Resource-saving Safety:

Highly Efficient Technological Policy of Leading Enterprises

In current market situation the main way to increase profitability of industrial enterprises with uninterrupted cycle is to reduct operation costs and losses caused by production accidents and downtime due to unexpected failures of process equipment. Operation costs can be minimized by conducting real-time monitoring of equipment technical condition timely and intentionally by using the equipment capacity to the full and eliminating any off-schedule (i.e. emergency) shutdowns and replacements. Analyzing the reliability of modern production facilities, it can be concluded that more than three fourths of the equipment failures refers to the machinery and often causes accidents and operational upsets or emergency shutdown of process units and plants. On the other side, quality of a product and its processing as well as product yield depend on basic process equipment condition which is mostly influenced by the process operation methods. The basic reason for equipment problems is the lack of objective assessment of equipment condition within the actual operating process. It prevents the personnel from keeping a production facility in technically prepared state. The solution to this problem was found in the beginning of 1990s when there were introduced the automated decision support systems which helped to determine the equipment condition and the terms of its repair. The main responsibilities of a companys departments responsible for maintenance of production facilities are: increasing run-to-failure time of process facilities to the maximum by preventing the equipment from accidents and shutdowns occurred due to equipment failure; reducing equipment repair time to the maximum by personnels focused actions based on data received from the monitoring systems; reducing operation costs and losses by eliminating off-schedule repairs and minimizing preventive maintenance. In 1980-90s automated control systems for safe resource-saving equipment operation - ACS SRSMTM COMPACS - were developed and implemented at more than ten Russian plants. The stationary condition monitoring systems COMPACS , stationary systems COMPACS-KSA and personal automated diagnostic systems Compacs -micro were implemented in process units; the stand systems for repair quality control of units and assemblies were used in maintenance departments; the computer diagnostic network Compacs-Net that allowed to keep real-time control of process operation was put into effect at the overall plant. Condition monitoring systems COMPACS allow detecting the following failure types without involving personnel: alignment damage; imbalance including motor wheel wearing and half-coupling; defects of rolling bearings and plain bearings; disruption of lubrication rate; hydro-gasdynamic problems in pumps and compressors; bad condition of mechanical seals; gear faults; weakening of units fastening to the foundation or mounted structures; process upsets (surpassing the units maximum load); electric motor failure; detachment of reactor cladding layer; intolerable deformation of the process equipment casings; failure of valves and crank gear of piston machines. According to modern classification, ACS SRSMTM COMPACS belongs to the MES-systems, i.e. realtime production control systems, and can be integrated with the PM module and ERR- control systems of high level production (SAP R/3, etc.). The high efficiency of the ACS SRSMTM COMPACS system is determined by automatic solution of operational tasks related to: diagnostics and prediction of the basic equipment failure modes

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(>95-98%) allowing detection of any defects at early stage, use of full capacity and maintainability; informing the personnel about actions of high priority to control equipment condition; control of execution of any diagnostic recommendations generated by the system and the actions of the personnel by using network technology (Internet); making purposeful repair plans based on actual equipment techni-

cal condition. The ACS SRSM TM COMPACS automates work process for specialists such as diagnosticians, process engineers, mechanical engineers, power engineers in: detection and correction of any mistakes in design and assembly; optimization of process flow diagrams and equipment configuration; control of data bass containing diagnosis, work, replacement

and capacity of equipment; providing reports for companys management. T h e u s e o f A C S S R S M TM COMPACS makes the process of asset management more transparent and thus better manageable, reduces the capital capacity of operation, raises the return on assets ratio, and, as a result, leads to the increased capitalization of an overall company.

The saving due to operation costs and losses reduction is more than 2 USD per 1t throughput, and the cost of ACS SMRSTM COMPACS implementation is less than 5 % of the value of the protected equipment and processes

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