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
Fast developing malfunctions are the most dangerous for operation and production economy. In order to ensure malfunction observability it is necessary to carry out continuous diagnostics with automatic delivery of objective results to the personnel. The system for diagnostics and monitoring detects malfunctions, monitors their development and promptly notifies the personnel about the necessity of equipment repair or shutdown.
Implementation of the COMPACS® systems containing vibration analysis sensors, sensors of axial and radial displacement, rotation frequency, pressure, level, temperature, and current enables use of equipment during the whole operating life provided retention of its maintainability and production safety. Need for the systems for continuous monitoring of equipment, which ensure profitability based on resource-saving safety, is dictated by the necessity of transition to a new level of reliability, safety and effectivity by the implementation of modern high-degree technologies of petrochemical productions.
Kostyukov V.N., Kostyukov A.V., Kostyukov Al.V. Increase of production efficiency on the basis of implementation of the COMPACS automatic systems for diagnostics and condition monitoring of machines // Chemical technique. - M.: 2002. - №2. - p. 16-22
The paper presents a new tried-and-true method for controllability (the product suitability for diagnostics by specified technologies) of machines and units to diagnosing without their dismantling at all stages of their life cycle. This method enables reduction of number of vibration transducers installed on the unit, which simplifies vibration measurement and diagnostics.
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. Controllability of machines in the diagnostics of build quality // Assembling in mechanical and instrument engineering. - №5. - M.: 2001. - p. 41-42
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.
The developed methodological approaches and firmware of vibration monitoring of condition enable to liquidate fundamental causes of equipment failures (LiFCF technology), minimize the flow of requirements for maintenance, formulate and implement the strategy for minimal cost diagnostics of tens of thousands of bearings, several thousands of pumps, electric motors, couplings, reduction gears, dozens of compressors and air coolers of more than 350 types. Thus, methodological approaches and firmware concerned made 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 // Proceedings of the Seventh International Symposium "Consumers and manufacturers of compressors and compressor equipment - 2001". - St. Petersburg, 2001. - p. 90-93