Safe resource-saving operation of the machinery of the industry and transport branches is a very urgent task. Real-time condition monitoring of the machinery provides observability and allows to implement safe resource-saving technology of the machinery maintenance and repair. This paper considers the experience in operation of systems for health monitoring of hazardous production facilities and the machinery of energy sector and rail transport in case of smooth or discontinuous changes in vibration diagnostic features that reflect the corresponding multi-stage processes of destruction machines generating multimodal trends vibration parameters.
The paper proves that real-time condition monitoring systems increase diagnostics productivity in million times in comparison to "manual" tools, and provide economical effect for a consumer due to:
Increase of technogenic safety and machinery run-to-failure in dozens and hundreds of times.
Increase of readiness coefficient and main production assets usage coefficient.
Kostyukov V.N., Tarasov E.V. Real time vibration-diagnostic condition monitoring of production and transport complex machinery // Condition Monitoring and Machinery Failure Prevention Technologies (СМ/MFPT 2015)
The paper dwells upon the results of implementation of the stationary system of condition monitoring and automatic vibration analysis COMPACS® for elimination of sudden failures of thermal power station units. A description of the system’s functions, capabilities and application advantages are presented in the paper. There are detailed examples of the operation of auxiliary equipment, mainly, rotating aggregates, under the system’s control.
Kostyukov V.N., Tarasov E.V., Putintsev S.L. Safety operation monitoring of thermal station facilities // New in Russian Power Industry (Novoe v rossiyskoy elektroenergetike). 2015. – #2. – p. 6-13.
PJSC Enel Russia has been cooperating with DYNAMICS SPC since 2009. Current situation at the power industry enterprises is that the control and emergency shutdown systems are equipped in operation only at the main power mechanisms – turbine units. At the same time, several dozens of auxiliary machines (mills, blowers, smoke exhausters, power, condensate, circulating, network pumps, cooling towers) are used to support the operation of one turbine. Also, there are a lot of auxiliary machines that are operated without a reserve, and their sudden failure leads to reduction of volume and quality of the generated electric power and, consequently, to a complete shutdown of the turbine.
In this connection, PJSC Enel Russia has begun stage-by stage procedure of equipping the auxiliary machines of thermal power stations with the COMPACS® systems.
Equipping the auxiliary machines of Reftinskaya State District Power Station with a stationary condition monitoring and automatic diagnostic system COMPACS® has allowed to eliminate accidents and, so called, “sudden failures”, to make them “gradual”, “observable” and “controlled” by timely warnings for the personnel. Thanks to that, machinery units are decommissioned for repair only after full usage of their resources and with full reparability. The automatic diagnostics carried out by the COMPACS® system ensures the after-repair commissioning of the unit with an objective assessment of its condition and guaranteed quality repair with the "Acceptable" technical condition.
Kostyukov V.N., Tarasov E.V., Putintsev S.L. DYNAMICS SPC: On Safety Guard // TOP Energoprom. - 2014. - November-December. - p. 28
All major factors causing high operational expenses and losses due to failures are revealing in machinery operation life, when cumulative damage directly depends on timeliness of failure detection and adequacy of personnel actions depending on various speed of resource losses due to wear of machinery elements. The later the personnel reacts to worsening of machinery condition the greater resources are required to restore it, and if the situation is critical the total costs may exceed the ones enough for building a new facility. In turn, personnel’s reaction rate is determined by two main factors: machinery condition observability and adequacy of reaction to its worsening which mostly is influenced by manager’s being demanding and aware of the situation’s criticality level.
Thus, it is necessary to ensure failure skipping risk monitoring in real-time, i.e. provide managers of all levels with financial assessment of the current rates of possible costs and losses to the company in existing operational conditions of hazardous production facilities. Observability of the machinery degradation process in real time and good labour discipline allow to avoid the risk of accidents.
Data on machinery condition and its malfunctions and developing defects of the most critical parts of a machine are presented by the COMPACS® systems to all levels of production management. The systems automatically, without involving diagnostic specialists, detect all major classes of machinery malfunctions and for each of them issues several prescriptions automatically diagnosing defects of centrifugal and piston compressors, pumps, air-coolers and other machinery. Multiple analysis of maintenance works carried out by system’s prescriptions has revealed that all shutdowns of machines in “Unacceptable” state due to the system’s prescriptions were really necessary. In 100% of cases not only the necessity of maintenance works, but the machinery defects detected by the COMPACS® system were proved to be real.
Kostyukov V.N., Kostyukov Al.V., Kostyukov A.V. Real-time condition monitoring of machinery // Controlling. - 2014. - №4. - P. 44-49.
It is shown in the article, that losses due to machinery operation may be reduced to the minimum by timely and well-aimed maintenance based on real-time condition monitoring and diagnostics of machinery. That allows to use full resource of machinery and to bar its unscheduled (accident-based) repairs. That can be achieved by means of automated control systems for safe resource-saving operation and maintenance of machinery - COMPACS®.
Kostyukov V.N., Kostyukov A.V. Automated control systems for safe resource-saving operation and maintenance of machinery // Modern methods of technical diagnostics and non-destructive testing of details and assemblies - 2014. - №2. - P. 37-43.
Solution of problems of safe and reliable operation of machinery units of hazardous production facilities in petrochemistry is closely connected to risk monitoring in operation. Hazardous production facilities monitoring requires real-time assessment of machinery reliability during its operation, which means, in particular, to know the machinery average running time before nucleation of a defect, and machinery condition turning unacceptable. Besides, the analysis of hazardous production facilities in petrochemistry has revealed that more than 70% of failures causing shutdown of facilities and reducing technical readiness coefficient are failures of machinery units.
In that connection, the solution of one of the most important problems of safe and reliable operation of machinery units of continuous hazardous productions in petrochemistry can be found in determining the average running time of machines considering their operation in different technical conditions.
The paper is aimed at development of models and methods for assessment of the average time of safe and reliable operation of hazardous production facilities machinery in petrohemistry by means of studying their operational behavior in various technical conditions.
Kostyukov V.N., Kostyukov A.V., Sinitsyn A.A., Tarasov E.V. Assessment of reliability of operational safety of petrochemical facilities // Industrial risk evaluation and management in industrial safety. Monitoring the risk for complex and unique units. Poligon-presss, 2014. - p. 142-154.
In recent years, the systems of standards containing the term risk have gained popularity in foreign and domestic reference documents, while many industrial enterprises have taken on creating risk-management systems for technogenic safety in order to decrease expenses on Maintenance, Repair And Operating (MRO).
Thus, it is necessary to point out the specific features of the risk management for technogenic safety. Firstly, risk avoidance is impossible, as it would mean the closedown of enterprises with hazardous production facilities. Secondly, to accept the risk is also impossible, since the risk increases together with the complexity and scale of production. Thirdly, transfer the risk to the third party (by means of insurance) is ineffective, as the worst possible consequences of failure inevitably result in losses that cannot be compensated financially. Therefore, it is necessary to focus on risk reduction.
The aim of the article is to present the procedure that allows monitoring the risk of production facilities failures in real time. The specialists of DYNAMICS Scientific & Production Center (DYNAMICS SPC) have been developing and perfecting the procedure for the last 20 years. The computer system for accident prevention and condition monitoring COMPACS® created by the Center is introduced at dozens of enterprises with hazardous production facilities in Russia and abroad where it monitors the condition of more than 17000 plants, production facilities and machinery of 1700 different types.
Kostyukov V.N., Kostyukov A.V. Real-time monitoring of machinery failures and operating risks // Industrial risk evaluation and management in industrial safety. Monitoring the risk for complex and unique units. Poligon-presss, 2014. - p. 37-48.
More than 25 years ago the pioneer of Siberian petrochemistry – PO Omsknefteorgsintez, which is now called Gazpromneft – Omsk Refinery, JCS, put its bet on Omsk scientific developments and let one RI scientist to create a unique software-hardware complex providing objective data on the most critical machinery condition in real time to the personnel and management of the enterprise.
Experimental operation of the very first systems has proved their efficiency and irreplaceability for large-scale refinery production. That resulted in further researches and development of the systems, and global novelty of the offered solutions, together with wise technical policy of Omsk refinery has allowed to establish a DYNAMICS Scientific & Production Center (DYNAMICS SPC) under the leadership of Vladimir Nikolayevich Kostyukov in 1991.
Scientists and engineers of the Center created a unique product – the computer monitoring system for accident prevention and condition control – COMPACS®. The system holds a leading position in the world not only by the combination of its characteristic features, but by its implementation scales. The COMPACS® condition monitoring system for accidents prevention was developed for the first time for PO Omsknefteorgsintez, where it became widely spread. Today, more than 20 production facilities of Omsk Refinery are equipped with the COMPACS® system and are operated according to their real-time condition.
Intensive implementation of the piston compressor monitoring systems at hazardous production facilities of refinery and petrochemical enterprises established a problem of standardizing of measured parameters, which are used for condition monitoring of piston compressors. One of the main physical processes applied in monitoring systems is vibration.
Vibration parameter standardizing method uses a deduced form experiments fact: when machines function normally the vibration parameters of some of the machines have lower values than those that can be used as limiting ones.
Today in Russia there are acting standards which allow together with monitoring systems for hazardous production facilities and in compliance with requirements of the 1st class monitoring systems, to ensure that static, dynamic errors and risk of failure of dangerous condition do not exceed 5%.
As a result, for the first time in the world, monitoring systems made in accordance with STO 03-007–11 standard using the developed algorithms of automatic expert system for decision-making allows to carry out condition monitoring of piston compressors of hazardous production facilities and to provide their safe resource-saving operation.
Kostyukov V.N., Naumenko A.P. Standardization in diagnostics and monitoring of piston compressors // Territoriya NDT (NDT Territory). - 2014. - №4. - P. 28-33.