A reliable real-time vibration monitoring system for Cristal Pigments UK Ltd

THE CHALLENGE We have worked on a wide range of projects for our client Cristal Global and our knowledge of vibrating systems has enabled us to develop a bespoke vibration monitoring system. Early projects with them led to the realisation that two of their support structures were in trouble because of continuous vibration imposed by violent chemical reactions in the process vessel. OUR SOLUTION Starting from scratch we developed a new structure that increased the mean time between failures from 4 hours on the old structure to 14 months. As part of the COMAH requirements given by the HSE, we were tasked with designing and installing a vibration monitoring system which provided a real-time overview of the vibrations. The continuous vibrations are monitored at 15 discrete locations on the structure, vessel and critical sections of pipework. Accelerometers are connected to a signal-processing computer which is converting accelerations into displacements, using software designed by DCW, before being fed into the plant's digital monitoring system. The system allows our client to calculate the fatigue life of nozzles and other components connected to the structure/vessel. The advances in technology have meant that we've been able to constantly improve the design of the housings to accommodate smaller and more accurate accelerometers. The system has been running for almost a decade and this has also given us the opportunity to constantly update the software, keeping it up to date with the latest technology. This has given our client a reliable and accurate vibration monitoring system.

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