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
Modern equipment usage in production and transport complex is impossible without application of monitoring systems. Today objects of production and transport complex have different impact on safety, economy and ecology of country - there are technical regulation facilities, dangerous industrial facilities, extremely important facilities, strategically important facilities. It is clear, that condition monitoring of such facilities should be conducted with different classes of systems.
Monitoring systems should provide the obtaining information about machinery condition in necessary quantity and quality for providing observability of its condition. Monitoring systems should allow take further actions considering results of monitoring, thus, providing necessary sustainability of technological system, functioning characteristics for creating its technological, ecological and economic safety.
The systems form a core of automated process control system for resource-saving operation of machinery in real time within the entire enterprise.
Kostyukov V.N., Naumenko A.P., Kostyukov An.V. Decision making risk assessment in monitoring systems // Assessment and management of risks in industrial safety. Risk monitoring of oil-refining and petrochemistry facilities: paper of scientific-practical workshop. – Moscow, 2013. – pp. 87-95
The current Russian and the International standards in the field of standardizing parameters for piston machines vibration including piston compressors are reviewed. It is shown that the current standards do not meet safe operation requirements for piston compressors of hazardous production facilities.
The article describes the branch standard "Condition monitoring of hazardous production facilities equipment. Stationary piston compressor units of hazardous production facilities: vibration operating norms" recommended for application at potentially hazardous facilities.
Kostyukov V.N., Naumenko A.P. Regulatory-Methodical Guidelines On Real-Time Vibroacoustic Monitoring Of Reciprocating Compressors // Work safety in industry. - 2013. - №5. - pp.66-70
To make an efficient evaluation of wheel-motor unit assembly bearings condition - the research on factors influencing the vibration level is required.
For such a research there was developed a mathematical model connecting a rolling bearing vibration signal level with linear dimensions of a defect and shaft rotation frequency, which shows that the vibration amplitude is proportional to the rotation frequency, linear dimensions of a defect and loading on the bearing.
Vibration level-vs-defect size curves are built.
Thus, creating systems for condition diagnostics and monitoring of EMU-train bearing assemblies, in order to increase the reliability of diagnostics it is important to consider the influence of the rotation frequency and characteristics of the defect mode at different speed rates.
Kostyukov V.N., Zaytsev A.V., Tsurpal A.E., Basakin V.V. Research on EMU-train rolling bearing defect influence on vibration parameters values // Increase of traction and energy efficiency and reliability of electric rolling stock: interuniversity special scientific paper volume – Omsk: OmSTU, 2013. - pp.50-53
Operating experience of machinery health monitoring systems for hazardous production facilities of energy complex, mining and metallurgical industry enterprises has been considered. The difference between condition monitoring and health monitoring systems has been shown.
Condition monitoring systems measure the physical processes parameters, though they do not determine the reasons for their change. Health monitoring systems determine not only the monitoring object’s technical state, but the reasons for its change, as well. These systems use the expert system algorithms for real-time decision-making support with an automatic diagnostics of machinery units’ failures. Simultaneously, the systems automatically detect the failures severity and point out actions the staff should take to solve the problem.
Sometimes in Russia such systems are called the diagnostic monitoring systems. Those, as a rule, are the 1st class-systems, according to GOST R 53564 . The term “real time”, when it comes to condition monitoring, means that the determining the parameters measurement rate, as well as the object condition identification and the diagnostics results displaying, should be adjusted with its degradation rate and even several times outpacing, it in order to eliminate surges and increase the diagnosis accuracy, thus, creating the leeway for management decisions making and compensatory measures execution.
The technical and economic indexes of monitoring systems application effectiveness have been provided in the article.
V. N. Kostyukov, S. N. Boichenko, Al. V. Kostyukov, ‘Automated control systems for safe resource-saving operation of equipment at refining and petrochemical plants (ACS SRSTM™ COMPACS®)’, Moscow, Mashinostroenie, ISBN: 5-217-02971-4, 1999, 163 p.
V. N. Kostyukov, ‘Monitoring of Production Safety’, Moscow, Mashinostroenie, ISBN: 5-217-03151-4, 2002, 212 p.
An. V. Kostyukov, V. N. Kostyukov, ‘Increase of operational efficiency of enterprises based on real-time monitoring’, Moscow, Mashinostroenie, 2009, 192 p.
V. N. Kostyukov, ‘Condition monitoring of the equipment in real-time technology of safe-save maintenance of the XXI century’, Тhe 5th International Conference on Condition Monitoring and Machinery Failure Prevention Technologies CM 2008/MFPT 2008/ 15-18 July, 2008, Edinburgh, Scotland, UK, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-31-4, 2008, pp 785-793.
V. N. Kostyukov, ‘Real-Time Condition Monitoring of Machinery’, The 6th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2009/MFPT2009/ 23-25 June, 2009, Dublin, Ireland, BINDT & Coxmoor Publishing Co., 2009, pp 1161-1170.
S. N. Boichenko, V. N. Kostyukov, ‘Equipment diagnostic expert system’, The 6th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2009/MFPT2009/ 23-25 June, 2009, Dublin, Ireland, BINDT & Coxmoor Publishing Co., 2009, pp 1132-1135.
An. V. Kostyukov, ‘Increase of safety and operating efficiency of continuous production cycle enterprises based on real-time comprehensive condition monitoring of equipment’, The 6th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2009/MFPT2009/ 23-25 June, 2009, Dublin, Ireland, BINDT & Coxmoor Publishing Co., 2009, pp 1164-1179.
V. N. Kostyukov, ‘Real-time Condition Monitoring of Equipment’, The 7th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2010/MFPT2010/ 22-24 June, 2010, Stratford-upon-Avon, England, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-33-8, 2010, Paper 236, 8 p.
V. N. Kostyukov, ‘Real-time Condition Monitoring of machinery by the recurrent selection of the noise and periodic components of vibration’, The 8th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2011/MFPT2011/ 20-22 June, 2011, Cardiff, Wales, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2011, Paper 205, 13 p.
Al. V. Kostyukov, V. N. Kostyukov, ‘Classification of vibration parameters trends for RTCM’, The 8th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM2011/MFPT2011/ 20-22 June, 2011, Cardiff, Wales, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2011, Paper 217, 10 p.
A. P. Naumenko, ‘Modern methods and means of on-line monitoring of parameters and real-time health monitoring of piston machines’, The 8th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM2011/MFPT2011/ 20-22 June, 2011, Cardiff, Wales, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2011, Paper 209, 13 p.
V. N. Kostyukov, ‘Real-Time Condition Monitoring of gear pumps by the recurrent selection of the noise and periodic components of vibration’, The 9th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2012/MFPT2012/ 12-14 June, 2012, London, England, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2012, Paper 259, 11 p.
V. N. Kostyukov, A. P. Naumenko, An. V. Kostyukov, S. N. Boichenko, Al. V. Kostyukov, ‘Standards in the field of technical condition of hazardous facilities equipment’, Industrial safety, Moscow, 2012, 7, pp 30-36.
GOST R 53563-2009. ‘Condition monitoring and diagnostics of machines. Hazardous equipment monitoring. Organizational procedures‘, Moscow, STANDARTINFORM, 2010.
GOST R 53564-2009. ‘Condition monitoring and diagnostics of machines. Hazardous equipment monitoring. Requirements for monitoring systems’, Moscow, STANDARTINFORM, 2010.
GOST R 53565-2009. ‘Condition monitoring and diagnostics of machines. Hazardous equipment monitoring. Vibration generated by rotodynamic pump and compressor units’, Moscow, STANDARTINFORM, 2010.
E. A. Malov, I. B. Bronfin, V. N. Dolgopyatov, V. N. Kostyukov, S. N. Boichenko, ‘Implementation of the COMPACS® systems – providing of safe operation at the plants with continuous production cycle’, Industrial safety, Moscow, 1994, 8, pp 19-22.
V. N. Kostyukov, S. N. Boichenko, A. P. Naumenko, E. V. Tarasov, ‘Comprehensive monitoring of hazardous production facilities’, Control. Diagnostics, Moscow, 2008, 12, pp 8-18.
Kostyukov V.N. Real-Time Health Monitoring Systems of Machinery // X International Conference Condition Monitoring and Machinery Failure Prevention Technologies - СМ/MFPT 2013
DYNAMICS Scientific & Production Center offers a brand new level of environmentally friendly resource-saving and safe operation of machinery and processes on the basis of real-time computer condition monitoring.
The basis of the technology is the COMPACS® computer system for condition monitoring of machinery - the DYNAMICS’ very own development. The company’s experts brought to life 40 years of experience in design and implementation of vibration analysis systems and latest achievements among global scientific and technical ideas in the form of a new proprietary product, which has no equals anywhere in the world.
Kostyukov V.N., Kostyukov An.V. Environmentally friendly systems and technologies of safe resource-saving operation of machinery on the basis of real-time computer condition monitoring // Nota Bene. Osoboe vnimanie, 2013. - №5. - pp.28-29
The methods of condition diagnostics of the auto braking system of multiple units of a motor driven-rolling stock given in the article provides the most accurate detection of malfunctions, allowing to find leakage in any assembly of an auto-braking system, including brake cylinders, and also is highly automated and, consequently, prevents the influence of “human factor”.
Due to obtained advantages, the methods increase reliability and depth of the diagnostics, ensure comprehensive diagnostics of all of the sub-systems of auto braking system units, which make full diagnostics possible.
The reached depth and fullness of the diagnostics in conjunction with the smaller time expenses can significantly reduce failure elimination time as well as cost of diagnostics, repair and maintenance of electric trains, it also improves the quality of repair, and as a consequence, contributes to the safety of the railways.
Kostyukov Al.V., Schelkanov A.V. Methods of condition diagnostics of the auto braking system of multiple units of a motor driven-rolling stock // Science, education, business: materials of all-Russian scientific-practical conference for scientists, teachers, graduate students, industry and communication professionals devoted to Radio Day. - Omsk, 2013. - pp. 210-216
Being one of the most important systems, the system of auxiliary machines provides normal functioning of all electric train systems with no exception. To feed auxiliary circuits of DC electric trains one uses a transverter. As a source of compressed air piston compressors are used, and since 2010 a screw compressor package is also used for this purpose. Besides, the system of auxiliary machines includes interior lighting and climate control unit, control and excitation transformers.
The aim of the method development is increasing of operational reliability of auxiliary circuits machinery of motor-driven rolling stock, as well as timely detection and elimination of defects on their initial stage by means of continuous condition monitoring of machinery.
The main advantage of the described above diagnostic method in appliance to the system of auxiliary machines of electric trains is wide coverage of diagnosed auxiliary machines. At the same time, the installation of only 3 current sensors on line wires of transverter generator feeding the system of auxiliary machines system – that’s what makes the method less expensive, simplifies the installation of diagnostic equipment and provides high reliability of the diagnostic system in general.
Kostyukov V.N., Kostyukov Al.V., Kazarin D.V., Tsurpal A.E., Ilyushin M.S. The development of diagnostic method for auxiliary circuits of DC electric trains // Science, education, business: materials of all-Russian scientific-practical conference for scientists, teachers, graduate students, industry and communication professionals devoted to Radio Day. - Omsk, 2013. - pp. 189-194
To prove the theory on the influence of bearing rotation frequency influence on vibration parameter rates and the influence’s dependency from the bearing condition, the researches were carried out using experimental unit and real bearings.
In order to reach the goal it is necessary to obtain and analyze dependencies of vibration parameters from rotation frequency both for intact and obviously defected bearings.
The subjects of the research were the following: intact bearings, bearings with physically simulated defects of inner and outer races, and a bearing with rolling body defect which formed during its continuous operation.
From the results of the experiments one can conclude that nature of dependency of vibration displacement rates from rotation frequency of the bearing is considerably influenced by its condition.
Zaitsev A.V., Basakin V.V., Teterin A.O. Research on dependency of bearing vibration parameters on the rotation frequency // Science, education, business: materials of all-Russian scientific-practical conference for scientists, teachers, graduate students, industry and communication professionals devoted to Radio Day. - Omsk, 2013. - pp.109-112
Large amount of various tools for diagnostics and control cannot guarantee the industrial and maintenance enterprises a good-quality assessment of machinery condition. As a rule, these tools are not unified and lacking of a single database of controlled parameters and results, as well as claimed metrological characteristics, also, often, the producers provide no maintenance services.
As a result, only one third of an enterprise’s control tools is actually operating. However, one more problem exists: to get some practical effect from the diagnostic and control results they should be available to all management levels.
In order to determine equipment state in technical field a few systems and devices were analyzed, in particular.
The known analogs have one main disadvantage – narrow functionality which cannot provide full diagnostics of EMU-train equipment and leads to considerable effect of human factor on the results of condition assessment.
The specified problems’ solution can be reached through condition monitoring and creation of automated control systems.
Kostyukov V.N., Kostyukov A.V., Kazarin D.V., Schelkanov A.V. Automatic control system for safe resource-saving operation and repair of rolling stock equipment at suburban passenger train // Bulletin of The Institute of Natural Monopolies Research: Railway Equipment magazine. - 2013. - №1. - pp.62-66.