Bearings vibration analysis system COMPACS®-RPP has been operated at "Mozyrsky Refinery" JSC since 2006. The primary objective of the system implementation at our enterprise is screening of substandard products, as well as ensuring of acceptance tests for rolling bearings, which are mounted on the explosive technological objects dynamic equipment.
COMPACS®-RPP potential allows to use it for rolling bearings acceptance tests with a bore diameter from 40 to 120 mm.
Advantages of the system are as follows:
during the control process a test bench is run automatically;
electronic data archiving is carried out, thus allowing to search, review and print a test report;
the life increase technology is realized according to the diagnostic results by means of bearings sorting into 3 quality categories with the following recommended rotational frequencies: up to 1000 rpm (low speed), up to 1500 rpm (average speed) and more than 3000 rpm (high speed);
bearings condition is reflected on the monitor in an ergonomic colour spectrum, comprehensible for an operator;
the system is unpretentious to environmental conditions, works in repair production and does not require special premises, air conditioning and cleansing systems.
Since September, 2012 the system for comprehensive technical condition monitoring COMPACS® has been implemented at the delayed coking unit UZK-1000 of the "LUKOIL-Volgogradneftepererabotka" LLC coking- bituminous production. The system monitors the technical condition of 30 crucial pump units, 2 smoke exhausters and 2 coke drums.
Pump units condition monitoring is carried out by vibration analysis and parametrical methods of non-destructive testing and by means of vibration and current consumption sensors.
Two coke drums condition monitoring is held by acoustic emission, thermal and parametrical methods of non-destructive testing and by means of acoustic emission, temperature, linear expansion and strain sensors.
The system monitors the technical condition and diagnoses the technological unit equipment defects in the automatic mode, thus allowing the personnel to follow changes of the state and to maintain and repair the equipment timely, purposefully and according to its actual technical condition.
As a result of the 5-month equipment operation under the COMPACS® system control, the safety and reliability activities of the technological unit have been improved.
On-board monitoring systems COMPACS®-EXPRESS-3 have been exploiting at electric trains ED4M of ‘DMZ’ JSC production for more than 1 year. The first electric train, equipped with the on-board monitoring system, entered the depot Moskva-2 Yaroslavskaya in June, 2011. During that time the system has proved itself from a positive side, rendering an invaluable assistance with maintenance of technical readiness appropriate level; alerting about presence and development of hidden defects and informing personnel about malfunctions even before trains have come to the depot to carry out scheduled maintenance works and repair.
The system has detected defects of four traction motors at the electric train ED4M, thus having provided an opportunity to carry out a timely inspection and prevent an unexpected motors breakdown and consequences, connected with that.
The systems operation is absolutely autonomous and does not require additional labour forces – the information on technical condition of rolling-stock under the control is handed over automatically to the depot diagnostic network Compacs-Net® server, as well as to workstations (personal computers), set at workplaces of responsible staff.
For the depot authorities these systems are powerful means to assure the transportation process safety and regularity and to increase effectiveness of maintenance works and repairs.
Authors: The depot Moskva-2 Yaroslavskaya head Gorelov A.V., the depot deputy head in the repair department Sautkin M.P. / 2012
In reply to your letter №282 from 13/04/2012, concerning life-time of electric motors with bearings which have passed acceptance tests by COMPACS®-RPP system, we inform you that our enterprise does not keep statistics about the bearings hours worked, as far as we produce but not exploit motors.
We would like to point out that in consequence of the bearings acceptance tests the number of electric motors returns from test stations has reduced.
Since we use the system COMPACS®-RPP at our enterprise, suppliers tend not to provide defective bearings, which consequently results in a significant decrease of condemned bearings at acceptance tests.
Moscow railway, 21/01/2011. All passengers of a new suburban electric train will be taken into account
Moscow railway - branch of "Russian Railways" JSC – has acquired an electric multiple unit ED4M, which has a passenger counting system over the door of each car.
Electro-optical sensors by means of LEDs and infrared photodetectors form three-dimensional optical images of moving objects. 3D image allows to determine accurately how many people get in and out of the car, in spite of the crowd and counterflows.
Information on the number of passengers, traveling in the train, goes to the on-board computer mounted in the cab. "When the system is installed in all trains, we will be able to analyze the traffic flow in each direction of the Moscow railway" - says the head of the Moscow Railway Vladimir Moldaver.
In addition, ED4M is equipped with leaning-sliding doors with advanced control unit. "This increases airtightness, not piling up snow through niches in the doors, and saves energy" - explains Valery Osipov, the chief designer of "Demikhovskiy engineering plant" JSC.
Each passenger can open the door by pushing the button at the entrance or output of the train. In several seconds after opening the doors are closed. If anyone did not have time to get in, the doors are opened again and after 7-8 seconds are going to close. And for the third time the doors just come to a stop. "Then the door can be closed from the cab or by pushing the button" - explains Alexander Borisov, the doors designer from "Steklomash" JSC. According to his words, the system is rather simple, but passengers will have to get used to it. «It makes sense to announce through a speakerphone how to use the doors. However I have seen on the platform how people hardily come up and push the button» - says Alexander Borisov.
Cars are fitted with air conditioning, new windows with air vents, having a larger volume of opening than serial ED4Ms. It will be comfortable for a locomotive crew to work in the summer. Air conditioners are installed in the cab as well.
The modern diagnostic system COMPACS® monitors the EMU condition. During the motion of the train diagnostic devices collect information on locomotive underframe, mechanical portion, traction apparatus and other equipment. Then the information goes to the depot. «The train condition is monitored with no participation of the locomotive crew. Critical assemblies have sensors, installed on them. For example, a machinist, not leaving the cab, can tell which wheelset has been stuck or which wheel spins if a coupling has happened. It is rather important for us» - says Roman Fairuzov, the machinist of the railcar depot Moskva-2.
The following stationary systems of computer monitoring COMPACS® are implemented at the Saratov Refinery:
CDU-AVDU-6 - in December 2005. At first 30 most critical pumps of the installation were connected - charging pumps and pumps with a speed of 3000 r/min of rolling bearings. The largest effect was obtained on charging pumps (up to 800 kW). Concerning system indications, timely stop allowed avoiding major accidents with the electric motor of charging pumps, which had been occurred before.
Due to timely system warning a large number of accidents with other pumps was avoided. At the same time, a number of accidents with pumps, not connected to the system, occurred despite of periodic vibration monitoring by Engineering Supervision Department, mechanic and operating staff.
In September there occurred an incident on CDU AVDU-6 with a charging pump of boilers TSNSG60-231 with the bearing destruction and shaft break. Similar incidents with equipment, not connected to the system, occurred before.
In 2011 the project of expanding the system CDU AVDU-6 takes place. All the remaining pumps will be connected: 53 pump units and 2 smoke exhausters will be connected.
In 2006 the stationary systems for computer monitoring COMPACS® have been implemented at the unit L-35/11-300 and visbreaking sections. All pump units, air blasts, exhauster (15 units) and the main circulating piston-type compressor of reforming unit (4GM16-45/35-55SM2, 2000 kW) have been connected at the unit L-35/11-300.
Implementation of the system avoided pumps accident at L-300. Earlier extremely dangerous accidents with charging pumps of oil pump station took place. The main hot and firing pumps of visbreaking (6 units) have been connected to the system at the visbreaking section. Before connection to the system there occurred accidents of electric motor of firing pumps (250 kW) with the complete destruction of shaft bearings. After the implementation of the system, there was not any incident with hot pumps of visbreaking, connected to the system.
In 2007-2008 COMPACS® system was implemented at the unit LCH-35/11-600. Almost all the pump units, exhauster (19 units) and circulating centrifugal compressor of reforming unit: gear and electric motor have been connected. Control system of relative vibration and axial thrust Bently Nevada of 3500 type, included in the system PAZ, had been installed on the compressor. The accidents occurred on 2 pumps, not connected to the system.
In 2011, concerning the project of the system expansion, both pumps and 2 air blasts will also be connected to the stationary system of computer monitoring COMPACS®. In 2011 18 air cooler units (ACU) of the unit LCH-35/11-600 will also be connected to the system. In May 2010 there was a fan breaking of one of air cooler units at LCH-600.
Connection of a number of air cooler units to the COMPACS® system have been included in the act of investigation. Air cooler units, which supports are highly located and it is impossible to touch them and control by the vibration meter, are connected to the system. Air cooler units with lower location of electric motors and bearings are mean while not connected.
In 2008-2009 the stationary system for computer monitoring COMPACS® has been implemented at the unit installation L-24/6. Firing and hot pumps (10 units) and 3 circulating piston-type compressors of the unit have been connected to the system. Earlier the accidents with piston-type compressors occurred at the unit. The accident stopped after the implementation of the system. Compressors timely stopped by the indications of the system. The incidents periodically occur on the pumps, not connected to the system, in spite of periodic vibration monitoring by Engineering Supervision Department, as well as mechanic and operating staff. In August 2011 there was an incident with a pump NK-65/35-70 position N-11 with the destruction of the bearing.
In 2010-2011 the expansion of the stationary system for computer monitoring COMPACS® took place on ELOU AVDU-6 and LCH-35/11-600, as well as connection of sealing bleeding control of piston-type compressors at the units L-35/11-300 (5 compressors) and L-24/6 (3 compressors) to COMPACS® system.
In 2011 centrifugal compressor (electric motor), implemented in April 2011, have been connected to COMPACS® system. Control system of relative vibration and axial shift Allen Bradley, included in the system PAZ, was installed on the compressor.
In 2006 we purchased the bearing acceptance test system COMPACS®-RPP. Currently, all bearings have passed control on COMPACS®-RPP system. At first 90% of incoming bearings have been discarded. After the elimination of unfair contractors discard rate has been decreased, but still remains extremely high for the domestic bearings, up to 75% is discarded.
Moscow railway got first suburban commuter trains equipped with air-conditioners
MOSCOW, July, 28 Moscow railway got first suburban commuter trains equipped with air-conditioners. This information was announced to the correspondent of ITAR-TASS by the metropolitan railway government.
First three trains of eleven cars each will soon begin to "run" towards Gorky and Yaroslavl direction. "They were produced in Demikhovskii Machine Engineering Plant, and all the constructive solutions, applied to them, were made according to the wishes of the Russian Railways as well as passengers who have been asked to fill out a questionnaire," - noted in the government.
But the main innovation was the installation of air-conditioners that can automatically maintain fixed temperature in the cars and ventilate air in the vestibules. In order not to damage the environment, the doors of new type were installed in the cars, and the windows can be opened for ventilation at a large angle, which should increase the air flow.
"Until the end of the year we will get 15 trains, which will have to "run" towards the most intense directions" - said the interviewee, stressing that these are "the most common routes, which are now mostly equipped with the ordinary "green" trains". The outside appearance of the new trains has also changed - they roll off the production line painted in the corporate red-gray color of Russian Railways, and center of the car is decorated with the company logo.
Having seen these trains of a new type in Demikhovskii Machine Engineering Plant, ITAR-TASS correspondent confirms that passengers will be surprised by the interior of the train, equipped with comfortable soft sittings, modern luggage racks and lamps, shining with gentle unflickering light. The inter-vestibule compartments are heat- and sound-insulated, so design engineers resigned doors which are now necessary to be opened and closed when going from one car to another.
Furthermore, each train is equipped with video control systems in cars and comprehensive condition monitoring systems. The latest with the help of wireless communication will give real time information on technical parameters and possible deviations to the specialists of the nearest depot server, responsible for the diagnostics of electric multiple units.
Authors: ITAR-TASS correspondent Roman Romishevsky / 2011
Large-scale reconstruction and implemented methods of lean manufacturing will help to increase competitive advantage of the depot in repair segment.
Reconstruction of the depot Bezymyanka was divided into five main stages.
It all started in 2005-2006 with the project development. During the implementation of the first 3 stages of the depot renovation in 2007, 2008, 2009, infrastructure of facilities (track complex, overhead system, supply systems) was improved. At the 4th stage a new railcar-wash complex was built. The final phase of major renovation was service shop repair and upgrade to a level of technical regulations. Total volume of the project investments was over 708,7 million rubles.
Now the depot Bezymyanka has new perspectives.
We recall that in the foreseeable future there will appear electric trans Desiro RUS ("Swallow"). These trains will serve the Olympic Games 2014 in Sochi, and then appear on Russian Railways network, including the Kuibyshev Railway. As explained by the head of Kuibyshev Railway Sergei Kobzev, overall performance and the majority of stands in the depot are adapted to the new trains.
− In expectation of the first "Swallows" depot Bezymyanka need to focus on the development of its competitiveness. Production capacity of the depot will be enough to provide quality repair of trains from neighbor railways - emphasizes Sergey Alexeevich.
Taking into account the region plans to purchase new rolling stock, Minister of Transport, Communications and Roads of the Samara Region Valery Matveev noted the importance of upgrading the depot facilities.
− Today Bezymyanka is modern service workshops, new equipment and decent working conditions - said Valery Matveev.
Bezymyanka can compete only with the depot, where Sapsan undergoes its technical maintenance.
The head of the depot Bezymyanka Sergei Romanychev said that the diagnostic system COMPACS®-EXPRESS has been installed, which allows to make diagnostics of all train systems - from roof to wheels. Complex for disassembly and assemblage of trucks also appeared in the depot. Before its implementation disassembly-assembly process took 13.2 hours, whereas now it does not exceed 8 hours. Modernization has affected all spheres of business activity.
If you had been armed with a wrench and a sledgehammer, now we have a great mechanics - said the foreman of instrumentation equipment and electrical engineering Nikolai Gritsin.
Specialists of the depot stake on the implementation of lean manufacturing methods, quality management, and one of its components - a system 5S, which involves the whole staff in regular activities to bring discipline in the workplace.
The implementation of computer aided management is proceeding. As explained by Sergei Romanychev, each employee has a magnetic card which allows recording all performed activities, controls the expense of material and technical resources. Moreover, computer aided management allows changing to electronic data processing.
One of the elements of lean manufacturing implementation was the installation of LED lighting, which gives annual savings of 6-8 millions RUB. Power consumption of LED lamps is 4-5 times lower than that of traditional incandescent lamps, in addition, LED lamps have a five-year warranty period.
General Director of "Samara PPK" JSC Evgeniy Silantiev says that passengers will estimate the trains, that is why the depot staff should maintain a high level and quality of commuter equipment repair.
Since 2004 to the present day the COMPACS®-RPP system with a drive unit 1602 for rolling bearing vibration analysis has been operating at Togliattikauchuk LLC. This system carries out acceptance test of all supplied bearings.
Since then more than 35,000 of rolling bearings of various types produced in Russia and abroad have been tested by this system. Percentage of supplied defective bearings lowered from 30% to 5% since the moment of implementation. The bearings, which did not pass acceptance test, had been returned to the supplier for replacement.
Using the COMPACS®-RPP system for rolling bearing vibration analysis enabled defective bearings not to be taken in production and, consequently, increased safety, reliability and significantly increased the lifetime of machine equipment.
Authors: Chief of bearing acceptance test office of "Togliattikauchuk" LLC A.N. Kazakov / 2011
Since 2005 at LK-6US unit ("Achinsk Refinery" JSC) the COMPACS® system carries out condition monitoring and diagnostics of two reciprocating compressors of 4M16M-45/35-55 type. Every compressor is equipped with the sensors in the following points:
At a cylinder head in axial direction;
In radial direction of the piston at inlet valves zone;
In radial direction of the piston at pressure valves zone;
Vertically above crosshead;
At main bearings;
TDC (Top Dead Centre) sensor at a tail bearing of the motor.
In total 18 vibroaccelerometers have been installed to the compressor. Monitoring and diagnosing of each compressor is carried out by more than 200 vibration parameters.
Since 2007 the COMPACS® system carries out monitoring of two compressors of 2GM2,5-6,2/38-46S type at a new ‘Isomerization’ unit. Vibration sensors are installed at each compressor:
At a cylinder head in axial direction;
At inlet valves;
At pressure valves;
Vertically above crosshead;
At a front end bearing of the compressor;
At a tail bearing of the compressor;
At a front end bearing of the motor.
TDC sensor has been installed at the motor bearing as well. In total each compressor has been equipped with 15 vibration sensors with more than 150 vibration parameters under control.
During the COMPACS® system operation at LK-6US unit a number of repairs based on the system indications have been carried out, which enabled elimination of fundamental causes of increased vibration activity of various compressor units.
Implementation of the systems for reciprocating compressor monitoring ensures real-time observability of compressor condition, enables timely response to changes in their condition due to malfunctions of various units and parts as well as failures of process parameters of their operation.
Gathered experience of use of monitoring system indications enables actual operation of the compressors based on the COMPACS® system indications at both units.