"Tobolsk Petrochemical Complex" OJSC: information on the COMPACS system operation in the central gas workshop fractionating unit (CGFU)

Since September 1995 the analysis of the pumping equipment operation in the CGFU workshop, controlled by COMPACS^® system, has revealed a number of problems.

The following pumps were operated with the high level of vibration: H-1 / 1, H-1 / 2, H-1, H-1 / 4, H-2 / 2, H-M / 1, H-3 / 2, H-3 / 3, H-7 / 1, H-7 / 2, H-9 / 2, H-16 / 1, H-19.

An overload of standard values of vibration velocity, vibration acceleration and vibration displacement, typical for malfunctions detected by COMPACS^® system, has occured.

Mechanical service "Butadiene" held activities for malfunction repair recommended by COMPACS^® system.

Total cases of overload of vibration standard values were 47, among them seven times the malfunction was on the motor (H-3/1, H-3/2, H-3/3, H-2/1).

The most frequent malfunction of the pumps (according to the spectra analysis) is a unit misalignment and bearing assemblies malfunctions.

Pumps H-1/1, H-1/4, H-3/2 show the unstable operation and constantly misalign because of temperature differential at night and daytime. After centering the unit works properly half a day, then the defect appears again. This has been happening since mid-March.

The second repeated defect is bearings malfunction. Organization technological safety engineer in the maintenance foreman's presence checked up all bearings as a set of spare part, available in the shop CGFU, and found out seven units with deviation from specification for axial and radial clearance.

More common defects of electric motors are bearings malfunction. Rotor unbalance was detected on the pumps H-1/1, H-7/1, H-7/2, and corrected during scheduled maintenance.

During operation, COMPACS^® system clearly reacted to the slightest changes of the vibration level. Strict control of vibration level allowed a significant reduction of mechanical seals breakdowns. So, during the period from September 1994 to March 1995 there were eight mechanical seals breakdowns, and during the same period a year later, from September 1995 to March 1996, there was only one mechanical seal breakdown.

Authors: / 1996

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