The implementation of stationary systems of pump-and-compressor equipment vibration analysis COMPACS® has been carried out by the specialists of DYNAMICS SPC since 1989. During this period systems of vibration analysis have been implemented at 8 units of 4 plants (AVDU-10, AT-9, AVDU -7, AVDU-8 - plant № 1; 43-103 - plant №2; 36/1-1, 2 - plant №3; 35/11 - 1000 - plant №7). Installation and implementation of systems at units 36/1-3, 4 of plant №3 and the largest complex KT-1 of plant №2, have come to an end and will be comissioned in the nearest future.
COMPACS® systems measure vibration, temperature and power consumption and according to these parameters diagnose the state of main plant units - centrifugal pumps and drive motor compressors. About 100 pumps are monitored according to 200 measuring channels. After the commissioning of the complex KT-1, the number of controlled units will be 270, and that of measuring channels - 800.
The main result achieved after the implementation of systems - the exception of the sudden failures of the equipment and improvement of its operation reliability due to timely warning of personnel about the location, time and causes of faults, including bearing defects, shaft misalignment, balancing problems, unfastening of pumps and motors to the foundation and pipes – to the pump flanges.
The systems are also used to monitor the quality of pumps and motors after repair and installation.
An important function of the systems is to control the operators` work, who overload the pumps to get the process data, which is one of the causes of accidents. The system warns the operators by voice messages about the intolerable operating conditions of the unit. All the measured parameters are accumulated in the databases, displayed on a color monitor of the diagnostic station, designed on the basis on the AT-486DX computer, and recorded in various ways by the request of the staff.
COMPACS® systems have showed good results, keep high reliability, ease of use for the staff and according to technical characteristics are equal to the best foreign analogues. The cost of the system implementation is 5-10 times lower than the foreign ones, and are totally paid off during the first year of operation.
At present, it is decided to organize a diagnostic network for technical supervision, which provides a centralized acquisition, storage and recording of information about state, defects and repairs of pump-and-compressor equipment in order to optimize the stoch of pump-and-compressor equipment, its operation conditions, spare parts planning and achievement of minimum costs for equipment operation.
Authors: Chief mechanic V.N. Dolgopyatov / 1993
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