COMPACS® HAS SAVED MONEY
The global diagnostic system has reduced the number of overhauls in 10 times.
To the global diagnostic system COMPACS®, which has become a visiting card of the Omsk Refinery, will soon join the equipment for oils, additives and lubricants production, where the system of equipment vibration monitoring Compacs®-micro will be implemented. The unique elaboration of Omsk specialists allows to minimize the risk of failures at the strategic enterprise and to save millions of rubles by increasing the machinery and units run-to-failure time.
To carry out timely repair of equipment first of all we need to know as much as possible about its actual technical condition. Scheduled-preventive maintenance (PPM), which is carried out in the recommended by the equipment manufacturers terms, until recently were considered in Russia as the only possible way to control the operation of complex technics. However the factors affecting the units technical condition may differ significantly from the calculated. And the equipment failure can occur much earlier than set by the PPM schedule run-to-failure will expire. It threatens with unplanned (in fact emergency) equipment shutdowns, which in turn will lead to unreasonable economic losses for the company.
Omsk Refinery became the first company of the branch where took up seriously the solution of that problem. The used today system COMPACS® refers to the new generation systems and is deprived of drawbacks which pertained to its predecessors (a series of devices RAPID, the complex SIGMA, the systems SVK and SVIP-64). This system, developed by the DYNAMICS SPC engineers with the direct participation of the Omsk Refinery specialists, during the units run-to-failure is capable to monitor the particular mechanisms condition according to the parameters of vibration, temperature, and current consumption. All data in real time are displayed on the monitors of all the concerned services managers and operators.
The square in the diagram, indicating a particular unit, glows green – the technics is in order; glows yellow – the mode deviated from the optimal one; glows red – an urgent specialists’ intervention is necessary. Moreover, in the case of failure danger COMPACS® will give the operator a signal not only by dint of the alarming red light, but also through the voice message. Now the plants has been operating 23 stationsry systems COMPACS® on the main process units, quickly alerting personnel about condition of more than 730 pumping and 20 compressor units. According to the words of Vil Sagirov, deputy chief engineer of the Omsk Refinery, almost all the "critical" equipment, which failure can lead to a decrease in technical and economic production rates to 75-90%, is under the control.
The implemented technology of maintenance and repair according to the actual technical condition allowed to halve the total number of repairs and at the same time to reallocate the volumes of repairs from overhaul to permanent. As a result, the number of overhaul repairs has decreased in 10 times. However, he believes that even greater economic effect can be achieved if the technology will be extended to all, without exception, mechanisms which operate at the enterprise, including auxiliary ones. Hourly and daily condition monitoring of auxiliary equipment has no sense, because such control will cost too much. That is why for the auxiliary equipment the personal system of automatic diagnostics Compacs®-micro is proposed to be used; it will successfully complete the stationary system, being in fact the part of it.
Compacs®-micro consists of a notebook with proprietary software, a diagnostic station and a sensor. All this fits in a standard size briefcase, which justifies Compacs®-micro nickname – "black suitcase". Only two these "suitcases", which during the past year were "ran" by the Omsk Refinery mechanics on the aromatic hydrocarbons production complex, allowed by increasing the equipment run-to-failure, to save nearly two million rubles. Such an efficiency speaks for itself, so this year the Omsk Refinery management intends to acquire a few more sets of Compacs®-micro to operate them on the complex for oils, additives and lubricants production.
In 1998 for the system creation the team of scientists, among which appear the heads and specialists of DYNAMICS SPC, JSC "Sibneft-Omsk Refinery" and the State Technical Supervision Service of Russia, was awarded with the Russian Federation government prize in the sphere of science and technology. First implemented in the Omsk Refinery, in 2004 the system COMPACS® was officially certified and approved by the the refinery Department Committee of the Fuel and Energy Ministry in conjunction with the State Technical Supervision of Russia, and was included in the State Register of measuring instruments and permitted for use on the entire territory of the Russian Federation.
Nowadays the unique Omsk developments are used practically at all major oil and gas production and processing enterprises of the country (including the Gazprom enterprises). They are known abroad as well. The stationary system COMPACS®, for example, has been recently installed at the Bulgarian company "LUKOIL Neftekhim Bourgas AD". Besides, in order to achieve the implementive experience the Bulgarians came exactly at the "Sibneft-Omsk Refinery" JSC. It seems justified that the refinery has the fame of one of the most technologically "advanced" Russian enterprises.
Authors: A. Semenov / 2006
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