Russian refineries are used groups of ten thousand pumping units, basically centrifugal pumps, both Russian and foreign production. It’s power ranges from tens kilowatts to tens megawatts.
Technological settings of primary oil processing, catalytic cracking, catalytic reforming and others contains a different number of units, which ranges from groups of ten to hundred units depending on powers of settings. Specialists never raised doubts the necessity an anti-accident protection a powerful compressor and other unique machines, but not a pumps, which high concentration in modern technological settings however offen was reason of damages and other production troubles.
Really, if we take probability of pump trouble-free operation in day equal 0.99, then for the group of machines, containing 100 units, refusal probability close to 1, and the technological system herewith practically disabled. For reaching stability of a technological system to different perturbations, including failures of motor pumps, it is necessary to provide overseeing with the exterior on it exterior and interior factors describing its availability index of product, and control by its state by means of opportune acceptance of engineering and organizational measures.
Kostjukov V. N., Boychenko S.N., Kostjukov A.V. Vibration monitoring of pumps in Russian refineries // Mimosa Meeting 17, Scottsdale, Arizona, April 12-16, 1999
The introduction of ecologically clean resourse-keeping technology is the main demand of modern production especially in dangerous branches of industry such as oil-gas-refining, oil-chemical etc.
It's impossible to imagine oil-chemical production without reliable accident-free work of technological equipment. By means of computer vibration monitoring COMPACS® system we provide fundamentally new level of safe processes and machine maintenance based on the latest information technologies, saving large financial and personnel resourses.
Kostjukov V. N. Safe Maintenance of The Equipment is The Technology of The XXI Century - Russian Experience // Mimosa Meeting 17, Scottsdale, Arizona, April 12-16, 1999
The paper presents the model of quasi-periodic vibroacoustic signal intended for diagnostics of batch-type objects.
In addition, we synthesized generic diagnostic features describing technical condition of batch-type objects, which are invariant to its construction. It enables to shorten the period of experimental and survey work as well as the time required for gathering of the signal statistics in different conditions of the objects during the implementation of diagnostic systems.
Kostyukov V.N. Generic diagnostic model of vibroacoustic signal of batch-type objects // Omsk Research Bulletin. - Omsk, 1999. - Issue 6. - p. 37-41
Ensuring accident-free operation of pump-and-compressor equipment (PCE) is inseparably linked with condition control.
The COMPACS® stationary and portable systems enable condition monitoring and diagnostics of a wide range of PCE (including reciprocating compressors) by vibroacoustic, temperature and other diagnostic parameters.
Сontinuous condition monitoring of the machinery forms the basis of the technology for safe operation of machine equipment that is intended to the elimination of sudden failures of the units, which cause accidents with important consequences. Condition monitoring is carried out by analyzing diagnostic features of the condition and automated detection of causes of the unit malfunctions with timely failure warning to the maintenance personnel in the form of voice and visual messages.
Boychenko S.N., Kostyukov Al.V., Naumenko A.P. Automation of the diagnostics of pump-and-compressor equipment // Consumers and manufacturers of compressors and compressor equipment: Proceedings of the Fourth International Symposium. - St. Petersburg, 1998. - p. 225-232
Researches of the processes of degradation of technical condition of pump-and-compressor units, which were carried out at Omsk Refinery by means of the COMPACS® stationary systems for vibration monitoring, showed that velocities of performability loss widely differ at various unit assemblies.
Therefore, vibration analysis should be carried out in terms of development of the destruction processes; and as far as possible vibration analysis should be invariant to the equipment construction. The accidents of centrifugal pumping units can be prevented by reduction of time required for construction of trends of changes of vibration parameters and for detection of defects of certain elements by the trends concerned.
Vibration of the set of the unit elements, pump and motor rotors, supporting bearing assemblies, coupling, suction and pressure pipelines, and a base supporting the unit should be measured simultaneously during operation of the unit.
Kostyukov V.N., Kostyukov A.V., Boychenko S.N. Diagnostics of pump-and-compressor units by monitoring of vibration parameter trends // Diagnostics of equipment and pipelines: Proceedings of XVII International Theme Workshop. - M: Gazprom, 1997. - p. 187-194
Machinery failures make up the major part of failures of units of oil-refining and petrochemical complexes. Machinery failures often cause accidents and manufacturing defects.
In order to mend matters it is necessary to ensure observability and evaluation of technical condition of the units during the manufacturing process, during acceptance at consuming plants, during repair at repair departments of refineries, during the mounting of assemblies at the unit, and during operation at process units.
Increase of petrochemical complex (PCC) reliability without replacement of equipment and reconstruction is realized by implementation of monitoring tools at all stages of life cycle of PCC units, i.e. by different systems for vibration analysis and vibration monitoring - stationary, personal and stand (on input diagnostics of the bearings, diagnostics and balancing of pump spindles, etc.), their integration into a single diagnostic network ACS SRSM™ (Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment), which enables automatic preparation and circulation of diagnostic information between the systems and submission of the information at all levels from operator and mechanic to the shop heads.
Kostyukov V.N., Boychenko S.N., Kostyukov Al.V. 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. - Odessa, 2001. - p. 154-170
Complexity of reciprocator vibration analysis consists in the cyclicity of operation of moving parts. Vibration signal is almost periodic process, and the wear rate of the unit influences vibration signal level under certain values of crankshaft rotation angle.
However, it is hard to recognize the worn part corresponding to vibration signal change because clearances of different details may cause change in vibration signal value under the same values of crankshaft rotation angle.
The problem concerned can be solved by the following: firstly, 'competent' choice of the number of points for vibration sensors installation; secondly, 'fortunate' location of the sensors on the unit; and thirdly, 'reliable' algorithm for the signal processing. The only criterion for solving of these problems is field experience of the analysis of reciprocating compressor malfunctions at the moment of their repair, and comparison of malfunctions with accumulated data.
Kostyukov V.N., Naumenko A.P. Condition monitoring of reciprocating compressors // Consumers and manufacturers of compressors and compressor equipment: Proceedings of III International Symposium. - St. Petersburg, 1997. - p. 254-256
The necessity of accident-prevention protection of powerful compressors and other unique equipment has never raised doubts of the experts, but not the protection of pumping units. High concentration of pump units at petrochemical process units often causes accidents and other production defects.
In case we take the probability of trouble-free operation of a pump unit per day equal to 0.99, the probability of failure for machine fleet containing 100 units will be near 1. In this case the process system is almost nonserviceable.
Increase of operating reliability and maintainability of the units, technical and environmental safety, corporate culture and procedures discipline represents a powerful source of prevention of accidents and personnel traumatizing, and saving of considerable means required for the reconstruction of Russian enterprises. It is achieved by the implementation of ecologically conscious resource-saving technology of operation of oil and gas equipment on the basis of the COMPACS® complex of methodological means and firmware for computer vibration monitoring, vibration analysis and prediction of technical condition of pump-and-compressor equipment.
Malov E.A., Shatalov A.A., Bronfin I.B., Dolgopyatov V.N., Kostyukov V.N., Boychenko S.N., Meling A.Y. Efficiency of implementation of the COMPACS stationary systems for vibration analysis at Omsk Refinery // Industrial safety. - M.: 1997. - № 1. - p. 9-14
Vibration-survey transducers (VST) are designed for transformation of mechanical oscillations, impulse and impact mechanical effects to a proportional electrical signal.
Among various classes of VST (electromagnetic, inductive, capacitive, etc.) piezoelectric vibration transducers have widespread application. Detecting element of concerned transducers is piezoelectric ceramics comprised in the form of plate, disk, and ring with working surfaces covered by the electrodes generally made of silver, platinum, and nickel alloys.
The article presents the requirements for VST for industrial application, their technical characteristics and terms of delivery.
Kostyukov V.N., Donskov V.I., Ivanov A.A., Zagorodniy V.S. Vibration-survey transducers for industrial application // Foreign radio electronics. - M., 1996. - № 9. - p. 65-67
The paper presents the results of long researches of the authors in the field of development and industrial implementation of the systems for vibration analysis of machines and processes on the basis of measurement of the parameters of secondary static and dynamic (mainly vibroacoustic) processes accompanying technological system operation.
We formulated a number of aufbau principles of measurement and diagnostic systems (MDS) for machines and equipment, which were proven in practice. MDS concerned laid the groundwork for wide implementation of such systems. We showed that the use of IBM-compatible computers enable to simplify the sensors and secondary equipment, improve metrological characteristics of the systems, ensure structural flexibility in coordinates "Cost - Capacity", create an unique man-machine interface (MMI), which exempts the operator from routine reading of indications of hundreds of devices and studying figures on the screen and clearly notifies of necessary targeted actions with minimum requirements to the personnel qualification.
We considered MDS software (SW) structure by example of SW of the COMPACS® system of computer vibration monitoring for accident prevention and condition control; SW concerned was compared with well-known SCADA-systems. In addition, we discussed the results of wide-ranging implementation of the COMPACS® MDS at Russian petrochemical enterprises.
Kostyukov V.N., Kostyukov A.V., Boychenko S.N. Principles of construction of measurement and diagnostic systems for machines and equipment. Actual problems of electronic instrument engineering - 1996 // Measurement in Electrical Engineering: Proceedings of the Third International Scientific and Technical Conference. - Novosibirsk, 1996. - V. 5. - P. 81-86