands to operating personnel qualification and provides a significant reduction in labour and energy costs for the equipment condition monitoring. Thus, the condition assessment of the axle assemblies, gearboxes and traction motors of one motor car, including preparatory and finishing-up measures does not exceed one hour.
During the operation, the system helped to identify the number of latent defects of the wheel-motor blocks that was not rolled out, during pneumatic and electrical equipment repairs, which positively influenced the level of safety and continuity of the suburban operation.
Taking into account the positive results of the system operation, we consider that it is advisable to equip the TR-1 shop with diagnostics system of wheel-motor blocks COMPACS® to monitor the actual condition of the rolling stock in operation, carrying out the maintenance and the first-stage current repair.
Among the most significant comments and suggestions we can emphasize the following:
It is necessary to consider the issue on the organization of data transmission from measuring devices of power circuits directly to the diagnostic station.
There is no means to compare the data obtained from diagnostic systems at the commissioning repair positions, with the data on the system COMPACS®-EXPRESS- TR3, because the data are not unified.
It is necessary to consider the possibility of establishing of DYNAMICS SPC representative office in St. Petersburg for the rapid correction of system faults.
The complexity of the operations to connect the diagnostic complex to the electric section in order to test the electrical circuits.
We suggest that an important step on the way to improve the production and technological discipline and quality of repair in general is the connection of the diagnostic systems into an integrated network to provide the unified data of the diagnostics results to the personnel in charge and depot management.
Authors: Chief engineer of the depot Gunenko N.D., Senior master Drozdov M.A. / 2013
The ten basic, the most important pump units were equipped with the COMPACS® system in June 2012 in the BK-4 shop of "Tobolsk-Neftekhim", LLC.
The diagnostic network of the enterprise Compacs-Net® allows technical specialists and managers, accountable for safe equipment operation, to get the information about condition of controlled pump units from the user workplaces, connected with intraplant network.
The employees of the enterprise successfully use the means of the system and diagnostic network for condition assessment and safe operation of machinery and its parts.
This allows to carry out a rapid condition assessment of controlled pumping units during the commissioning and operation, and timely perform maintenance and repair of pump units.
Authors: Chief of BK-4 shop, M.S. Gataullin / 2013
Since 1998 the system of machinery continuous monitoring and condition control COMPACS® has been implemented in 36 pumping units in DBO-10, "Tobolsk-Neftekhim", LLC, but since 2012 the system has been extended for 13 pump units more. As a result, the continuous monitoring and machinery health control are realized on mentioned units by the 180 vibration channels and 36 measuring current channels.
Compacs-Net® diagnostic network of the enterprise allows to technical specialists and managers, accountable for safe equipment operation get the information about condition of controlled pump units from the user workplaces, connected with intraplant network.
The employees of the enterprise successfully use means of the system and diagnostic network for condition assessment and safe operation of machinery and its parts.
This allows to carry out a rapid condition assessment of controlled pump units during the commissioning and operation, and timely perform maintenance and repair of pumping units.
The system of machinery continuous monitoring and condition control COMPACS® during its operation allowed to reduce a downtime of pump units due to the unscheduled repairs, and also contributed to the production of finished products in full by the target date.
Authors: Chief of DBO-10 shop, A.N. Armantovich / 2013
The implementation of vibroacoustic diagnostic and condition monitoring systems COMPACS® in oil-refining plant of "Angarsk Petrochemical Company" JSC began in 1995 with equipping of 354 assemblies of 35-11/1000, 11/4, GK-3 units. Currently, in "Angarsk Petrochemical Company" JSC the 673 main assemblies of the first class of hazard are connected with condition monitoring and vibration diagnostic systems COMPACS®.
Equipping units with the COMPACS®-systems, sensors must be mounted on the drive motor and actuator (pump, compressor etc.), then it becomes immediately obvious in which part of unit the problematic assembly is and what measures it is necessary to assume for the providing of fault-free operation.
Mounting on the electric motor of the:
vibration sensors - allows to control the lubrication condition, the nucleation and development of bearing defects, electromagnetic defects, disbalances, alignment problems, weakening of traction motor fastening;
temperature sensors - allows to follow up the operating temperature of the electric motor, the lubrication condition, the beginning of the bearing elements destruction;
current sensors - allows to control unit operators work in terms of stable technological operation and unit loading (overweight, idle, and etc.).
Automated expert system for decision-making support of COMPACS® helps personnel to maintain safe fault-free operation of electric motors. The equipping electric motors with systems COMPACS® permits to refuse scheduled preventive repairs and go over to condition-monitored operation.
In 1996, there was an implementation of stand system COMPACS®-RPE. The COMPACS®-RPE system provides the automatic diagnostic and health control of electric motors based on such parameters as vibration, temperature, current consumption with their registration and the issuance of the final protocol on test results. In April, 2013 the system COMPACS®-RPE (COMPACS®-M) at the workshop № 20 was modernized, thus, enabling to support 100% control of the electric motors repair quality.
Intuitive interface of the COMPACS® system allows technological personnel to use the system in their work without special training. System COMPACS® is simple in operation and service.
Authors: Director of the plant A.V. Kondakov / 2013