The Challenge: Ensuring Safe and Continuous Refinery Operations
Operating a large-scale oil refinery involves managing critical infrastructure where unexpected machinery breakdowns can lead to severe production halts and safety risks. Initially, there was no oil refinery condition monitoring. The facility required a highly reliable, automated solution that aligns with rigorous industry guidelines, such as the API 670 standard for machinery protection, to ensure the timely detection of defects and malfunctions across its extensive fleet of rotating equipment. The goal was to move away from reactive repairs and establish a proactive strategy to manage the technical state of the plant effectively.
The Solution: Real-time Diagnostics with the COMPACS system
To address these challenges, the plant launched the implementation of the real-time diagnostic COMPACS system in 2019. To date, the technology has been successfully deployed on 819 pieces of machinery across 13 vital technological units (including PAU, PTP, PGP, and PKS).
The core advantage of this implementation is its ability to provide a safe, resource-saving technology for operating machinery. Moreover, the COMPACS system operates entirely automatically, without human intervention. In addition to oil refinery condition monitoring, it performs continuous monitoring, diagnostics, and forecasting of equipment technical condition in accordance with global guidelines for machine condition monitoring and diagnostics.
Also, by setting a new standard in rotating equipment monitoring, the integration features the diagnostic system COMPACS-Net. This allows engineers and mechanics to seamlessly monitor and control machinery status directly from their workstations. At the same time, providing actionable prescriptions for technical personnel and operators.
Expert Insights on the Implementation
“The implementation of this project will allow us to increase the reliability of rotating equipment and ensure a smooth transition to condition-based maintenance.”
“The COMPACS system protects equipment from serious breakdowns. Now we have access to parameters that were previously unavailable. The system also simplifies the work of the staff.”
Project Outcomes & Benefits
The deployment of the COMPACS system at the refinery has delivered measurable improvements in operational safety and efficiency:
- Zero Human Intervention: Fully automated diagnostics, monitoring, and forecasting of machinery health.
- Early Defect Detection: The ability to detect developing defects and plan repairs or switch to backup units in advance.
- Accident Prevention: Significant reduction in the risk of serious breakdowns and production malfunctions.
- Condition-Based Maintenance (CBM): A successful transition to maintaining equipment based on its actual technical state rather than fixed schedules.
Maximize Equipment Reliability at Your Facility
Are you looking to eliminate sudden machinery breakdowns and automate diagnostics without relying on the human factor? Schedule a meeting with our engineering team to discuss integrating the real-time diagnostic COMPACS system into your processing facility.
Read Full Video Transcript
The real-time diagnostic COMPACS system enables early defect detection for Oil & Gas plants.
The project to implement the real-time diagnostic COMPACS system was launched in 2019. Today, the COMPACS system has been implemented on 819 pieces of rotating equipment. Across 13 technological units of PAU, PTP, PGP and PKS.
The purpose of implementing this project is to ensure the timely detection of defects and malfunctions in the technological condition of the plant’s rotating equipment.
The real-time diagnostic COMPACS system is designed to provide a safe, resource-saving technology for operating machinery, to prevent accidents, production malfunctions, and to manage the technical condition of equipment through continuous computer monitoring, diagnostics and forecasting of its technical state. The system operates automatically without human intervention.
Diagnostics, monitoring, and forecasting of the technical condition of units are performed with recommendations provided for the next necessary actions regarding the equipment, technological personnel, and operator station.
This system also features the diagnostic system COMPACS-Net, which allows engineers and mechanics to monitor and control the condition of rotating equipment from their workstations.
The implementation of this project will allow us to increase the reliability of rotating equipment and transition to maintenance based on actual technical condition.
I would like to introduce to you the COMPACS system. The COMPACS system makes it possible to prevent potential malfunctions and equipment failures, detect developing defects, and plan repairs and switching to a backup unit in advance.
Regarding the COMPACS system, I want to say that, first and foremost, in my opinion, it protects equipment from serious breakdowns, because now we have access to parameters of components that were previously unavailable to us. They were not. And secondly, I believe it simplifies the work of the staff.
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