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.
Our company cooperates with your Centre since 1995 on the implementation of vibration analysis and condition monitoring systems of rotary equipments, and since 2000 specialists of "Tobolsk-Neftekhim" LLC are trained and certified by DYNAMICS SPC Independent organization on personnel certification (DYNAMICS SPC IOPC).
During this time 15 our specialists, who are engaged in diagnostic equipment using instruments and methods of VA (vibration analysis) and VMT (visual and measuring testing) of NDT, underwent training and certification in your Centre.
Training was carried out by highly qualified who have extensive experience. Technical standards and organizational and methodical documents for non-destructive testing (GOST, international standards, technical specifications, manuals) were used during the theoretical training. Different instruments and monitoring systems (including those developed by DYNAMICS SPC) were used during practical training, moreover the training center provided the opportunity to visit Omsk leading enterprises for carrying out practical work.
100% passing of all our experts the independent qualification examination is the best confirmation of quality education.
We hope for further profitable cooperation.
Authors: First Deputy General Director - Chief Engineer of "Tobolsk-Neftekhim" LLC V.I. Anokhin / 2011
Since 2005 the specialists of the Syzran Refinery (engineers of technical supervision, mechanics of shops, mechanics of plants) have been repeatedly trained and certificated in DYNAMICS SPC.
I think the quality of NDT specialists’ training, held in your center, is satisfactory.
This is expressed in sufficient objectivity and reliability of technical condition assessment of process equipment by the parameters of vibration, which is important for reliable and trouble-free operation, as well as timely repairs.
Ensuring accident-free and optimal operation of equipment and mechanisms – that is the daily or even hourly problem for the plant workers. Implementation of new technologies enables maximum controllability and predictability of this process. Thus, the main units of the plant have been gradually equipped with the COMPACS® systems produced by DYNAMICS Scientific & Production Center (SPC) "Dynamics". Our collaboration with this enterprise is mutually advantageous. So, the isomerization unit became experimental platform for adjustment of the system for emission-acoustic control of reactors.
We have a talk about the results of work and prospect development of the equipment monitoring systems with Alexander Naumenko who is the chief of the training unit and nondestructive testing laboratory of DYNAMICS SPC.
- What has been already done at the isomerization unit?
- DYNAMICS SPC has a long experience of monitoring systems installation at coking reactors, but isomerization unit reactors are specific. After two years of operation the plant specialists accumulated statistics (average information on the modes, influence of climatic features, etc.) that helped to adjust the system for acoustic-emission monitoring directly on the reactors.
From the very beginning the COMPACS® system has been controlling all significant equipment of the isomerization unit: reactors, pumps, air coolers. At the moment of launching the cases of pressure increase and operating practices failure were evidenced. It should be noted that the system responded adequately: it timely notified the troubles. Since then the time passed, and the system has already generated the signals of defects, which indicate initiation of the material damaging in the points of fastening, and the metal deformation. There are only crystal lattice microcracks so far, but it requires special attention because it may influence useful life of apparatus and electricity consumption.
- In what way?
- The system enables to fix the violation at the proper time and, therefore, to take measures. Let’s make an example. A centreless assembly, for example, the pump consumes more energy per shift. The analysis of operation of the most widespread equipment (pumps, compressors, electric motors) showed that improving their technical condition can reduce energy consumption by 15-25%.
- Are there any more advantages of the monitoring system installation?
- The right strategy for maintenance and repair of equipment helps to reduce operating costs. It's not a secret that schedule-based preventive maintenance and repair are very expensive. A timely and targeted maintenance is much more profitable for the enterprise.
The proposed SM™-technology includes the COMPACS® stationary systems for monitoring and diagnostics of pump-and-compressor equipment, stand systems for quality control of rolling and plain bearings, quality control of rotor balancing and assemblage of cradle-mounted pumps and electric motors, and the Compacs-Net® computer diagnostic network, which integrates stationary and portable systems and notifies of actual condition of the equipment under control.
- How is it implemented at the Achinsk Refinery?
- Investigations of Russian scientists in the field of real-time equipment monitoring were confidential for a long time. Perestroika and defence industry crisis forced to look for practical application of our own know-how.
In 1996 the first system of the Achinsk Refinery was installed on C-100 pumps. Seven COMPACS® systems have already been installed at the Achinsk Refinery, they realize vibroacoustic, acoustic emission, thermal, current, eddy current and parametric methods for diagnostics of machines, vessels and apparatus.
Acceptance test of reciprocating equipment is carried out at experimental stands produced by DYNAMICS SPC.
- What innovations have been recently introduced at LK-6Us?
- 30 more air coolers have been equipped with the systems for condition monitoring by the parameters of vibration and alternating current (AC) in December 2009. And since June, after repair, the COMPACS® system has been installed to 40 air coolers; the system monitors their technical condition by the parameters of vibration and AC. During repair DYNAMICS SPC specialists carried out metrological calibration of the systems operation at LK-6Us units (C-100, C-300), gas compressor house and isomerization unit.
- Could you offer the plant any innovations in the nearest future?
- We have already drawn up the projects of the systems installation at C-100 furnace, and extra binding C-300/1. Air coolers of C-400 type are in our short-range plans as well.
- In your opinion, what are the main development directions of the concerned technology?
- We have been developing the COMPACS® system for 20 years. Now we are developing a brand new operating system UNIX. It enables expansion at the fieldbus level and increase of the switching rate. Field equipment is planned to be wireless because it will improve the data transmission. We have already created the prototype models.
The systems for diagnostics and monitoring were taken up not only in production but also in railway transport and in aeronautics. In addition, the doctors addressed a request to develop such systems for the purposes of medicine. Control of the main parameters of human body condition is a promising but not examined area.
The COMPACS® systems installed at the Achinsk Refinery monitor technical condition of 310 machine units and 3 reactors of the first danger class. At LK-6Us 98% of pumps, air coolers, and compressors are under control. Rather long experience of the COMPACS® system operation enabled significant reduction of failures of machine and pumping equipment.
The Comprehensive System for EMU Sections Diagnostics COMPACS®-EXPRESS-TR3 has been used in the depot over six months, but during this time the system approved itself.
The main advantages of the system are:
high automation of testing;
high reliability of diagnosis;
easy perception of the diagnosis.
The system has become an irreplaceable, powerful and convenient device for the maintenance staff of the depot which helps not only to detect the smallest defects and deviations of the equipment parameters, but also make fine-tuning and adjustment of equipment, quickly detect hidden defects in the "problem" electrical sections and take reasonable decisions while choosing the strategy for the equipment recovery, parameters of which have been out of the norm.
The system COMPACS®-EXPRESS-TR3 guarantees quality repairs and a high level of safety and regularity of commutation service on Oktyabrskaya Railway.
Authors: Head of the depot Kryukovo A.V. Tumanov / 2010
Comprehensive System for EMU Sections Diagnostics COMPACS®-EXPRESS-TR3, designed for comprehensive automatic diagnostics of basic EMU equipment: wheel motor units, collectors, airbrake system elements, control circuits, power and supplemental circuits with condition assessment of their electrical isolation, has been used in depot Bryansk-1 since November 2008.
48 double-current electrical sections, repaired for the depot Bryansk-1, Novomoskovsk, Aprelevka, Smolensk, have been diagnosed during the system operation.
Previously, testing and further development of DC EMU were associated with difficulties related primarily to the lack of a proof ground for a direct current, so these works were made directly in the home depot, in this case workforce and time expenses were significant, and the results of technical condition evaluation and working efficiency of the equipment were complete and objective. System COMPACS®-EXPRESS-TR3 have provided checkout while reducing the cost of condition monitoring and performance evaluation of EMU equipment of main series, repaired on the basis of depot Bryansk-1.
Today, the system COMPACS®-EXPRESS-TR3 is one of the most important elements in depot Bryansk-1 which provides high-quality repair and guarantees the safe EMU operation on the suburban lines of the Moscow railway.
Authors: Head of Diesel house 45, V.P. Karpichev / 2010
During 1.5 of a year Comprehensive System for EMU Sections Diagnostics COMPACS®-EXPRESS-TR3 is used as the prime tool of quality control in production of EMU current repair of large volume (TR-3).
COMPACS®-EXPRESS-TR3 is designed for quick condition assessment of the most complex and critical EMU equipment: electrical control circuits, power and supplemental circuits, airbrake system, collectors. The system allows carrying out fine-tuning and adjustment of equipment, with minimal labor and energy resources, bringing their parameters to the requirements of safe and trouble-free operation, and also helps to identify hidden defects in the "problem" electrical sections.
42 electrical sections, repaired under the program TR-3, have been diagnosed during the system operation. At first a number of detected defects was significant and reached 11-13 per section, but the systematic repetition of the same defects allowed adjusting the technological cycles of repair and equipment tests in the production areas of these works in such a way that prevents the installation on the train of low-quality units and devices. Today the number of detected malfunctions is significantly reduced and does not exceed 6-7 per electrical section that clearly indicates repair upgrading.
The use of COMPACS®-EXPRESS-TR3 allowed to improve reliability and safe operation of EMU on the Moscow railway.
Authors: Head of the depot Lobnya O.Y. Sergeev / 2010
Comprehensive System for EMU Sections Diagnostics COMPACS®-EXPRESS-TR3 is designed for automatic comprehensive diagnostics of EMU Sections of the depot Pererva testing station and has been successfully operated since the 4th quarter of 2008. During this time more than 60 EMU sections, which passed lifting repair on the basis of our depot, have been diagnosed.
The system was approved as a reliable source of accurate, comprehensive information about the technical condition of the wheel-motor units, collectors, airbrake system equipment, control circuit, power and supplemental electrical circuits.
Using this system allowed to repair the electric multiple units qualitatively and put them on the track, completely abandoning the long-lasting, energy-intensive break-in tests, reduce labor intensity of the repair, increase smooth production flow and improve working conditions of mechanical technician.
Today, Comprehensive System for EMU Sections Diagnostics COMPACS®-EXPRESS-TR3 is a key element in the depot Pererva providing reliable safe operation of EMU on the suburban lines of the Moscow railway.
Authors: Head of the depot Pererva V.V. Firman / 2010
Since March 2010 comprehensive condition monitoring system COMPACS® was implemented at delayed coking unit 21-10/600 of workshop № 2 Detection Starting Devices (DSD) of "Fergana Refinery," which monitors the technical condition of 8 critical raw, firing pump units and 4 coking reactors.
Condition monitoring of 8 pump units is carried out by using vibration analysis, thermal and parametric methods of non-destructive testing by means of vibration, temperature and power consumption sensors.
Condition monitoring of 4 coking reactors is carried out due to acoustic emission, thermal and parametric methods of non-destructive testing by means of atomic power, temperature and linear expansion and pressure sensors.
The system automatically monitors the technical condition and diagnosis of equipment defects on running conditions of processing unit, which allowed the staff to control changes of equipment condition and timely, purposefully provide condition-monitored maintenance and repair of the equipment.
As a result of a three-month equipment operation on the actual technical condition under control of COMPACS® system, the indications, responsible for the safety and reliability of the processing unit, have been improved several times.
In addition, there appeared a diagnostic network Compacs-Net®, which allowed the leading specialists of the enterprise (OTN equipment, workshop number 2) to obtain objective information about equipment condition of installation in order to automate scheduling and repair process, control personnel performance discipline and evaluation of its efficiency. Professionals do not need to visit the object; the users of the diagnostic network at their workplace get a complete picture of the processing unit equipment.
The Comprehensive System for EMU Sections Diagnostics COMPACS®-EXPRESS-TR3, designed to assess repair quality of assemblies and electrical multiple units of ER9T and ED9 series (m, m, n) after the maintenance TR3, was put into operation in depot Anisovka in September 2008.
During the operation period, 36 electrical sections, passed a large amount of repairs in the depot, were completely debugged with the help of the system. All malfunctions, detected by the system, were confirmed by the results of further breaching and inspections, required by the system. A lot of malfunctions could not be found during traditional breaking-in tests and debug under the contact wire. The result of pass of such malfunctions in operation could be defects and failures of itinerary with significant delays in time-schedule.
The positive properties of the system COMPACS®-EXPRESS-TR3 are as follows:
High reliability of diagnostic results.
Efficiency of diagnosis receipt and a high degree of automation.
High coverage of diagnosed assemblies and units, including: wheel reduction gear units, isolation of high-voltage circuits, pantograph, equipment of compressed-air braking system, air brake systems, electrical control circuits, power and supplemental electrical circuits.
Way of presenting information of the electrical section state on diagnostic results, saving the results in memory, printing test reports for each subsystem and whole electrical section.
Gained experience during the system operation allows us to conclude that the system COMPACS®-EXPRESS-TR3 is a modern, powerful and convenient tool, irreplaceable during repair and debugging, as well as fine-tuning and adjustment of the basic and most critical assemblies electric multiple unit.
Using the system provides a reliable and well operation of EMU equipment for a long period of time ensuring a high level of safety and regularity of the railway transport operation.