The experience of introduction and operation of condition monitoring system for potentially hazardous production facilities

The solution for the problems of safe operation of machinery of hazardous production facilities is provision of the condition observability of the facilities which have the largest impact on technical-and-economic performance of production and occurrence of technical accidents. The condition observability of production facilities can be reached by monitoring of their machines in order to determine its current state and predict the moment when the state turn extreme. The result of monitoring is a complex of diagnoses of monitored facilities included in production complex obtained in inseparably linked time periods during which state doesn’t change.

The machinery degradation process observability allows to eliminate emergency repairs and to carry out planned condition-based repair of machines, which ensures 100% elimination of accidents. Resource-saving means not only reduction of material expenditures, but, also, decreasing of labour force and money expenditures for operation, elimination of consequences of accidents and faults, as well as losses due to downtime of production facilities. Such a clear increase of time-between-repairs of technological units up to 2-5 years (which all companies demand from their plants) is impossible without introduction of a monitoring system – which is a basic element of safe resource-saving operation of refineries and petrochemical companies, providing observability of machinery and the most important static equipment of the main technological units on an integral diagnostic network of the enterprise.

The selection and validation of range of facilities which are to be monitored is carried out by analysis of the production technology scheme including the influence of the facilities on the operational process and technogenic accident probability by means of a special method. As a result, the categories of facility hazard are specified. The final result of the analysis is development of a program of equipping the enterprise with monitoring systems and transferring to condition-based machinery operation. The analysis of reliability of technological units at the modern refineries and petrochemical companies shows that more than three-fourths of all faults happen to machines which high concentration at the units often causes accidents and production troubles, as well as downtime of units and plants.

Kostyukov V.N., Naumenko A.P., Kostyukov Al.V., Kostyukov An.V., Boychenko S.N., Belyavsky O.G., Samkov S.F. The experience of introduction and operation of condition monitoring system for potentially hazardous production facilities // Chemical equipment. – 2012. – № 12. – pp. 24-28

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