The stable operation of continuous technological processes directly depends on the accident-free operation of the dynamic equipment that ensures the output of products. On oil refineries, pumping, compressor units, smoke exhausters, air blowers, air cooling units equipped with rolling bearings are widely used. The rolling bearing is the main part, from the technical condition of which the working capacity of the entire unit depends. Monitoring vibration of dynamic equipment in operation allows you to monitor the degree of degradation of its components and parts. The purpose of the study is to develop a methodology for monitoring the process of stage-by-stage degradation of rolling bearings in operation and timely warning of the technological personnel of the oil refinery on the need to take measures to eliminate accidents and incidents.
The vibration monitoring of dynamic equipment in operation at oil refineries was carried out with the help of stationary monitoring systems for the technical condition and automatic diagnostics of COMPACS® and analysis of changes in the technical condition of the units. It is established that in some cases fatigue degradation and subsequent destruction of parts occur in stages. In this case, the vibration emissions reflect the stages of degradation. The developed technique for controlling emission amplitudes and intervals between vibration emissions allows us to detect in a timely manner the presence of a process of stage-by-stage degradation of parts in the operating unit, to warn personnel, to provide preparation for repair work and to prevent emergency situations.
V.N. Kostyukov, Е. V. Tarasov Fatigue Degradation Evaluation of Details and Substructures of Dynamic Equipment in Operation by Vibration Parameters // NDT World. - #3-2017, p.11-14
Integration of the results achieved by Russian scientific and technical institutions with developments in the same fields made by foreign countries gave rise to a conflict of interest and misunderstandings, particularly, in condition control, diagnostics and monitoring. The conflict of interest is, mostly, connected to commercial interests of certain firms and companies aimed at selling their product and, consequently, twisting technical diagnostic facts, deliberately or unintentionally. The misunderstanding is caused by foreign countries having a technological gap in certain scientific and technical fields, such as vibroacoustic diagnostics and health monitoring.
The paper is aimed at suggesting basic terminology for diagnostics, monitoring, and vibroacoustics and the method of their application in real technological decisions.
The terminology is suggested by regulatory and procedural documents, reference, scientific and guidance literature, including the researches carried out by the authors.
The analysis of terminology used in Russia and abroad revealed that there are differences in understanding the methods of technological solutions of tasks in the fields of technological control, diagnostics, and machinery condition observation. In particular, the term «condition monitoring» is intended to be understood as condition control, not condition observation.
It is shown that the vibration acoustic signal is a random process, and vibroacoustic diagnostics requires analysis of its stochastic characteristics. It is necessary to measure the acceleration, velocity and displacement, since the stochastic characteristics of these vibroacoustic oscillations parameters are statistically independent,
The researches have concluded that real-time condition monitoring systems should provide real-time diagnostics of machinery at such time intervals that machinery condition cannot change from normal to limiting. To minimize the chance of skipping a dangerous condition and ensure reliable by vibroacoustic parameters one should measure vibration acceleration, velocity and displacement with an error which does not exceed 5% in the frequency range of at least 3000Hz.
V. N. Kostyukov, A. P. Naumenko Vibroacoustic Diagnostics as the Basis of Machinery's Health Monitoring // NDT World. - #3-2017, p.4-10
In modern conditions, the growth of refinery production efficiency can be reached mostly by increasing machinery operation time between repairs and decreasing operation costs for machinery maintenance and repair which is impossible without its high operational reliability.
Traditional methods of maintaining machinery operability based on PPM are low-effective and do not ensure the required time between repairs and production safety rates. In that connection, for the last 25 years, the COMPACS Systems has been implemented nation-wide to ensure safe resource-saving operation of machinery by means of real-time condition monitoring.
References:
Kostyukov V.N., Boychenko S.N., Kostyukov A.V. Automated control systems for safe resource-saving operation of equipment for oil refining and petrochemical industries (ACS SRO) / Ed. V.N. Kostyukov. Moscow: Mashinostroenie, 1999.163 p.
Kostyukov V.N. Production safety monitoring. Moscow: Mechanical engineering. 2002.224 s.
Kostyukov A.V., Kostyukov V.N. Improving the operational efficiency of enterprises based on real-time monitoring. Moscow: Mashinostroenie, 2009, 192 p.
Kostyukov V.N., Naumenko A.P. Fundamentals of vibroacoustic diagnostics and monitoring of machines: a textbook. Novosibirsk: Publishing house of the SB RAS, 2014; 378 p.
Chepurnov P.E., Kudryashov V.A., Berezhnoy A.N., Kostyukov V.N., Kostyukov A.V., Sinitsyn A.A. Innovative highly efficient resource-saving technology for operation of rotating equipment of process units of JSC Kuibyshevsky Refinery based on condition monitoring systems // Chemical Engineering. 2015. No. 12. P. 16-20.
Kostyukov A.V., Sinitsyn A.A., Kazarin D.V., Zarubina D.S. Maintenance of Safe Resource-Saving Operation of Equipment Under The Control of The COMPACS Systems // Improving the reliability and safety of the equipment of refinery production units. - Moscow: OOO "Council of Chief Mechanics", (December 5-6, 2016, Moscow) - 2017 .—512p., p. 192-198.
The article considers the issues of using different physical processes parameters in systems for real-time condition monitoring of reciprocating compressors.
The locations for sensors of absolute and relative vibration are defined.
Trends of parameters of absolute and relative vibration at emergence of malfunctions and defects are given.
Examples of diagnosing of reciprocating compressors in parameters of relative and absolute vibration are reviewed.
It is shown that real-time monitoring of the absolute vibration parameters and the relative position of rod provides observability of the piston compressors’ condition and, consequently, their safe operation.
Kostyukov V.N., Naumenko A.P. Real-time monitoring on vibration- based diagnostics of reciprocating compressors // Proceedings of The First World Congress on Condition Monitoring 2017. -152
The article considers the issues of using different physical processes parameters in systems for real-time condition monitoring of reciprocating compressors.
The locations for sensors of absolute and relative vibration are defined.
Trends of parameters of absolute and relative vibration at emergence of malfunctions and defects are given.
Examples of diagnosing of reciprocating compressors in parameters of relative and absolute vibration are reviewed.
It is shown that real-time monitoring of the absolute vibration parameters and the relative position of rod provides observability of the piston compressors’ condition and, consequently, their safe operation.
Kostyukov V.N., Naumenko A.P. Real-time monitoring on vibration- based diagnostics of reciprocating compressors // Proceedings of The First World Congress on Condition Monitoring 2017. -152
Condition diagnostics and monitoring of machinery by vibration-acoustic diagnostics methods is widely used nowadays in production industries, in order to quit the expensive preventive maintenance and implement an effective modern system of condition-based maintenance. The papers [1,2] show that the effectiveness of a condition monitoring system implementation is mainly determined by the value of the error of the result issued by the expert system. One of the components of the diagnostic errors is low resolution power of spectral analyzer which is currently the main instrument for vibration-acoustic signal analysis.
Kostyukov Al.V., Boychenko S.N. Improving reliability of vibration spectrum identification without increasing sampling rate using spectral interpolation algorithm // Proceedings of The First World Congress on Condition Monitoring 2017. -152
The article reviews and suggests certain results of an experimental analysis of low-frequency vibrations on a bench for rotor installed on plain bearings and having a residual deflection.
Kumenko A.I., Kostyukov V.N., Kuzminykh N.Yu., Timin A.V. Auto-oscillations and subharmonic vibrations as illustrated by an experimental rotor // Proceedings of the 7th international scientific and technical conference (Omsk, April 24-28, 2017). - Omsk: Publishing House of OmSTU, 2017. - p.186-187
Bearing units of rotary machines are critical points on the technical condition of which depend on reliability and steadiness of machinery operation, as well as its safety.
For an objective assessment of the condition of bearing units, one should consider the nature of dependency between the rotary vibration parameters and shaft rotation speed, thus, creating new diagnostic signs combination of which ensures higher diagnostic reliability.
The paper is aimed at determining the dependency of diagnostic signs from shaft rotation speed to solve practical engineering tasks.
Kostyukov V.N., Kostyukov Al.V., Zaitsev A.A., Teterin A.O. Studying dependency of vibration parameters occurring in bearing units of rotary machines on shaft rotation speed // Proceedings of the 7th international scientific and technical conference (Omsk, April 24-28, 2017). - Omsk: Publishing House of OmSTU, 2017. - p.185-186
Currently the only method for determining machinery condition is vibration diagnostics, when the condition is determined by analyzing a vibration signal in its housing. As a result of signal analysis, a special expert system forms a set of diagnostic signs based on which a diagnostic expert message is formed using logical rules.
To form a vector of diagnostic signs, signs invariant to machinery construction are used: RMS signals of vibration acceleration(Ae), vibration velocity (Ve), and vibration displacement (Se),as well as a set of spectral signs obtained from an analysis of spectral components of the vibration signal.
Kostyukov Al.V., Boychenko S.N. Studying orthogonality of system of fractal and integrated diagnostic signs of vibration signal // Proceedings of the 7th international scientific and technical conference (Omsk, April 24-28, 2017). - Omsk: Publishing House of OmSTU, 2017. - p.183-184
The research is aimed at increasing diagnostic reliability for complex machines by creating an adaptive method of health evaluation of parts of their same-type units operating in uniform environmental conditions.
Kostyukov V.N., Kostyukov Al.V., Kazarin D.V., Basakin V.V. Method for diagnosing same-type units by vibration parameters // Technique and technology of the petrochemical and oil and gas production: Proceedings of the 7th international scientific and technical conference (Omsk, April 24-28, 2017). - Omsk: Publishing House of OmSTU, 2017. - p.182-183
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