Practical development and implementation of the technology for liquidating fundamental causes of equipment failures (LiFCF™) showed that less than 15% of the units consume more than half of all resources intended for equipment repair. More than 2/3 failures of face seals are caused by above-standard vibrations of the pumps and electric motors.
The implementation of the COMPACS® stationary systems for vibration analysis and equipment condition monitoring at process units of petrochemical complexes enabled elimination of major cause of failures – latent unobservable nature of their emergence or development. The systems enabled immediate elimination of severe accidents of pumping units associated with shafts breakage and bearings failure causing depressurization of face seals and further ignition. For instance, for 3 years of operation at JSC Tobolsk petrochemical combinat the COMPACS® systems prevented 122 failures of pumping units and accidents with ignition. It should be noted that in 1994-95, before implementation of the system, 5 such events took place.
The averaged estimation of cost efficiency of ensuring resource-saving safety by the implementation of stationary systems for continuous vibration monitoring of hazardous production facilities shows that the main sources of profitability increase are: decrease in number and duration of process unit downtimes, reduction of equipment losses, and reduction of costs of equipment repair and restoration, faster commissioning of process systems.
Kostyukov V.N., Kostyukov Al.V., Boychenko S.N. Russian experience of automatic diagnostics and monitoring of pump-and-compressor equipment on the basis of the COMPACS systems // Safe operation of compressor and pumping equipment. Proceedings of Scientific and Technical Seminar. - Odessa, 2001. - p. 154-170
The developed models and determined mechanisms of initiation and development of vibration and other processes accompanying operation of units of petrochemical complex enable their normalization in order to determine relative boundaries between different conditions of the units.
Experimentally proved fact underlying the methodology of normalization of machinery vibration parameters is that under normal operation of various units the values of vibration parameters are below certain values which can be used as the limits.
Adaptive expert system (ES) for diagnostics enables to accumulate the information on the law of variation of the unit condition and use the determined mechanisms for the purpose of diagnostics. High complexity of equipment of petrochemical complex and short timing of the diagnosing and decision-making necessitate ES creation. Methodological approaches and firmware of condition monitoring enable elimination of main causes of equipment failures, minimize the flow of requirements for maintenance and make a major contribution to the company profitability on the basis of resource-saving safety.
Kostyukov V.N. Normalization of vibration parameters in reciprocating compressor diagnostics // Consumers and manufacturers of compressors and compressor equipment - 2001: Proceedings of the Seventh International Symposium. - St. Petersburg: 2001. - p. 90-93
The rate of change of diagnostic features (vibration parameters) is uniquely determined by the weighted sum of the rates of change of relevant errors of the unit. The rates of change of vibration parameter trends supplement the space of orthogonal diagnostic features that enables to increase the reliability of diagnosing and reduce diagnostic error.
Numerous acts of failure of various mechanisms of the units, which were investigated by the analysis of vibration parameter trends, are exponential. Exponential trends of malfunction development on a short interval of time make up a group of sudden failures of equipment that cause significant economic and environmental losses in petrochemical complexes.
Growth rates of vibration parameters and vibration parameter values are independent diagnostic features. The use of growth rates of vibration parameters as independent diagnostic feature put a new spin on the diagnostics. It is confirmed by the patents and vibration standards for safe operation of the units of petrochemical complexes, which well in advance anticipated the boldest suggestions for vibration normalization.
Kostyukov V.N., Kostyukov Al.V. Diagnostics and prediction of condition of the units of petrochemical complexes by vibration parameter trends // Omsk Research Bulletin. - Omsk: 2001. - № 17. - p. 109-112
The analysis of reliability of process units of modern refining and petrochemical complexes (PCC) shows that high concentration of machinery – pumping and compressor units, air coolers, smoke exhausters etc. with the unit capacity from tens of kW to several MW - often causes production defects and emergency situations.
Condition monitoring enables the unit personnel to predict most failures (formerly considered as sudden) by means of early detection and reporting about developing malfunction.
The implementation of the COMPACS® stationary systems for diagnostics and monitoring at PCC process units enables elimination of major cause of failures – latent unobservable nature of their emergence or development. Implemented systems enabled elimination of severe accidents of pumping units associated with shafts breakage and bearings failure causing depressurization of face seals and further ignition. Thus, it enables minimization of the time and cost of maintenance as well as realization of the strategy of minimum value diagnostics (SMVD™) that make a major contribution to the company profitability.
Kostyukov V.N. Control of equipment of petrochemical plants on the basis of the COMPACS automatic systems for diagnostics and monitoring // Proceedings of industry conference of chief mechanics of refineries and petrochemical plants of Russia and CIS. Equipment condition control and repair management system. - Kirishi, 2000. - p. 186-199
The article presents new tried-and-true method of controllability (suitability of the product for diagnostics by certain technologies) of machines and units to be diagnosed without dismantling at all stages of their life cycle.
This method enables to reduce the number of vibration transducers mounted on the unit; hence vibration measurement and diagnosing become more easy.
All developed sensors have a number of features and advantages that ensure their application with minimal costs: differential construction and output, self-diagnostics of detecting element, high precision and low power consumption, wide range of operating frequencies.
The developed method for unit controllability showed itself to good advantage during the implementation of the systems for diagnostics and monitoring of thousands of units of petrochemical complexes. In addition, this method is a part of the strategy for minimal cost diagnostics that is developed by DYNAMICS Scientific & Production Center (SPC). The novelty of its solutions is confirmed by the patents for invention.
Kostyukov V.N. Control of equipment of petrochemical plants on the basis of the COMPACS automatic systems // Proceedings of industry conference of chief mechanics of refineries and petrochemical plants of Russia and CIS. - Kirishi: 2000. - p. 186-199
The paper presents the method of adaptive standardless vibration analysis of equipment on the basis of the analysis of vibroacoustic signals associated with unobserved errors of machines and units, which arise during the manufacturing process and in operation. Part of these errors is not presented adequately in ratio and interval scales.
We derived a canonical equation of links between diagnostic features of the signal and structural parameters of the machine condition, which represents the bisector of the first angle of information plane. The results of simulation for normal distribution are presented as well.
Kostyukov V.N. Adaptive method of vibroacoustic diagnostics // Actual problems of electronic instrument engineering: Proceedings of V International Conference. - Novosibirsk, 2000. - V.6 - p. 142-147
Trouble-free operation of equipment of petrochemical plants - one of the main factors determining production quality and output, technical and environmental safety.
The COMPACS® system enables automatic vibration analysis and monitoring of development of defects and malfunctions without dismantling of machinery of petrochemical and other fire explosive factories.
The maximum effect is achieved by comprehensive equipping of a number of units with the COMPACS® systems for automatic vibration analysis afterwards integrated into computer network of vibration diagnostics for supervision over the departments of chief mechanic and chief power engineer.
In estimating of saving rate of the system implementation at the refinery the following components are taken into consideration: increase of productivity and reliability of measurements and diagnostics, reduction of equipment repair costs, saving of the time of commissioning, number and length of emergency situations, number of production defects and downtimes.
Kostyukov V.N., Kostyukov Al.V., Shatalov A.A., Serdyuk F.I., Mahonkijj B.N., Makler B.V., Yolshin A.I., Aktuganov A.N., Mukhin S.V., Zyuzin A.V. Trouble-free operation - the way to increase the profitability // Chemistry and Technology of Fuels and Oils. - № 3 (501). - M.: 2000. - p.9-13
The COMPACS® system for computer monitoring carries out vibration monitoring and analysis of centrifugal compressors by means of the sensors of absolute and relative vibration installed on the outside (on the housing of each compressor bearing) and inside (above the rotor shaft) in orthogonally related directions in order to measure and control radial displacements and axial shift of the shaft.
The sensors of temperature, rotational speed and current consumption are used additionally. It enables diagnosing of technical condition and mode of operation of the compressors. Continuous vibration analysis and monitoring of technical condition of the units have positive results.
Every unit may become "good" in case of timely repair and estimation of its quality according to the unit condition by means of the COMPACS® system for vibration monitoring (both stationary and personal - COMPACS®-Micro), which enables to collect vibrations from all points of the compressor unit and transmit them to COMPACS-NET® diagnostic network of engineering supervision or to the Internet in order to analyze and control safe resource-saving operation.
Kostyukov V.N., Starikov V.A., Tarasov E.V. Monitoring and diagnostics of centrifugal compressors // Proceedings of VI International Symposium 'Consumers and manufacturers of compressors and compressor equipment'. - St. Petersburg, 2000. - p. 174-177
The article is concerned with the experience of creation of automated control systems for ecologically conscious and safe resource-saving operation of machinery of the plants with uninterrupted cycle (Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment - ACS SRSM™ - COMPACS®) on the basis of stationary systems for monitoring.
The created ACS systems enable elimination of harmful effect of human errors on the operation of technological systems, use of equipment during the whole operating life provided retention of its maintainability and production safety. In addition, ACS systems realize the strategy for minimal cost diagnostics and the technology of search and liquidating fundamental causes of equipment failures.
Kostyukov V.N. Automated systems for diagnostics and monitoring of resource-saving operation of equipment of oil-and-gas industry // CITOGIC. - 2000. - Volume 10. - Book 3. - M.: 2000. - p.22-35
The report deals with the problems of vibration analysis of machine equipment on the basis of the analysis of vibration parameter trends. Main modern methods of machine vibration analysis are based on the evaluation of vibration parameters and on the analysis of vibration signal spectra.
Harmonic analysis of the spectrum usually requires knowledge of an exact construction of a machine; and existing methods of vibration analysis and prediction of technical condition do not take into consideration harmful effect of the human factor. Reliability of evaluation of machine equipment condition can be increased considerably by the use of the laws of processes of destruction and operability loss.
The processes of pump-and-compressor unit degradation were researched at a number of Russian refineries by means of the COMPACS® stationary systems for vibration monitoring. The researches concerned showed that rates of operability loss differ at various machine assemblies.
Kostyukov A.V. Evaluation of machinery performability by vibration parameter trends // DYNAMICS OF MACHINE AGGREGATES: Proceedings of the 5th International Conference. - Gabcikovo (Slovak Republic), 2000. - p. 101-104