Safe Resource-saving Operation and Maintenance of Machinery
(Andrey Kostyukov – President of DYNAMICS SPC USA, Inc.)
Why is it called disruptive? If you implement this Technology at your refinery, several usual actions will have no further purpose, however let's be consistent... The main causes of unexpected costs and losses in downstream are well-known. There are accidents and fires caused by equipment failures, downtime of refinery units due to equipment breakdowns, and extended turnaround duration as the exact information about the damage to equipment is unknown. The maintenance expenses are significant as well because of both planned and unexpected maintenance's orders due to sudden breakdowns.
Within the last 70 years, the reliability strategies have repeatedly changed from Preventive Maintenance (PM) to Reliability-Centered Maintenance (RCM). All of them are based on a probability assessment of the failure instance. However, the probability assessment does not include the possibility of eliminating any of the failure sources mentioned above. There are two main cases occur either with PM or RCM approach: the equipment is removed from operation before or after some critical time point.
The total amount of expenditures due to breakdowns directly depends on early failure detection and the efficiency of personnel actions under conditions of various velocities of machinery resource's losses. Consequently, the frequency of diagnostics is the basic factor that will decrease the number of unplanned expenses and losses, as well as increase the reliability and safety of the refinery operation.
Even if you determine and identify the failure in its early stage you also need to localize its impact on expenditures before the critical time point passes. Therefore, we have developed the Technology of Safe Resource-saving Operation and Maintenance of Machinery. Today Dynamics offers the SROMM-Technology, which significantly cuts the duration of equipment health improvement at each stage of decision making. Implementation of the SROMM-Technology means that you start using the following on a regular basis: management of the objective real-time information about machinery health, efficiency of machinery operation modes, quality and timeliness of fulfilled maintenance actions, and efficiency of root cause reliability analysis at the refinery.
Using the real-time machinery health information, you can determine a failure, its cause, what should be done to prevent expenses, what type of actions were done or were not done, and who is or was responsible for those actions. This objective information provides the trust basis between all plant personnel, including management, reliability, maintenance, and operations staff of the refinery. It provides the possibility of moving the responsibility for your safety processes from top-management to the plant operator's level. The main advantage of the technology is that personnel become the real team because of extremely high visibility and trust in each other. Due to the elimination of asymmetric information, personnel achieves safe and reliable refining, maximum possible uptime, short as possible turnaround times, efficient maintenance costs, and significant reductions in power consumption.
The critical element of the SROMM-Technology is the Real-Time Diagnostic COMPACS System which provides everyone at the refinery with objective information on machinery health and the nearest urgent actions required to prevent specific failures. The system considerably cuts the machinery diagnostics interval and makes its duration less than the failure development time. Using AI prescriptions makes it possible to eliminate destructive forces and prevent almost any failures without a significant cost. It provides very fast feedback to the involved personnel and management about the efficiency of the completed actions. It also provides visibility into the efficiency of every involved employee without any restrictions regarding their position in the refinery hierarchy.
As operation staff receives AI prescriptions they must immediately initiate the nearest urgent actions to increase the lifetime of a diagnosed machine. The unit’s maintenance budget should be used in case the maintenance actions were done efficiently, according to current machinery health assessed by the COMPACS system. The same requirement should be assigned for commissioning of new or repaired equipment. When a machine is operated under "action required" or "unacceptable" states for a long time, or it has been repaired too many times, the reliability team should analyze the COMPACS system data. They should provide the root cause reliability analysis and provide recommendations to eliminate the found causes. Our original software can be used for automatic analysis of reliability as well as mechanical readiness.
If the prescriptions issued by the COMPACS system are fulfilled accurately and on time, you see normal charts of maintenance actions below. You can see both typical distributions of repairs which were done in the workshops, and quantity of maintenance actions which were done to machinery in operation. Usually, in six months the quantity of operational maintenance actions doubles, but at the same time, the quantity of costly repairs significantly drops. And finally, if you significantly drop the general level of all machinery vibration at the unit, according to our customers’ feedback, you achieve the considerable - not less than 7% - the reduction of total power consumption in the unit.
To achieve these significant and valuable outcomes with the technology, we have developed unique AI algorithms for machine failure detection. We have decreased the diagnostics error rate of the COMPACS System from the usual 30-40% to an unbelievable 1%. It provides almost a total elimination of all detectable failures. It is best to select machines to be equipped with the system. Using the COMPACS-NET plant diagnostic network the information from the systems should be collected and presented to all levels of refinery management at the same time. This provides visibility of machinery health and efficiency as well as machinery operation and maintenance.
In conclusion, the outcome of the SROMM-Technology implemented at the Aromatics Unit of Omsk Refinery, where it made a huge positive impact on the overall unit performance. According to our customers’ published testimonials, the economic benefit of the COMPACS System and the Technology of Safe Resource-Saving Operation and Maintenance of Machinery is not less than 10 US dollar per 1 US dollar of investments. The typical payback period of investment is less than 6 months, but sometimes it is less than one month.