In reply to your letter from 20.10.2014 №187-10/2014 we would like to inform you, that the coke drums of 21-10/3M unit are, indeed , equipped with the diagnostic system COMPACS®-AE.
In 1998 there was the first experience of equipping the coke drum №3 with temperature sensors, pressure sensors, and sensors for control of the drum linear size changes during operation. Installing the sensors on the coke drum we received the data on the drum surface temperature fields distribution, temperature gradients and control of the linear extension and the drum linear extension rates, at the same time the stages when the accidents arise were figured out – considerable deformations of the drum material (Appendix 1). The operating practices of the drum are cyclical, that is why the considerable deformations arise on every cycle, which leads to nucleation and development of fatigue cracks in the drum material.
In 2000, in order to provide the control for nucleation and development of defects in material of coke drums of delayed coker units (DCU), we equipped all 4 drums with the system for acoustic-emission monitoring of condition COMPACS®-AE.
The COMPACS®-AE system allows to detect the presence, place and category of AE-sources. When a defect is nucleating and developing in the drum side the COMPACS®-AE system points out the defect’s place, nature, development speed, danger rate. The technological personnel of the unit gets an opportunity to take timely actions on the repair work planning or accident prevention. During the overhaul of the drum, the repair is carried out in the places shown by the system.
In 2003, the Refinery technical supervision department has conducted cross-validation testing of two systems: the mobile station of AE-control SPARTAN and the system for automatic condition monitoring COMPACS®-AE (Appendix 2), which proved the correctness of measurement and analysis.
The comprehensive equipping by the COMPACS® system of the dynamic (pumps, air-coolers) and static equipment (coke drums) of the DCU allowed to detect the problem areas and to carry out some actions for the unit operation reliability increase and provision of the technological process stability (Appendix 1).
In the end of 2003, by the COMPACS® system readings from the 21/10-ЗМ unit operation, Russian State Technical & Mining Inspectorate has carried out interauthority testing of the system for comprehensive condition monitoring of petrochemical equipment – COMPACS®, with a help of RF Ministry of Energy. As a result of interauthority testing - the approach to the equipment operation based on the COMPACS® system for comprehensive condition monitoring of petrochemical equipment was approved and recommended to application on the hazardous production facilities (Appendix 3).
The fully operated system was designed and assembled by DYNAMICS SPC in 2011.
The system operation is set on a continuous computer monitoring, analysis and forecasting of the condition of coke drums. The system measures and controls the following physical parameters: acoustic-emission signals and their time and amplitude-frequency components; temperature; pressure; linear size measuring; trends of coke drum parameter changes, - all in all, about 49 measuring signals per one coke drum. The system displays the technological system and the equipment’s condition on a colored monitor in the form of three-color pictograms.
During the operation the system has not registered any defects of coke drums, the AE-testing of the operating coke drums before the planned overhaul in 2013 proved the absence of defects.
The COMPACS® system is on user maintenance provided by DYNAMICS SPC. The maintenance frequency rate, as a rule, is about once a month, considering the pump units. The system is repairable in period of the unit’s run-to-failure, since all the sensors are placed outside the coke drum casing. Some of the system’s details should be protected from high temperatures, oil products and water steam. During the coke drum isolation repair the damages of cable paths and AE-sensors can occur, so it is necessary to demount the sensors before the repair.
In general, the diagnostic system COMPACS® has proved itself to be reliable and efficient monitoring system, and an integral part of the equipment operational reliability provision.
DYNAMICS SPC and Omsk Refinery are cooperating since 1991. From the first days of the cooperation DYNAMICS SPC provides timely and qualitative services. Except for the whole complex of works on the design and equipping of the units with the COMPACS® systems in turnkey mode, DYNAMICS SPC also provides full maintenance and repair of the operating systems.
- Minutes of technical meeting from 09.04.2007, 2 pages
- Test report of the subsystem for acoustic-emission monitoring COMPACS®-AE, 2 pages
- Conclusions on the opportunities and expediency (made by the testing results and trial operation) of using the system for comprehensive monitoring of petrochemical equipment condition COMPACS® on chemical, petrochemical enterprises and refineries of Russia, 4 pages.
Authors: Deputy Director General, technical director, А.V. Panov / 2014
Download the response