Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS® solve the following problems: vibration analysis and prediction of major malfunctions of equipment with early detection, full use of resources and retention of maintainability; monitoring of execution of diagnostic instructions and personnel actions through network (Internet) engineering; elimination of design and installation mistakes; optimization of flow charts and configuration; keeping of the databases of diagnostics, works, equipment replacement and service life; reporting at all control levels of the enterprise.
The Compacs-Net® network for vibration analysis is of service in on-line monitoring of execution of instructions of automatic systems for vibration analysis. The central element of the CompacsNet® network for vibration analysis and the collector of diagnostic information is the server that periodically examines the COMPACS® stations connected to a diagnostic network and saves the findings as SQL-database.
Internet-based technologies integrate various systems for vibration analysis of equipment condition, which are located hundreds of kilometers apart, into single information complexes used in ACS SRSM™ COMPACS®, improve observability and controllability of equipment, and increase the systems efficiency by significant reduction of maintenance costs.
Kostyukov V.N., Boychenko S.N., Kostyukov Al.V. Internet technology in the COMPACS control systems for safe resource-saving operation of equipment // Oil Industry. Innovative Technologies in Oil and Gas Industry. - M.: 2005. - № 10. - p. 104-107
The problem of increase of anthropogenic safety and profitability is urgent for oil and gas industry in whole and especially for modern refineries with high concentration of power-intensive and potentially hazardous equipment.
One of the most promising ways to solve this problem is implementation of the technology for safe resource-saving operation of equipment on the basis of vibration analysis and real-time condition monitoring based on the new class of systems - Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS®.
Kostyukov V.N., Boychenko S.N., Bezzubov A.V., Mikerin O.B., Fedorinov I.A., Durosov V.M., Lvov O.S. The COMPACS saving system ensures safe resource-saving operation of equipment at OOO LUKOIL-Volgogradneftepererabotka // Automation and information technology. Special edition of 'Oil of Russia' journal. - M.: 2005. - № 4. - p. 101-105
The paper presents the results of long experience of vibration analysis and condition monitoring of reciprocating compressors.
On the basis of the collected data the principles and methodological support for data collection and analysis, which enable vibration analysis and condition monitoring of reciprocating compressors, have been developed in order to determine normative values of the measured parameters.
The paper also presents some results concerning the ways to measure the parameters, collect data, and diagnose the compressors, as well as data processing scheme and some normative values.
Kostyukov V.N., Naumenko A.P. Regulatory and methodological support of reciprocating compressor condition monitoring // Control. Diagnostics. - M.: 2005. - № 11. - p. 20-23
This regulation document is developed on the basis of the Conclusion of the commission of State Technical Supervision Service of Russia carrying out acceptance tests of complex systems for monitoring of equipment of hazardous production facilities. This commission was created according to the decree № P-20 (02 December 2003) of Deputy Chief of State Technical Supervision Service of Russia. The conclusions reflect long-term experience of creation and implementation of comprehensive systems for real-time condition monitoring of machine and process equipment of hazardous production facilities in chemical, petrochemical, oil producing, oil and gas processing, mining industry, rail transport, public service, power engineering. This standard is recommended for expert, engineering companies and industrial enterprises as a guideline for selection and use of vibration indexes system for monitoring of machine unit condition in order to prevent technogenic accidents and ensure safe resource-saving operation of the equipment according to actual technical condition.
The standard has been developed by DYNAMICS SPC and the Scientific-and-Industrial Union "RISCOM".
The paper presents statistical analysis of distributions of characteristics of a spectral matrix of vibrations of batch-type equipment by a centrifugal pump unit.
The results of work have been used in the construction of automated expert system (ES) for diagnostics and decision-making in respect of technical condition.
The developed ES is integrated into the software of the COMPACS® stationary system for continuous vibration monitoring and vibration diagnostics, stand systems and Compacs®-micro portable device. Thus, it integrates into the system that provides measurement, storage of the measurements, ES measurements processing and automatic instructions – without the personnel being involved. Consequently, it helps to avoid subjective errors and expenditure of time.
Boychenko S.N. Normalization of characteristics of a spectral matrix of vibrations of batch-type equipment // Collected articles on propulsion engineering dedicated to 175th anniversary of MSTU n.a. N.E. Bauman - M.: 2005. - p. 22-25
Operative reciprocating compressors and those put into operation are almost indispensable equipment of processing trains of petrochemical enterprises. Reciprocators operating for a long time especially require condition control due to the termination of service life of some units and parts with different operating lives.
Automated Control System of Safe Resource-saving operation and Maintenance of equipment of refineries and petrochemical plants (ACS SRSM™) COMPACS® is the most optimized system in terms of the cost of a single channel and explosion safety. ACS SRSM™ COMPACS® realizes the strategy of the minimum cost of the systems for vibration analysis and vibration monitoring.
The COMPACS® system for vibration monitoring of technical equipment enables focused and reliable condition control of the equipment, including reciprocating compressors, prevention of sudden malfunctions and shutdowns, real-time control and correction of the personnel actions by integration of the data from the systems of a single diagnostic network Compacs-Net® with a single database of the monitoring parameters. Thus, the COMPACS® system provides vibration monitoring of equipment condition and promotes transition to operation in accordance with the actual technical condition. Consequently, it reduces material costs of maintenance.
Durosov V.M., Kostyukov V.N., Naumenko A.P., Pidsadnij A.S. Сondition monitoring of reciprocating compressors // Chemical technique. - M.: 2004. - № 6. - p. 6-12
The report presents the concept of resource-saving safety of gas-processing enterprises, which enables elimination of production failures caused by the equipment diagnosed, reduction of cost of repairs and spare parts, equipment operation in accordance with the actual technical condition, justified replacement of the equipment, control of the personnel actions, significant increase of the safety and degree of technical readiness of production on the basis of the systems for automatic vibration analysis and condition monitoring of equipment in real-time mode.
Kostyukov V.N., Geraskin V.I., Berdnikov V.M., Kiyashko V.P., Boychenko S.N., Naumenko A.P. Automatic condition monitoring of LLC Astrakhangazprom machinery on the basis of ACS SMSPM™ COMPACS // 14 International Business Meeting "Diagnostics 2004". - 2004. - p. 1-4
The article presents the technology for safe resource-saving operation of equipment in real time mode (Safe Maintenance™ - SM™-technology) which was created on the basis of Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS®. The technology enables to increase the safety and efficiency of the plants with uninterrupted cycle with minimum cost of maintenance of process units.
The use of ACS SRSM™ COMPACS® makes the operation of fixed assets transparent and manageable, decreases capital output ratio, increases capital productivity and capitalization of business in whole.
Kostyukov V.N., Boychenko S.N., Kostyukov A.V. Manufacturing Execution System (MES) for safe resource-saving operation of equipment on the basis of ACS SRSM™ COMPACS // World of computer automation. - M.: 2004. - № 4. - p. 35-44
The purpose of monitoring system implementation is visualization of the equipment condition for early prevention of accidents and maximization of run-to-failure period of the equipment.
Only the availability of the systems, which automatically evaluate the equipment condition, enables complete elimination of a human factor from the process of diagnostics and control of execution of the regulations. Therefore, such systems enable to solve the problem of timely and targeted maintenance and repair on the stipulation that the unit capacity does not reduce.
The COMPACS® monitoring system meets the requirements and enables diagnostics and prediction of basic malfunctions. The system notifies the personnel about urgent immediate actions intended to control the equipment condition; it enables to control execution of diagnostic regulations of the systems and the personnel actions, to develop the plans of targeted repairs in real-time mode, to release from repair equipment with the maximum potential life.
Kostyukov A.V. Monitoring systems // Proceedings of industry conference of chief mechanics of refineries and petrochemical plants. - Kirishi, 2004. - p. 177-180
In most Russian fuel-and-energy companies considerable proportion of the investments in production process is spent on elimination of the accident consequences, production defects and unreasonable costs of repair of fixed production assets.
The emergence of Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS® and SM™-technology (Safe Maintenance™) for safe resource-saving operation of equipment enabled condition monitoring at all stages of its life-cycle by timely detection of malfunctions, supervision over malfunction development, provision the personnel with the instructions on the necessity of repair or emergency shutdown, and control of the timeliness of execution of above instructions.
Characteristic features of a new operation technology, which is being successfully implemented at refinery, petrochemical and other enterprises with uninterrupted cycle: significant economic effect tested through practice, short payback period and resource-saving safety.
Kostyukov V.N., Kostyukov A.V. New technology of operation of processing equipment - long-term goal of management of Russian fuel-and-energy companies // Proceedings of the meeting of chief mechanics of the enterprises JSC AK SIBUR. - Togliatti: 2004. - p. 58-62