"Syzran Refinery" JSC: Response to the machinery condition monitoring system COMPACS at the technological units

The implementation of the machinery condition monitoring system COMPACS^® at the technological units of Syzran Refinery, JSC has started in 2001. Currently, the COMPACS^® systems provide condition diagnostics of rotating equipment of 10 technological units of Syzran Refinery: ELOU-AVT-6, UMK-2, L-24/8, LG-35/11-300, LCh-35/11-600, PGI-DIG/280, TK-3, TK-4, USMN, 43-102 assembly 2.

Such a large-scale implementation has allowed to cover 224 units with real-time condition monitoring. The maintenance personnel constantly uses system readings in their work, timely reacting to any changes of the machinery condition. For example, there are two latest cases when the COMPACS^® system detected the defects of bearing assemblies:

1. Beginning from 18.10.2014 TK-3 unit maintenance personnel using the COMPACS^® system readings detected the increase of the vibration acceleration value of the rear bearing assembly of the N-16 unit motor. Gradually, the condition became "Unacceptable". 20.10.2014 the unit was decommissioned for repair after the replacement of the motor rear bearing and the unit start-up the vibration parameters were back to normal.


2. 28.11.2014 TK-4 maintenance personnel during the idle running testing of the N-116 unit has discovered by the COMPACS^® system readings a rapid growth of the vibration acceleration value of the front bearing assembly, after that the unit was decommissioned for repair. After the replacement of the front bearing the unit operates normally.

Many years of the COMPACS^® system operation have proved its high efficiency, providing timely detection of the malfunctions and recommendations issuing to the personnel. That helped to increase the technological process safety rates and to provide the faultless operation of the rotating equipment of Syzran Refinery.

Authors: Technical director Yu.V. Popov, Chief mechanical engineer K.A. Nadrshin / 2014

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