"LUKOIL-Volgograd Refinery" LLC: Analysis of reliability improvement of the refinery equipment on the basis of stationary monitoring

The stationary system was installed on the phenolic oil purification unit 22 of LLC "LUKOIL-Volgogradneftepererabotka in April 1997 and showed that 25 pump units of NK6 type were defective and contained 16 malfunctions. 6 units had 3 motors and 5 pumps out of work, which contained 5 and 11 malfunctions respectively:

• five machines required replacement of the bearings;
• four machines required to be centered;
• three machines required fastening improvement;
• one motor had overheated bearing, and the other was overloaded.

All these malfunctions were constantly displayed on the monitor of the diagnostic station and during units repair the staff clearly saw the results of their work. Three months later, in July, the main mechanical causes for these units had been eliminated. In November, only one unit demanded the replacement of bearings, fastening improvement and centering, and three were a bit overloaded. At the end of January 1998 there were no units with mechanical causes, and only one of them was a bit overloaded.

Thus, during 9 months of stationary system operation the number of failed units was reduced 8 times and number of malfunctions - 15 times. The main factors that violated operation conditions of the units were detected and remedial measures were undertaken.

To improve the reliability of repaired pumps and motors, bearings installed in them previously inspect for quality on a special stand. Before pump assembly, the rotor with coupling is preliminarily balanced on the special stand. The measures for cooling systems improvement and rational choice and equipment load are developed.

The implementation of stationary systems allowed operating equipment with its maximum resources while saving its maintainability, that became possible due to warning system of the staff about dangerous development of the malfunction.

There were changes in repair structure, from general and midlife repairs to operating repairs and maintenance. Considering that the cost of units equipage with the system is approximately equal to the cost of the average repair (25-30 millions rubles), it can be said that the system has already paid off its keep with respect to repairs.

More than 30 emergency situation, connected with the loss of units efficiency due to alignment problems, fastening problems, bearings breakdowns were prevented during 9 months of the system operation. Effect is determined not only by reducing the number and labour intensity of repair, but also by reducing additional losses, first of all, downtime of the unit or its elements that is more than 100 million rubles per unit.

Thus, the economic effect of the system implementation is estimated at 120-150 million rubles per unit, i.e. not less than 3 billion rubles. Payback period is maximum 4-6 months.

Reliability management of the equipment has become visible and effective.

Authors: Deputy Chief Engineer O.S. Lvov / 1998

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