Omsk Refinery guarantees the quality of the production
Equipment diagnostics in automatic mode
The quality and volume of production of any enterprise, and a refinery in particular, are dependent on the condition of its main process equipment. The scheduled-preventive maintenance (SPM) until recently was considered as the only possible way to control the operation of complex equipment. However, in practice the operating conditions, the quality of previous repairs and spare parts, and other factors may differ significantly from the calculated and the hardware failure may occur much earlier than set by SPM schedule run-to-failure period will expire. Emergency shutdowns inevitably lead to economic losses for the company.
To carry out timely equipment repair it is really needed to know as accurately as possible about its actual condition. Omsk Refinery became the first company of the branch, which took up the problem seriously. Even back in 1972 the plant engaged in the development of fundamentally new methods and instruments for vibro-acoustic diagnostics of mechanisms. Today the plant has implemented 23 stationary systems COMPACS® on the main process units, which quickly alert the staff on the condition of more than 730 pumping and 20 compressor units. "Thus, 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", - said the Omsk Refinery deputy chief mechanic Vil Sagirov. According to his words, the greatest economic effect from the implementation of the new technology can be achieved by transferring of all, including support mechanisms, to the repair on the actual technical condition. For this purpose the enterprise uses the personal system of automatic diagnostics Compacs®-micro consisting of a notebook with proprietary software, a diagnostic station and a sensor. All this fits in a standard size briefcase.
Only two these personal systems in 2005 were "ran" by the Omsk Refinery mechanics on the aromatic hydrocarbons production complex, which, however, allowed to save nearly two million rubles by increasing the equipment run-to-failure. In 2006 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.
COMPACS® belongs to a new generation systems, capable during the units run-to-failure to monitor the particular mechanisms condition according to the parameters of vibration, temperature, and current consumption. All data in real time is displayed on the monitors of all the concerned services managers and operators. Experience has shown that 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. The Omsk Refinery in-house development allows to minimize the risk of failures, to save millions rubles by increasing the time of the machinery and units run-to-failure.
First implemented in the Omsk Refinery, in 2004 the system COMPACS® was officially certified and approved by 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.
Authors: V. Shakhlin / 2006
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