The book presents various aspects of safe operation of the complexes of oil-and-gas enterprises, reconstruction and creation of new equipment based on conversion technologies and targeted programs.
It was shown the necessity and perspective of solving the problems of increase of production safety and efficiency on the basis of modern computer systems for vibration analysis and monitoring of equipment condition during its operation based on multiple-recognition methods by the use of the systems that measure the parameters of different physical processes: absolute and relative vibration, acoustic emission, temperature, electrical current, pressure, levels, etc.
Static and dynamic models, the methods of vibration analysis and vibration monitoring, the structure of expert systems, firmware of computer monitoring systems and automated control systems for safe resource-saving operation of equipment (ACS SRSM™) were presented.
The book is concerned with the problems of metrological support, the quality of the systems and technologies, personnel training, technical and economic efficiency of ACS SRSM™ and safe resource-saving (Safe Maintenance Technology) equipment operation.
Kostyukov V.N. Monitoring of production safety // M.: Mashinostroenie, 2002. - 224 p.
The report is concerned with the COMPACS® complex of methodical means and firmware providing new technology of resource-saving and safe operation of equipment. The systems implement vibroacoustic, thermal, acoustic emission, current and parametric (pressure, level, consumption, temperature) methods for diagnostics of machinery, vessels and equipment, which are protected by the patents for inventions, production prototypes and trademarks.
Built-in expert system carries out fully on-line automatic vibration analysis of the equipment malfunctions. This expert system is invariant to equipment construction and forms of connection between diagnostic features and structural parameters of the objects diagnosed.
At repair departments stationary systems for vibration analysis ensure output of 'nonvibrating' pumps and motors, which have the minimum dynamic loads and the maximum potential life, with 'one-time' assembling and commissioning.
COMPACS®-micro personal systems (automated working station of a diagnostician) ensure (off line) objective vibration monitoring of quasistatic equipment, transmit information to the stationary systems of vibration analysis for general announcing and reminding the personnel of condition of quasistatic equipment, realize the advantages of WINDOWS 95/98.
All these systems are integrated into a diagnostic network Compacs-Net®, they present diagnostic information according to the principle of MIMOSA standard ('look&feel') that considerably simplify training process.
Kostyukov V.N. Monitoring of safe operation of equipment // Proceedings of industry conference of chief mechanics of refineries and petrochemical plants. - Kirishi, 2002. - p. 269-270
The COMPACS® complex of methodical means and firmware provides new technology of resource-saving and safe operation of equipment. Direct economic effect of the implementation of such technology at the enterprises is achieved by the saving through the elimination of accidents caused by machine equipment, reduction of losses caused by the downtimes of process complexes, and reduction of repair expenses.
The advantages of the COMPACS® systems: high reliability, comprehensive self-diagnostics of the firmware, comprehensive monitoring of the personnel actions, use of equipment during the whole operating life. That enables continuous elimination of major causes of equipment failures, minimization of flow of requirements for maintenance of equipment and systems.
Application of the COMPACS® technology makes the operation of fixed assets manageable, reduces losses, saves material, financial and human resources, and increases capitalization of overall business.
Kostyukov V.N. Profitability based on resource-saving safety in petrochemical industry // Branch meeting proceedings. - Perm: 2002
Experience of long-term operation of the COMPACS® systems for automatic vibration analysis and computer monitoring of technical condition of machinery enabled to accumulate the data on the diagnostics of reciprocating compressors.
In order to make the analysis vibration sensors were installed at different points. Vibration examination of the compressor with the COMPACS®-micro portable system usually preceded the mounting of sensors.
Thus far the information has been accumulated, and the algorithms of operation of expert system for diagnostics of hydraulic impacts, loosening of piston nut, wear of rod seals and babbit layer of the slider have been developed.
Kostyukov V.N., Naumenko A.P. Vibration analysis of reciprocating compressors // Compressors and pneumatics. - M.: 2002. - № 3. - p. 30-31
Energy-saving and reduction of power consumption of equipment are vital problems for modern businesses. One of the ways to solve them is equipment operation in conditions ensuring energy-saving.
The analysis of operation of equipment most accepted by the enterprises - pumps, compressors, fans, electric motors - showed that electricity consumption may be reduced by 15-25% by improvement of its technical condition, which requires timely determination of equipment condition and unfavorable operating conditions, informing service and managing personnel in case of degradation of technical condition and violation of operation conditions in order to take urgent measures.
The assigned task is successfully solved by various systems: the COMPACS® system for vibration monitoring and vibration diagnostics, the COMPACS®-micro personal system, vibration diagnostics systems for repair departments integrated into diagnostic network Compacs-Net®. The analysis of sources and reasons for immediate effect after the system implementation permits to affirm that real-time vibration monitoring of equipment complexes enables company profitability on the basis of resource-saving safety.
Kostyukov V.N., Kirillov V.I. Energy-saving based on real-time condition monitoring of equipment // Energy-saving and energetics in Omsk region. - Omsk: 2002. - № 4 .- p. 95-98
Self-diagnostics of the firmware is the most important feature of modern systems for vibration diagnostics and vibration monitoring containing thousands of measuring channels and tens of thousands of diagnostic features.
We have developed the system for vibration diagnostics and vibration monitoring with self-diagnostics of overall measuring and transforming channel, which is realized by the signal injection into the circuit of detecting element of the sensor and its further analysis by the firmware.
The system ensures reliable diagnosing of failure of the sensor or cable routings. The system displays a message in the form of a "blue" corner at operator's desk situated in petrochemical complex, and at the stations of users of vibration diagnostic network, including the specialists of control equipment and automatics. This solution ensures quick elimination of causes of malfunction and failure, high metrological reliability, high availability, possibility of trailbuilder operation by actual technical condition.
Kostyukov V.N. Self-diagnostics of vibration diagnostic systems // Control. Diagnostics. - M.: 2002. - № 9. - p. 18-22
The book presents information on the automated control systems for safe resource-saving operation (ACS SRSM™) of machine and other equipment at petrochemical and other enterprises with uninterrupted cycle.
The realization of ACS SRSM™ based on the COMPACS® systems of computer monitoring for accident prevention and condition control is the subject of wide contemplation. The COMPACS® systems ensure automatic diagnostics of equipment on the basis of vibration, thermal, acoustic-emission and other methods covering process units with rotating equipment, repair production, other quasi-static equipment and enterprises integrated into a diagnostic network. The information on the equipment condition and repairs is transmitted to all interested departments of the company.
The sensors, modules, diagnostic controllers and software of the systems, the problems of design, production, quality control of the systems produced, their mounting, checkout and operation in oil-and-gas and other industries have been considered.
The book is of interest for engineers and technicians engaged in designing, manufacturing, testing and maintenance of equipment, automated control systems and safe resource-saving productions of high reliability.
Kostyukov V.N., Boychenko S.N., Kostyukov A.V. Automated control systems for safe resource-saving equipment operation // M.: Mashinostroenie, 1999. - 163 p.
Operation of complicated productions including hundreds and thousands of units of machine and process equipment is only possible with the information on its technical condition being submitted to the company administration. Repair and modernization of equipment, reconstruction of sections, shops and factories require reasoned decisions based on reliable information on the causes of insufficient productivity, frequent repairs, downtimes, production malfunctions and emergency situations.
Information on the equipment condition (diagnosis) is obtained through the means of technical diagnosing, and their reliability is determined by the prescribed methods of diagnosing, measurement precision, diagnostician skills and quality of adjustment of devices to informative characteristics of the signals of diagnosed object.
The article presents some results of development and application of the systems for vibration analysis and monitoring of assembling and mounting of machines and units. Their use has prospects for engineering because it enables to increase reliability and service life of output products without significant reconstruction of manufacturing and process base and subsequent huge expenses.
Kostyukov V.N. Diagnostics of quality of assembling and mounting of equipment // Assembling in mechanical and instrument engineering. - M.: 2002. - № 7. - p. 25-32
In order to create faultless systems for vibration analysis and vibration monitoring in conditions of a priori uncertainty concerning the parameters of the signals, noise and the types of diagnosed units it is necessary to solve the problem of the signals filtration under conditions of correlated noise.
In such a case auxiliary independent random variable is usually introduced. By means of this variable the correlation between averaged values is eliminated through a random selection of these values according to 0 or 1 value of auxiliary random variable.
The paper presents the method and system of increase of reliability of the results of vibration analysis and vibration monitoring by randomized averaging of certain diagnoses with detection of randomizing characteristics by vibration parameters of diagnosed machine on the basis of extreme characteristics of spikes of vibration phase.
Kostyukov V.N. Randomized filtration in the problems of equipment vibration analysis // Control. Diagnostics. – M.: 2002. - № 7. - p. 18-19
During run-to-failure period of the units the COMPACS® systems continuously monitor their condition by the parameters of vibration, temperature and consumption current. Thus, the COMPACS® systems ensure efficient vibration analysis and notify the personnel about inappropriate modes of equipment operation, critical defects of pumping units, dynamic loads, modes of friction, and free distances in the bearings of centrifugal compressors, condition of bearings and gears, driving multipliers, crank-crosshead gear, valves and cylinder-piston group in reciprocating compressors.
The systems for automatic vibration analysis and condition monitoring of equipment are very effective. Thus, elimination of downtime of millionth reforming unit at the expense of unfounded halting of hydrogen compressor, which is the heart of the unit, in a day covers the expenses for the system implementation.
Kostyukov V.N., Starikov V.A., Tarasov E.V. Vibration analysis of centrifugal compressor condition // Compressors and pneumatics. - M.: 2002. - № 2. - p. 27-29