Practical development and implementation of the technology for liquidating fundamental causes of equipment failures (LiFCF™) showed that less than 15% of the units consume more than half of all resources intended for equipment repair. More than 2/3 failures of face seals are caused by above-standard vibrations of the pumps and electric motors.
The implementation of the COMPACS® stationary systems for vibration analysis and equipment condition monitoring at process units of petrochemical complexes enabled elimination of major cause of failures – latent unobservable nature of their emergence or development. The systems enabled immediate elimination of severe accidents of pumping units associated with shafts breakage and bearings failure causing depressurization of face seals and further ignition. For instance, for 3 years of operation at JSC Tobolsk petrochemical combinat the COMPACS® systems prevented 122 failures of pumping units and accidents with ignition. It should be noted that in 1994-95, before implementation of the system, 5 such events took place.
The averaged estimation of cost efficiency of ensuring resource-saving safety by the implementation of stationary systems for continuous vibration monitoring of hazardous production facilities shows that the main sources of profitability increase are: decrease in number and duration of process unit downtimes, reduction of equipment losses, and reduction of costs of equipment repair and restoration, faster commissioning of process systems.
Kostyukov V.N., Kostyukov Al.V., Boychenko S.N. Russian experience of automatic diagnostics and monitoring of pump-and-compressor equipment on the basis of the COMPACS systems // Safe operation of compressor and pumping equipment. Proceedings of Scientific and Technical Seminar. - Odessa, 2001. - p. 154-170
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