We must reduce the mean time between repairs

The Omsk Refinery set the target of 97-98% operational availability by 2020. In the first quarter of 2015 we reach 96% so we can't stop now.

To carry out repair by cycles remains the most important action for us.

This kind of repair causes many organizational difficulties but refuse it would have been an unattainable luxury for any Refinery. From the first cycle we gathered an economical benefit of more than 1,5 bill. rubles.

In general, the way repair is conducted in 2015 at Omsk Refinery will influence the economic condition of the enterprise for the next few years.

The important task is to increase the mean time between repairs from the standard two-years to three-four-years cycle. Solving this task will give a considerable advantage of the peers. As a matter of fact, we have reached these results, although, there is a contravention of the law, and we’re doing our best to eliminate the contravention.

The main point of the issue is the development and implementation of the condition control system and risk evaluation of machine operation between shutdown repairs.

That’s why the project of machinery monitoring under the COMPACS^® system is a key economically viable tool of Omsk Refinery. The COMPACS^® is a fine instrument to bring us to Smart Plant, and which we should successfully apply. However, in that relation we have not much to boast of. The analysis of the system’s operation in 2014 had showed that some of the machinery can work in "red- yellow" zone for quite a long time - from 90 to 3000 hours.

One of the pumps at the unit 35/11-1000 was operating in a "red-yellow" zone for more than 5 thousand hours, or about 8 months. General statistics of failure causes is the following: 43,8% — failures due to degradation, 37,2% — operation mode violation, 10,6% — bad quality of repairs, 8,2% — bad quality of design, and 1% is caused by a human factor.

Authors: Deputy technical director of reliability and repairs, chief mechanical engineer Sergey Samkov / 2015

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