Reference to COMPACS
In 2006, on the complex for oils, additives and lubricants production of Omsk Refinery will be implemented the system of equipment vibration monitoring Compacs®-micro. Personal "black suitcases" will be a part of the global diagnostic system COMPACS®, which has become one of the company visiting cards. The unique elaboration of Omsk specialists allows to minimize the risk of failures at the strategic enterprise, to save millions rubles by increasing the machinery and assemblies run-to-failure time.
It is not a secret that production quality and volume of any modern enterprise, and in particular Omsk Refinery, are directly dependent on the condition of its main technological equipment. The scheduled-preventive maintenance (SPM), held in periods recommended by the producers, until recently were considered in Russia 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 affecting the units technical condition, may differ significantly from the calculated. In this connection, the hardware failure may occur much earlier than set by SPM schedule run-to-failure period will expire. This threatens with unplanned (actually emergency) shutdowns of units, which in their turn will lead to unnecessary economic losses for the company as a whole.
To carry out timely equipment repair it is necessary 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 mountings, which quickly alert the staff on the status of more than 730 pumps 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. However, according to his words, the greatest economic benefit from the implementation of new technology can be achieved by transferring of all, including support mechanisms, to the repair on the actual technical condition. There is no sense to monitor their condition every minute, every hour or every day – this is too expensive. That is why it is proposed to use the personal system of automatic diagnostics Compacs®-micro, which aptly adds (being in fact a part of it) the stationary system.
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 as well, to save nearly two million rubles. 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.
COMPACS® belongs to a new generation systems and is deprived of drawbacks which were inherent to its predecessors - a series of devices RAPID, the complex SIGMA, the systems SVK and SVIP-64. Advanced (for the period of implementation) solutions were combined in them with one significant drawback - the human factor. This is how the company veteran, the former chief mechanic of the Omsk Refinery Victor Dolgopyatov responds: "I used to check the work of engineers and mechanics for several times. Having come into the pump part, I was waiting for 40 minutes - no one was there, even though a machinist should constantly bypass the pumps. Having come to the operator part I found them discussing something. The machinist came to me, "Viktor Nikolayevich, I have just come from the pump part- it's all right there." If the good machinist behaves in such a way, then what about others? Lack of equipment monitoring, visual information about its condition is the main cause of failures. For several times I equipped the mechanics and machinists with vibroacoustic devices with headphones and pointers - that lead to nothing good: someone’s device is out of work, someone does not use it, the sensor is placed where the vibration is less, etc. Subjective methods are not suitable, an objective control, independent of the opinions, desires and abilities of the staff, is necessary. The equipment condition should be reliably determined, simply and effectively presented, to be comprehensible to a semi-skilled specialist."
Formulated by Dolgopyatov approach became the basis of the system COMPACS®, developed by engineers of Omsk DYNAMICS Scientific & Production Center (SPC) with the direct participation of the Omsk Refinery specialists. During the units run-to-failure the system 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. Submission of information is realized very clearly, on the basis of traffic lights. 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. "Originally we had to deal with a demanding male voice, but some female operators were frightened with it, especially at night, - says Vil Sagirov, deputy chief mechanic of the Omsk Refinery, the member of the first stationary systems COMPACS® tests. - Then the "Dynamics" recorded female voices of professional speakers. Now everyone is content, including me."
However, Sagirov can be more content with the economic effect, received from the new monitoring system operation. Experience has shown that the implemented technology of maintenance and repair according to the actual technical state 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. 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 Committee of the refinery Department 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 JSC "Sibneft-Omsk Refinery". It seems justified that the refinery has the fame of one of the most technologically "advanced" Russian enterprises.
Authors: I. Razin / 2006
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