It is known that the lack of fact-based equipment quality control during production and service, as well as the lack of in-service observation over the real health degradations do not allow us timely take cost-effective and technically efficient measures to maintain a high level of equipment reliability.
The problem of diagnostics reliability and guaranteed delivery of the diagnostics data to the executives and managers of different responsibility levels is solved by automatic condition monitoring and creation of automated control systems.
DYNAMICS SPC expertise in monitoring and diagnostics of critical equipment at various industries and railway transport made possible to create innovative health control technology for rolling stock on the basis of real-time monitoring that is Automated Control System for Safe-Money-Saving Real-Time Maintenance of equipment (ACS).
The purpose of introducing ACS into railway transport is to increase the safety and smooth functioning of the transport through the effective health monitoring of rolling stock and infrastructure facilities on the basis of continuous automatic real-time monitoring.
Kostyukov V.N., Kostyukov Al.V., Kazarin D.V., Schelkanov A.V. Resource-Saving Operation and Maintenance of Motor-Driven Rolling Stock // Eurasia Vesti. - 2013. - August. - p.20.
DYNAMICS Scientific & Production Center (DYNAMICS SPC) was founded in June 11 in 1991 by Vladimir Kostyukov in Omsk.
The crucial moment for the company was a successful implementation of the first computer monitoring system for pump units developed by the DYNAMICS SPC specialists for the 36/1-3 deasphalting unit and AVT-10 atmospheric and vacuum crude unit of Omsk refinery.
Over 2 years there were more than 6 systems on the refinery. The systems were protecting about 138 machines of the 6 most important plants from the breakdowns. Also, there was the diagnostic network Compacs-Net® used for issuing voice announcements for the specialists.
In 1994 the preventing shutdowns and condition computer monitoring system COMPACS® was approved by Ministry of Fuel and Power and State Committee for Industrial and Mining Safety Supervision of Russian Federation.
Today more than 500 systems are implemented in Russia and other countries in 12 industry branches: petrochemical, oil-refining, mining, metallurgic, railway transport and community facilities, etc.
Kostyukov V.N. DYNAMICS Scientific & Production Center // Success as a lifestyle. - 2013 - September. - P.38-39
The article represents a brief biography of V. N. Kostyukov who is a member of Russian Engineering Academy and International Academy of Social Science, The Russian Government laureate and professor.
V.N. Kostykov has developed the concept of machinery and production facilities condition monitoring based on the stated and justified scientific provision. The provision claims that the observation may be conducted by measurement of diagnostic signals (vibration parameters) and their changes speed.
During 40 years fundamental experimental and theoretical researches were made. The researches were touching the relation between the vibration acoustic signals and fault inception and development, machinery condition degradation within the serial and pilot production and real operation at the production facilities.
The basic techniques of monitoring were created; synthesis principles and basis of adaptive diagnostic and monitoring systems design were developed. The diagnostic and monitoring systems are invariant to the production facilities construction and configuration.
The brand-new system class was developed: real-time automatic control systems for resource-saving operation of production facilities and its implementation technology were developed and approved by the Department of Energy and Federal Service for Ecological, Technological and Atomic Supervision and also was recommended for large-scale implementation.
Kostyukov V.N. The goal is to provide reliability of machinery operation // Business Glory of Russia: interbranch anthology 2013. – No.3 (41). - P.60-61 (http://www.slaviza.ru/944-cel-obespechenie-nadezhnosti-raboty-oborudovaniya.html)
The proprietary development of DYNAMICS SPC is machinery computer monitoring system utilizing pollutant-free, resource-saving and safety operation technology. The specialists of DYNAMICS SPC translated into reality 40-years of experience in creation and implementation of vibration analysis systems, embodying the latest scientific and technological discoveries into the unique product.
The monitoring system provides automated data processing of sensor readings, elimination of ineffective manual data collection and analysis, display of the diagnostic results in understandable form. The continuous measurements and analysis of sensor readings allow determining deviations from the normal values on early stages of failure appearance, predicting any sensor behavior and prompting personnel on failure repair and conducting condition-based decommissioning for repair only in case of full use of machinery operation resource and with preservation of reparability.
The unique automated patented expert system for vibration-acoustic machinery diagnostic in real-time exists only in the COMPACS® systems and is one-of-a-kind.
Kostyukov V.N. Rapid response system // Omsk Business Journal. - 2013. - P.7-9
There is a quite huge area of compressor equipment use where its operation safety is a primary and dominant factor. Such equipment is created for hazardous production facilities of petrochemical industries. Receiving not only reliable but timely diagnostics is highly significant for the equipment. The diagnostics provides accident-free operation with maximal operation life of replaceable assemblies and details. In order to achieve this, it is essential to diagnose the equipment within shorter period of time than failure development period. For the petrochemical and gas industries such diagnostic period may amount to several minutes, hours, days, weeks or even months.
Safety and reliable production facilities operation is one of the major problems which can be solved by providing observability for production facilities. The condition of the equipment significantly affects techno-economic performances of the production and technology-related incidents.
Observability of production facilities condition is carried out through monitoring, which is a supervision of production facilities.
Kostyukov V.N., Naumenko A.P. Condition monitoring and diagnostics of compressor equipment in real-time // Modern concepts of choice and maintenance of compressor equipment at refineries and petrochemical industries: seminar proceedings. - Moscow: “Research and development Center of Board of Master Mechanics”, Ltd., 2013. - P.122-139
Current level of industrial development requires special attention to environmental safety of machinery operation and processes especially at explosive and fire-hazardous productions. DYNAMICS SPC offers brand-new level of environmentally friendly and resource-saving machinery operation and processes based on computer condition monitoring in real-time.
The implementation of automated control system for safe and resource-saving machinery operation provides accidents elimination, turnaround increase, machinery and facilities processes repair and operation in real-time. DYNAMICS SPC products are certified by Federal Agency on Technical Regulating and Metrology and Russian Technical Supervisory Authority, and approved for usage in potentially hazardous productions.
Monitoring system allows to process data provided by sensors automatically, to eliminate effectless manual labor of data collection specialists, to analyze data and reporting diagnostic results in understandable form. The system conducts continuous measurements and analysis of sensors readings, which makes possible to reveal abnormals on the early stages of failure nucleation and to predict machinery behavior. The instructions for failure elimination and taking the machinery out of service for repair due to actual machinery condition with full usage of its residual life and sustaining its reparability are given to the specialists automatically and in advance.
Kostyukov V.N. We make future safe! // Regions of Russia. - 2013. - №8. - p.48 (http://www.gosrf.ru/mag/rr88/index.html p.50-51)
The basis of reliable and resource-saving machinery operation of potentially hazardous productions is real-time condition monitoring of facilities. This is proved by a long-term experience of using monitoring systems on “Lukoil” refineries. The reciprocating compressors (RC) condition is determined by the number of parameters (absolute and relative vibration of assemblies and RC details; temperature of the assemblies, oil and compressed gas; gas pressure in decreasing space, in suction and discharge manifolds).
Any monitoring system is based on the following efficiency criteria:
Providing safety measures for reciprocating compressors maintenance;
Timely system response to fast-evolving and potentially hazardous defects and failures of assemblies and details;
Minimum costs for the system are determined by the system’s architecture and number of measuring channels.
The results of many years of the research reveal that absolute vibration parameters change due to degradation of assemblies and details structural parameters. The distance between interacting and coupled details determining the machinery condition increases as a result of degradation. Therefore, the absolute vibration monitoring is a common technique for accident prevention and diagnostics of reciprocating compressors.
Kostyukov V.N., Naumenko A.P., Fedorinov I.A., Zolotarev V.N. The experience in operation of real-time condition monitoring of reciprocating compressors // Compressors and pneumatics . - 2013. - №5 (July). - P.4-8
Rotating equipment vibration signal analysis is currently the most common method of determining its technical condition. For this purpose, in the signal spectrum the harmonics levels, associated with the defect magnitude, are determined at the defects frequencies. To improve the diagnosis accuracy and reliability the analysis should be carried out not by the instantaneous spectrum, which is strongly influenced by noises, but by the average spectrum. However, if the equipment speed mode is non-stationary, a direct averaging of the spectrum will lead to recognition errors due to the defects frequencies dependence on the rotation speed.
The paper considers diagnostics of rotating equipment with non-stationary operating mode by the example of a rolling mill diagnostics. To obtain the averaged spectrum, a scale transformation in frequency, which ratio depends on the mill speed mode, has been used. Thus an ordinal average spectrum in rotation frequency terms has been received. To determine accurately the speed mode two independent channels are used – a hardware speed sensor and a software channel of an automatic rotation frequency recognition according to the case vibration.
Using the ordinal average spectrum and two independent channels for the rotation frequency determining has provided an accurate and reliable system for the mill technical condition diagnostics.
Kostyukov V.N., Boichenko S.N. Vibration diagnostics of rotating equipment with non-stationary speed mode // X International Conference Condition Monitoring and Machinery Failure Prevention Technologies - СМ/MFPT 2013
The paper is aimed at examination of acoustic-emission signals occurring as a result of imitation and growth of local corrosion pits on steel samples in laboratory conditions. The revealed regulations can be used for establishing the assessment criterion of danger level of corrosive damages on various facilities of different application.
In order to reveal the regulations in the way AE-signals’ features correspond to their occurrence pattern during the metal corrosion process, an analysis of statistic data obtained in the experiment was carried out.
The results of the data analysis are parameters of amplitudes and AE-signal lengths corresponded to corrosion processes. The parameters are used in the comprehensive monitoring system COMPACS®-AE for classification of AE-processes.
Kostyukov V.N., Naumenko A.P., Boychenko S.N., Kostyukov Al.V. Research on AE-signals of corrosive processes // Acoustic emission. The technique’s application in comprehensive condition monitoring systems for hazardous production facilities: 3rd International Scientific and Technical Conference – Moscow, 2013. – pp. 249-257
Refinery and petrochemical companies in Russia are operating tens of thousands of machines and pieces of static equipment providing regulation of operating process.
Steady operation of machinery determines production of high-quality goods. At the same time, unstable operating process, sudden changes in operation parameters cause hydro-dynamical problems of facilities, that, consequently, leads to nucleation and development of defects in the weakest point of the technological process – pump units.
The diagnostic and monitoring system operating on the unit allows the personnel to prove the existence of errors in ACS algorithms.
The observability of machinery degradation in real time allows to exclude the emergency repairs and to carry out scheduled repairs of units according to their actual condition.
Kostyukov V.N., Kostyukov An.V., Tarasov E.V. Monitoring in refinery and petrochemical industries // TehNADZOR. - 2013. - № 8. - pp. 44-46