"Angarsk Petrochemical Company" JSC has implemented and successfully operated stand systems: COMPACS®-RPM for diagnostics and dynamics balancing of cradle-mounted pumps since 2000 and COMPACS®-RPP for bearings acceptance tests since 2010.
The systems main advantages are:
high rates of diagnostic results reliability;
easy to operate;
high operating speed;
built-in self-diagnostic system;
built-in automatic expert system for defects diagnostics;
high reliability and long service life.
Implementation of COMPACS®-RPP and COMPACS®-RPM systems has allowed to save a great amount of money due to prevention of low-quality bearings and cradle-mounted pumps rotors commissioning and, as a result, to increase the operated equipment reliability and service life.
Authors: Deputy head of "Angarsk Petrochemical Company" JSC mechanical repair shop E.N. Diakonov / 2013
COMPACS®-RPE system has been implemented at shop № 20 of "Angarsk Petrochemical Company" JSC in 1996. The system carries out an automatic diagnostics and control of electric motors according to vibration, temperature and current consumption parameters. The system can test both low-voltage and high-voltage electric motors, followed by issuing and printing of the test reports.
COMPACS®-RPE eliminates commissioning of electric motors with increased vibration values caused by bearings, rotor and stator and assemblage defects. The automatic expert system allows to carry out the electric motor debugging as soon as possible, when following its recommendations and prescriptions.
Authors: Deputy head of shop № 20 D.V. Khlebnikov / 2013
COMPACS® system has been operated at GK-3 unit of "Angarsk Petrochemical Company" JSC since 1995. Currently the system monitors 223 rotating equipment units.
The unit maintenance personnel uses the system data, thus preventing the equipment operation in developing defects conditions, timely reacting to all the changes and taking actions prescribed in the system expert messages. It is necessary to point out a high reliability of diagnoses. There are a few examples (March, 2013):
N-32 unit of КК sector. COMPACS® system has detected an increase of Ае and Ve parameters. Following the expert system readings, the maintenance personnel has detected a problem with an electric motor bearing fit, and the unit has been decommissioned for repair.
N-3/1, N-9 units. COMPACS® system has detected an increase of Ае parameter. Following the expert system readings, the maintenance personnel has taken actions on adding lubrication to the bearing. Consequently, the increased vibration has been eliminated, and the unit has started to operate in an "ACCEPTABLE" state.
COMPACS® system implementation allows to carry out timely and purposeful repair and maintenance in real time, which plays an important role in accidents prevention.
Authors: Mechanical engineer of GK-3 unit V.P. Tretyachenko / 2013
COMPACS® system has been operated at ELOU AVT-6 unit of "Angarsk Petrochemical Company" JSC since 1995. Currently the system monitors 144 rotating equipment units. The system performs measurements via:
277 vibration channels;
125 temperature channels;
144 current channels.
Due to a constant control of the units health, with a possibility of observation and changes analysis, COMPACS® system provides safe equipment operation. For example, on March, 18, 2013 the system has detected a rapid growth of a velocity parameter at N-21A unit pump. The maintenance personnel has reacted promptly and turned to an emergency unit. Within the pump examination it has become clear that a rotor wheel fastening nut has turned off.
COMPACS® system has helped to minimize the equipment sudden and unscheduled shutdowns, as well as to plan and carry out repairs with optimal labour and material costs in short time periods.
Authors: Mechanical engineer of ELOU AVT-6 unit A.Yu. Krasnobayev / 2013
Comprehensive monitoring system COMPACS® has been implemented at 39/7 3M unit of "Angarsk Petrochemical Company" JSC in 2007. Currently the system monitors 48 rotating equipment units.
The system excludes the units sudden failures caused by bearing defects, poor lubrication, imbalance, centering and fastening violation, cavitation, hydraulic impacts, electric motor defects, etc. The automatic expert system and verbal messages allow to carry out repairs according to the units actual state of health, and not according to schedule-based preventive repairs, as previously.
The system implementation has allowed to pass to another level of the processing unit reliability with a simultaneous increase of service life.
Authors: Mechanical engineer of 39/7 3M unit N.M. Byrgazov / 2013
COMPACS® system has been implemented at 36/2М ЗМ unit of "Angarsk Petrochemical Company" JSC in 2011. Currently the system monitors 23 pump-and-compressor units.
As a result of COMPACS® system implementation, a number of pump-and-compressor units emergency decommissioning has decreased, as well as amount and complexity of repairs. Moreover, production discipline and repair quality have been improved, the equipment operational processes have become "transparent".
COMPACS® system implementation has allowed to save a great amount of labour and material costs due to elimination of accidents caused by pump-and-compressor equipment and units downtimes. Operation according to the units actual health allows to decrease the number of repairs, and replace overhauls and midlife repairs with current repairs.
Authors: Mechanical engineer of 36/2M 3M unit A.V. Vlasevsky / 2013
COMPACS® system has been implemented at 35-11/1000 unit of "Angarsk Petrochemical Company" JSC in 1995; it has controlled 57 rotating equipment units. Currently 66 units are being under the system continuous monitoring.
It is necessary to point out a high accuracy of technical parameters readings and a timely diagnostics of different units and components malfunctions development. For example, on February 2013, a velocity parameter of N-108 unit electric motor has occasionally gone beyond the acceptable values limits and the maintenance personnel has decided to shut the unit functioning down and turn to an emergency unit. Afterwards the specialists have found an electric defect.
COMPACS® system implementation has allowed to exclude schedule-based preventive repairs and carry out repairs according to the actual health, thus providing the full use of the unit service life.
Authors: Mechanical engineer of 35-11/1000 unit E.D. Morozov / 2013
Comprehensive monitoring system COMPACS® has been implemented at 37/3 3M unit of "Angarsk Petrochemical Company" JSC in 2007. The system monitors 35 pump-and-compressor units.
COMPACS® system implementation has excluded severe accidents and shutdowns, and has extended the units run-to-failure.
The system implementation has significantly decreased labour and material costs for repairs, as COMPACS® system carries out a continuous health monitoring, and all the repair works are performed according to the units actual health.
This has become possible due to a high quality of the equipment health diagnostics and the automatic expert system, which timely warns the maintenance personnel on the units pre-emergency and emergency states and gives prescriptions on actions required for defects elimination.
The system implementation has allowed to pass to another level of the equipment safe and money-saving operation.
Authors: Mechanical engineer of 37/3 3M unit S.N. Vinogorov / 2013
Comprehensive monitoring system COMPACS® has been implemented at 225/1 unit of "Angarsk Petrochemical Company" JSC in 2010. The system monitors 42 pump-and-compressor units.
The monitoring system implementation provides a real-time observability of the equipment health, a timely reaction to changes, connected both with units and components malfunctions and processing mode violation.
The system is easy to cope with and does not require special skills and diagnostic means, and the automatic expert system allows to operate the unit according to its actual health.
Authors: Mechanical engineer of 225/1 unit A.Yu. Rychagov / 2013
DYNAMICS SPC specialists have implemented COMPACS® system at 21-10/3M unit of "Angarsk Petrochemical Company" JSC in 2001. The system carries out health monitoring of rotating and static equipment according to parameters of vibration, temperature, current, pressure and linear expansion.
The system distinctive feature is not only an ability to carry out health monitoring, but to diagnose defects in the unit operating mode. This allows the maintenance personnel to observe changes in the equipment health and to carry out purposeful maintenance and repair according to the unit actual health.
As a result of the equipment long-term operation under COMPACS® system control and according to actual health, the values of the processing unit safety and reliability have been significantly improved.
Authors: Mechanical engineer of 21-10/3M unit G.Kh. Denislamov / 2013