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Real-time vibration diagnostics
of machinery with probability close to 1
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Home Customers & responses Responses "Saratov Refinery" JSC: Response to the stationary system of computer monitoring COMPACS and bearing acceptance test system COMPACS-RPP

"Saratov Refinery" JSC: Response to the stationary system of computer monitoring COMPACS and bearing acceptance test system COMPACS-RPP

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The following stationary systems of computer monitoring COMPACS® are implemented at the Saratov Refinery:

  1. CDU-AVDU-6 - in December 2005. At first 30 most critical pumps of the installation were connected - charging pumps and pumps with a speed of 3000 r/min of rolling bearings. The largest effect was obtained on charging pumps (up to 800 kW). Concerning system indications, timely stop allowed avoiding major accidents with the electric motor of charging pumps, which had been occurred before.

    Due to timely system warning a large number of accidents with other pumps was avoided. At the same time, a number of accidents with pumps, not connected to the system, occurred despite of periodic vibration monitoring by Engineering Supervision Department, mechanic and operating staff.

    In September there occurred an incident on CDU AVDU-6 with a charging pump of boilers TSNSG60-231 with the bearing destruction and shaft break. Similar incidents with equipment, not connected to the system, occurred before.

    In 2011 the project of expanding the system CDU AVDU-6 takes place. All the remaining pumps will be connected: 53 pump units and 2 smoke exhausters will be connected.

  2. In 2006 the stationary systems for computer monitoring COMPACS® have been implemented at the unit L-35/11-300 and visbreaking sections. All pump units, air blasts, exhauster (15 units) and the main circulating piston-type compressor of reforming unit (4GM16-45/35-55SM2, 2000 kW) have been connected at the unit L-35/11-300.

    Implementation of the system avoided pumps accident at L-300. Earlier extremely dangerous accidents with charging pumps of oil pump station took place. The main hot and firing pumps of visbreaking (6 units) have been connected to the system at the visbreaking section. Before connection to the system there occurred accidents of electric motor of firing pumps (250 kW) with the complete destruction of shaft bearings. After the implementation of the system, there was not any incident with hot pumps of visbreaking, connected to the system.

  3. In 2007-2008 COMPACS® system was implemented at the unit LCH-35/11-600. Almost all the pump units, exhauster (19 units) and circulating centrifugal compressor of reforming unit: gear and electric motor have been connected. Control system of relative vibration and axial thrust Bently Nevada of 3500 type, included in the system PAZ, had been installed on the compressor. The accidents occurred on 2 pumps, not connected to the system.

    In 2011, concerning the project of the system expansion, both pumps and 2 air blasts will also be connected to the stationary system of computer monitoring COMPACS®. In 2011 18 air cooler units (ACU) of the unit LCH-35/11-600 will also be connected to the system. In May 2010 there was a fan breaking of one of air cooler units at LCH-600.

    Connection of a number of air cooler units to the COMPACS® system have been included in the act of investigation. Air cooler units, which supports are highly located and it is impossible to touch them and control by the vibration meter, are connected to the system. Air cooler units with lower location of electric motors and bearings are mean while not connected.

  4. In 2008-2009 the stationary system for computer monitoring COMPACS® has been implemented at the unit installation L-24/6. Firing and hot pumps (10 units) and 3 circulating piston-type compressors of the unit have been connected to the system. Earlier the accidents with piston-type compressors occurred at the unit. The accident stopped after the implementation of the system. Compressors timely stopped by the indications of the system. The incidents periodically occur on the pumps, not connected to the system, in spite of periodic vibration monitoring by Engineering Supervision Department, as well as mechanic and operating staff. In August 2011 there was an incident with a pump NK-65/35-70 position N-11 with the destruction of the bearing.

  5. In 2010-2011 the expansion of the stationary system for computer monitoring COMPACS® took place on ELOU AVDU-6 and LCH-35/11-600, as well as connection of sealing bleeding control of piston-type compressors at the units L-35/11-300 (5 compressors) and L-24/6 (3 compressors) to COMPACS® system.

  6. In 2011 centrifugal compressor (electric motor), implemented in April 2011, have been connected to COMPACS® system. Control system of relative vibration and axial shift Allen Bradley, included in the system PAZ, was installed on the compressor.

  7. In 2006 we purchased the bearing acceptance test system COMPACS®-RPP. Currently, all bearings have passed control on COMPACS®-RPP system. At first 90% of incoming bearings have been discarded. After the elimination of unfair contractors discard rate has been decreased, but still remains extremely high for the domestic bearings, up to 75% is discarded.

 

Authors: Deputy Chief Engineer of "Saratov Refinery" JSC D.M. Galeev / 2011

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Tags: COMPACS condition monitoring bearings vibration analysis COMPACS-RPP accidents prevention acceptance test Date: 03.11.2011
Views: 1115
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