Operation costs can be minimized by conducting timely and focused maintenance based on real-time condition monitoring, full using the equipment resource, and elimination of unscheduled shutdown and replacement.
Main causes of equipment operation problems at petrochemical enterprises are:
lack of observability of actual operation processes;
lack of quality control of the units and their assemblies during production and repair;
design errors in calculation of the required aggregate capacity;
lack of efficient control over the actions of the personnel responsible for conducting of the process and maintaining of equipment operability.
These problems often block timely and focused measures for maintaining a high degree of technical readiness of production. The problems above can be solved by the implementation of the COMPACS® stationary systems for vibration analysis and equipment condition monitoring at process units, at repair departments - stand systems for vibration analysis and repair quality control of the units and their assemblies, at whole enterprise - computer diagnostic network Compacs-Net® that enables direct management of the operation in real-time mode. The implementation of the systems for vibration analysis and equipment condition monitoring on the basis of Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS® enables high level of anthropogenic safety and production efficiency.
Kostyukov V.N., Kostyukov A.V. Real-time condition monitoring of equipment // Eurasia Processing. - 2004. - № 1. - p. 2-7
The article presents the analysis of implementation of the COMPACS® system for computer vibration monitoring of condition and accidents prevention, which enables condition diagnosing of reciprocating compressor valves, detection of malfunctions at early stage, registers and reflects overload of compressors and valves due to changes in operating practices, and ensures vibration monitoring of condition of reciprocating compressors in full compliance with Safety Norms 03-582-03.
Kostyukov V.N., Vostrikov I.Y., Zarudenskijj A.A., Pavlenko B.A., Naumenko A.P., Lvov O.S. Experience of diagnosing valves of reciprocating compressors // Consumers and manufacturers of compressors and compressor equipment: Proceedings of X International Symposium. - St. Petersburg: 2004
Improving the quality and reliability of aviation equipment is impossible without correct information on its technical condition at all stages of life cycle: in developing in design office, at the manufacturing stage and in operation. Information on present, past and future technical condition of a product is obtained by the methods of technical diagnosis, genesis and prediction.
The quality of these methods is characterized by PD probability of acquisition of correct information on the product condition at a time. Vibration monitoring of condition integrates these methods into a single continuous process by the elimination of passing through the time intervals with unobserved changes of the condition.
Reliability of the results of monitoring (PM) is determined not only by the reliability of vibration analysis (PD), but also by the frequency of vibration control (TK) that should be considerably smaller than duration of malfunction development (TN) because it determines the probability of detection (PT) of a critical malfunction.
Kostyukov V.N. Condition monitoring of aircraft units // Collection of reports of scientific and technical conference "Sensors and detectors for aviation equipment "DDAT-2003". - Penza, 2003. - p. 87-95
Efficient and reliable operation of rolling mills in many respects depends on reliability of direct current motors of primary drives, which is in large part determined by the conditions of commutation. Emergence of ring fire in the collector and increased sparking of the motor may cause the accident. Approximate cost of elimination of such accident may amount to tens of thousands rubles that convincingly confirms importance of vibration analysis and commutation adjustment of commutator electric machines of direct current.
The paper presents some results of examination of commutation conditions of motors of primary drives of finishing mill train 320 of JSC Metallurgical Plant in the Name of A.K. Serov and mill 800 of JSC Chusovoy Metallurgical Works.
We must conclude that the developed method of commutation adjustment in terms of operating conditions and application of a modern device system enables to reveal the reserve of use of the equipment installed. It results in the increase of productivity of rolling mills in whole or reliability of primary drive operation with lower operating costs.
Kostyukov V.N., Kovbasa N.I., Avilov V.D., Savelieva E.N. New technology for diagnosing and commutation adjustment of direct current motors of primary drives of rolling mills // Modern trends in development and construction of collector and other electromechanical energy converters. - Omsk: OSTU, 2003. - p. 203-208
The COMPACS® system for automatic vibration analysis is the firmware complex providing new technology for safe operation and maintenance of mechanical equipment. The COMPACS® system falls into the category of the systems for measurement and diagnostics; it is intended to solve the problems of vibration monitoring of process equipment condition.
The hardware of the COMPACS® systems for automatic vibration analysis is constructed with the most advanced components; the characteristics of the COMPACS® systems constantly improve. In addition, the systems have a flexible structure at the expense of microprocessor control. All modern systems have a backbone network of the links between modules and diagnostic controller by control and signal lines; also they correspond to all fundamental principles of construction of the COMPACS® measurement and diagnostic systems.
The hardware structure of the COMPACS® system for vibration monitoring includes:
distributed system of end devices which control major parameters of the equipment;
distributed system of portable modules which enable initial conversion of the signals from the sensors and their translation to a diagnostic controller as well as control over the integrity of the sensors and communication lines;
vibration analysis station that control portable modules and ensure data collection and processing.
Starikov V.A. COMPACS system hardware // Collection of reports of scientific and technical conference "Sensors and detectors for aviation equipment "DDAT-2003". - Penza, 2003. - p. 18-21
DYNAMICS Scientific & Production Center (SPC) developed and implemented the COMPACS® stationary system for vibration analysis and computer polyvalent monitoring of the equipment condition at 70 petrochemical complexes and 12 factories. The COMPACS® system enabled complete elimination of sudden failures of equipment.
On the basis of the COMPACS® systems for vibration analysis and automatic condition monitoring DYNAMICS SPC specialists first in the world created and widely implemented a new class of Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) for hazardous industries.
The technologies for total resource-saving are successfully used in the COMPACS® systems for vibration monitoring which ensures reliable operation of equipment of hazardous petrochemical plants with minimum costs.
Kostyukov V.N., Boychenko S.N. Total resource-saving in the COMPACS systems for computer polyvalent monitoring of the equipment condition // Energy-saving and power engineering in Omsk region. - Omsk: 2003. - № 4(9). - p. 48-49
The necessity of creation of an expert system (ES) for automatic vibration analysis and prediction of technical condition of electric drives is conditional on a high speed of the degradation processes and a large number of the units in petrochemical industry.
ES use enables to copy and spread the knowledge, and thus makes a unique experience of several highly skilled professionals available for a number of specialists. The COMPACS® ES enables reasonably quick, complete and reliable vibration analysis of technical condition of an electric motor without dismantling since it detects the following malfunctions:
unfastening of a motor to a base;
dog leg and unbalance of revolving parts;
inadmissible oscillations of a base;
inadmissible temperature of machine units;
frequency content and amplitudes of current of drive electric motors.
Kostyukov V.N., Boychenko S.N. Use of spectral matrix algorithms for vibroacoustic analysis of electric drives of centrifugal pumps of petrochemical production // Proceedings of 8th All-Russian Scientific and Technical Conference "Modern development trends of construction of collector and other electromechanical energy converters". - Omsk, 2003 .- p. 239-243
The article presents the results of research of orthogonality of the signals of vibration acceleration, vibration velocity and vibration displacement in the course of the defect development by means of numerical simulation of defects and correlation analysis.
Orthogonality of diagnostic features is an important condition that significantly simplifies the process of vibration analysis of the equipment condition. The more independent characteristics form a vector of diagnostic features, the easier to relate it to the vector of the equipment condition.
The dependence of the equipment condition is simplifying if all diagnostic features of a vector are orthogonal.
Kostyukov A.V., Kostyukov V.N. Experimental unit for research of vibroacoustic processes in electromechanical units on the basis of Agilent VEE software suite // Proceedings of 8th All-Russian Scientific and Technical Conference "Modern development trends of construction of collector and other electromechanical energy converters". - Omsk, 2003. - p. 226-239
We developed resource-saving technology for production and repair of electric machines with the quality diagnostics at all stages: vibration analysis of the components quality, build quality of the units, quality of assembled machines and units in running and during acceptance test.
The technology is based on stand systems for vibration analysis of technical condition of rolling and plain bearings, dynamic balancing of rotors, build quality of bearing supports and rotary assemblies in own supports, comprehensive diagnostics of assembled machines and units.
This technology is realized on the basis of the COMPACS® stationary system – the system of computer monitoring for accidents prevention and condition control of machine equipment.
Kostyukov V.N., Karpov S.Y., Kovbasa N.I. Resource-saving technology for production and repair of electric machines on the basis of condition diagnostics // Proceedings of 8th All-Russian Scientific and Technical Conference "Modern development trends of construction of collector and other electromechanical energy converters". - Omsk, 2003 .- p. 214-219
The analysis of failure level of process equipment (furnaces, columns, machinery, etc.) shows that machine equipment failures make up about 70% of all failures. Thus, the automation of control over equipment operation on the basis of real-time vibration monitoring of the equipment condition is an actual problem.
Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™), which were developed by DYNAMICS Scientific & Production Center (SPC) for vibration analysis and control over safe resource-saving operation on the basis of real-time condition monitoring of equipment, solve the following problems:
vibration analysis and prediction of major malfunctions (> 95-98%) of equipment with early detection, full use of resources and retention of maintainability;
notification to the personnel of urgent immediate actions intended to control the equipment condition;
monitoring of execution of diagnostic instructions of the systems and the personnel actions through network (Internet) engineering;
development of the plans of targeted repairs in accordance with the actual technical condition of equipment;
elimination of design and installation mistakes;
optimization of flow charts and equipment configuration;
keeping the databases of diagnoses, works, replacements and service lives of equipment, reporting at all control levels of the enterprise.
Naumenko A.P., Boychenko S.N., Kostyukov Al.V. Condition monitoring of machine equipment is a solution to the problems of safe operation // Workshop meeting "Problems of safety, ecology and automation of shipment operations and storage of oil and oil products". - 2003. - p. 85-91