Conclusion on the possibility and expediency of the comprehensive monitoring system COMPACS® application in chemical and petrochemical enterprises and refineries of Russia by the results of testing and trial operation.
1. Work on creation and implementation of computer systems for technical condition monitoring of petrochemical industries equipment have been conducted by "Sibneft-Omsk Refinery" JSC and DYNAMICS SPC since 1989, according to the instructions of the Ministry and government bodies of supervision, set out in the following documents:
1.1. Letter from GU GM and GE of the Ministry of Petrochemical Industry of the USSR N19-1-14/1318 dated 25/07/1989.
1.2. Letter from the Ministry of Petrochemical Industry of the USSR N12-L-1/178 dated 28/03/1991.
1.3. Letter from GU PO of the State Ministry of Internal Affairs of the USSR N7/2/338 dated 02/04/1991.
2. The system of comprehensive monitoring of the PCC equipment COMPACS®, developed and submitted for testing by DYNAMICS SPC, brings together the various methods of diagnosing and non-destructive testing (NDT) - vibration analysis, thermal, electrical, eddy current, acoustic emission, by the process parameters (pressure, level, temperature, changes in linear dimensions, etc.) and an expert system of decision-making support on the management of the equipment condition, ensuring real-time CIP monitoring and diagnostics without decommissioning of machine (pumps, compressors, motors, fans, etc.) and process (reactors, columns, pipelines, etc.) equipment.
3. At present "Sibneft-Omsk Refinery" JSC operates the system of comprehensive monitoring COMPACS® at a process unit 21-ZM-10 (31 pumping units, 2 air-coolers, 4 coking chambers).
4. The system COMPACS® provides an automatic generation of the current assessment and prediction of future technical condition of the pump-and-compressor and production equipment that allows to operate it according to its technical condition and create repair schedules for the current and coming periods.
5. The system COMPACS® provides a visual display of the equipment current state, issues recommendations to the staff, concerning the immediate urgent actions, and automatic verbal warnings without operator’s intervention. The system archives the results of measurements and displays the graphs of diagnostic features deviations over time (trends), brings the data on the status of equipment in the enterprise diagnostic network Compacs-Net®, registers the textual and graphical information on the condition of equipment in the "Log-book of mechanical engineer" and on the printing device.
6. Analysis of the process equipment failures statistics and indications (alerts) of the system COMPACS® concerning the unit 21-10-ZM, carried out by comparing the archives of databases and causes of PCE breakdowns, based on the information of mechanics, electricians of facilities and technical supervision data, has shown that the implementation of the system of comprehensive monitoring of PCC equipment COMPACS®:
6.1. Allows reducing 12 or more times the number of the equipment emergency breakdowns due to early personnel warning of an invalid state of the diagnosed equipment.
6.2. Allows to reduce 4 or more times the number of repairs as well as to carry out a high quality redistribution of repairs amounts from overhauls to permanent, resulting in 10 or more times decrease the number of expensive repairs.
6.3. Allows controlling the course of the process to ensure reliability and longevity of technological equipment.
6.4. Provides a reliable diagnosing the bearings defects, cavitation modes of pumps operation, violations of shaft alignment and balancing of rotating parts, weakening of pumps and motors fastening to the foundation, face seals failures, over 70% of which are due to unacceptably high levels of pumps and motors vibration.
6.5. Provides a reliable diagnosing of reactors bodies defects by acoustic-emission methods, the degree of strain and tension by methods of displacements and temperature fields parameters measurement.
6.6. Provides a low laboriousness and high rate of of process equipment diagnosing (not more than 1 second per a sensor) that can detect high-growth defects.
6.7. Provides a creation of a diagnostic network of technical supervision and transfer of information on the status of the equipment to a higher authority (a dispatcher, chief mechanic services and chief power engineer) to control the processes of the quipment operation.
6.8. The systems are highly reliable, simple to install and operate.
6.9. Implementation of comprehensive condition monitoring systems of PCC equipment allows to make repair according not to the SBPM system but to the actual technical condition and expected failures.
7. On the basis of the submitted materials and the systems testing by the members of the committee, the committee reached the following conclusion:
1. Implementation of comprehensive condition monitoring system of PCC equipment COMPACS® provides a sharp decline in the number of sudden failures of all diagnosed equipment of the process unit and increases its reliability
2. High reliability, low cost and simplicity of the system use distinguish it from Western counterparts.
3. The widespread implementation of comprehensive condition monitoring systems of PCC equipment at Russian enterprises will allow to operate and repairing the pump-and-compressor as well as the processing equipment by the actual technical condition, and will result in the great economic and environmental benefits and is necessary, according to the opinion of the committee.
4. The Committee recommends that:
1) design organizations include the systems of comprehensive real time condition monitoring of machinery and production equipment, when carrying out projects of reconstruction and construction of process units;
2) chemical, petrochemical and refining enterprises equip the existing, reconstructed and re-input production capacities with these systems;
3) the designer-producer of the comprehensive monitoring systems - DYNAMICS SPC - together with concerned organizations prepare a guidance document, which regulates the procedure of implementing the requirements and recommendations, set out in the enterprises under the control of the State Technical Supervision Service of Russia.
Authors: Head of Omsk Department of the State Technical Supervision Service of Russia S.N. Medvedev / 2003
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