"Silvinit" JSC: Report on the stationary condition monitoring system COMPACS

At present time information technology is widely used in the accounting department, economic service (corporate information system ALFA) and process management (Automatic Process Control System) of Novosolikamsk Potash Combine SKRU-3. Further development of information technology has led to software for the equipment condition monitoring, repair and maintenance management. The use of condition monitoring systems allows obtaining updated information about actual state of the units, their wear degree and the origin and development of defects.

In order to improve the maintenance management and to gain experience in the use of stationary diagnostic systems the stationary system COMPACS^® of DYNAMICS SPC was installed in the drying department SKRU-3 of "Silvinit" JSC in May 2000.

25 units were diagnosed: conveyor drives, drier drums, mixers, smoke exhausters, powerful blasts. The following defects were detected by the system: poor lubrication of bearing assemblies, bearing defects, misalignment, non-rigid unit fastening, coupling defects, gearing defects, blasts and smoke exhausters imbalance, increased temperature of assemblies and units, increased current of motor.

According to the indications of the diagnostic system the following work was performed: balancing, centering, unit tensioning, bearing replacement, bearing lubrication, replacement of gears with defective gear sets, motor replacement.

The diagnostic system allows the staff to make timely processing steps under equipment degradation, assess the state of repaired units without the help of technical diagnostics service, identify and remove a significant part of the malfunctions.

Since May 2002 the system COMPACS^® has been working correctly. The system has demonstrated its working capacity and reliability in equipment defects detecting. During the system operation the equipment condition has improved.

Conclusions:

During operation of COMPACS^® system there appeared the following problems with the equipment repair management:

• There is no acceptance test of rolling bearings, as a result a part of the units was not improved.
• The units (electric motors, pumps, smoke exhausters) after-repair condition is not better than before the repair. The units after repair do not pass the final check.
• The acceptance act of COMPACS^® system is not signed and the equipment is not reflected on companies books.
• The workplace operating instructions for COMPACS^® system are not developed.

Further development of information technology, creation of new diagnostic equipment and software significantly increase the level of equipment operation and maintenance management. Proposals of DYNAMICS SPC by equipping the mine SKRU-3 with stationary monitoring system are rather interesting, but need to be worked out and require more profound technical and economic assessment.

Authors: Chief Engineer V.V. Konovalov, Deputy Chief Mechanic F.L. Neklyudov, Chief Power Engineer V.I. Babenyshev, Deputy Chief Engineer for Automation - Chief Metrologist S.M. Lozkov / 2002

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