Yousef, Abdul Halek

Zenkin, M.

Electronic Repository Kyiv National University of Technologies and Design

III Міжнародна науково-практична конференція «Мехатронні системи: інновації та інжиніринг» Інновації та інжиніринг мехатронних, електротехнічних та електромеханічних систем  73 UDC 665.6 OIL-PROCESSING PUMP UNITS VIBROMONITORING SYSTEM Yousef Abdul Halek, Ph.D., Associate Professor Amman Arab University, Amman, The Hashemite Kingdom of Jordan М. Zenkin, Doctor Sciences Technical, the Professor Kyiv National University of Technologies and Design Keywords: рump, oil refineries, metrology, measurement, control. In the petrochemical and oil refining industries, tens of thousands of pumping units are operated, mainly centrifugal pumps of domestic and foreign manufacturers with a unit capacity from tens of kilowatts to units of megawatts. Process plants for primary oil refining, catalytic cracking, catalyticreforming and others contain a different number of aggregates, which varies from tens to hundreds of units independing on the power of the installation. High concentration of pumping units in process plantsPetrochemical industries often served as the cause of accidents and other manufacturing problems. Indeed, if we take the probability of failure-free operation of the pump unit per day equal to 0.99, then for a team of machines containing 100 units the probabilityfailure is close to 1, that is, the technological system atthis is practically inoperative. To achieve technological sustainabilitysystems to various kinds of disturbances, including failures of pumping units, it is necessary to ensureobservation of external andinternal factors characterizing its technical condition, and managing its condition through the timely adoption of technical andorganizational measures. The main direction of ensuring resource-saving and safe operationdynamic equipment for oil refining production, as shown by many years of experience, is the introduction of stationarycontinuous monitoring, diagnostics andpredicting its technical condition. Stationary monitoring systems. Systemcontinuous computer monitoring for accident prevention and status management COMPACS®represents a distributed measurement and control system in which the signals of sensors located on the equipment are transmitted for processing,display, accumulation, storage and registration ondiagnostic station, based onindustrial computer installed in the operator's technological installation. Jordan’s plant operators usually don’t haveair conditioning and air purification systems. Sensorsconsistent with the station using universalremote modules. The systems implement vibroacoustic, thermal, acoustic emission, current and parametric (pressure, level, flow, temperature) diagnostic methods for machines, vessels and apparatuses,the novelty of which is protected by a number of patents for inventions, industrial designs and trademarks. Modules and sensors adapted for the harsh Russian climate and personnel, certified foruse in explosive areas in which the formation of hydrogen-air mixtures is possible. The system collects information about the status of equipment without additional repeaters within a radius ofless than 1500 m. Power, control and signals betweencomputer and modules are transmitted in just twocoaxial cables or twisted pairs, which provides ease of design, quick III Міжнародна науково-практична конференція «Мехатронні системи: інновації та інжиніринг» Інновації та інжиніринг мехатронних, електротехнічних та електромеханічних систем  74 installation andlarge-scale implementation of the entire system and its maintenance. The “op line” system diagnoses the condition of each machine around the clock, excluding manualthe work of highly qualified data collection specialists. The system provides full self-diagnosis of all measuring channels, including sensors. The results of the system are displayed onsix color screens,working under the control of the main and the series Drop-down menus.Information on the condition of equipment is presented on the mainscreen of the "Monitor" system, which containsseveral windows according to the “look & feel” principle (seeand perceive) that practically does not require time for training, similarly to the principles of the standardMIMOSA [1]. COMPACS® expert system provides fast enough, completeand reliable in-place diagnostics of technicalthe condition of the pump unit by identifying the following faults: loosening the pumpand engine to the foundation; violation of alignment and balancing of rotating parts; unacceptable fluctuations in the foundation and pipelines; cavitation andwater hammer ("surge") in the pump; defects in the bearings of the pump and motor; coupler wear;Pass the mechanical seal of the pump; unacceptabletemperature of machine components; unacceptable ripple,frequency composition and current amplitudes of drive motors. The system continuously measures, diagnoses andaccumulates data in five time bases lasting from 12 hours to 9 years. This allows notnot only to observe the “life path” of the unit, but also to restore and analyze in detail the behavior of equipment and personnel in emergency situations. On technological installations provides (online) objective automatic monitoring of dynamic equipment, troubleshooting,resource forecast, personnel warningabout a malfunctioning accident or a malfunction, issuing instructions to personnel on working with equipment that is critical at a given time, removing equipment torepair and its acceptance from repair. Protective monitoring mode with automaticdisabling hazardous objects based on dialoguewith staff. Personal Systems - Diagnostic Workstation -COMPACS-MICRO™ provide (off line) objective monitoring of quasi-static equipment with automatic on-line diagnostics of units and assemblies on site, balancing the assembled unit onlocation, transmit information to stationary systems for wide alert and remind staff about the state of quasi-static equipment, preparation of reports WORD, EXCEL, advantages WINDOWS 7, 8, 10. Continuous monitoringvibration conditions of the equipment and automatic diagnostics with the indication of defects led to a decreasecrashes and manufacturing equipment malfunctions(taking into account the "unfriendly" actions of the staff) ineight or more times; reduction of failures of mechanical seals of pumps by 3 - 8 (when working on gas condensate) and more than once; to reduce the volume of repairs andthe number of parts replaced during repair morethan 3 times.   REFERENCES 1. Mitchell J.S. MIMOSA Building the Foundation for 21st Century Optimized Asset Management - S&V, September, 1995. 

Oil-processing pump units vibromonitoring system

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Oil-processing pump units vibromonitoring system

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Electronic Repository Kyiv National University of Technologies and Design