It has been almost 25 years since DYNAMICS SPC took up fundamental and applied research and development works, production and wide-scale implementation of the COMPACS® automatic diagnostic and condition monitoring systems into refinery and petrochemical companies.
The presented basic approach towards provision of petrochemical safety based on automated control systems for safe resource-saving operation of machinery – COMPACS® allows full utilization of each refinery enterprise and the whole company in general, and adopting the technology of safe resource-saving operation of machinery in real time which provides maximum possible run life at minimum operational costs. A perfect example of utilization of such approach is Syzran Refinery, JSC.
Kostyukov A.V., Sinitsyn A.A., Tkachenko A.A. General approach towards safety of refinery and petrochemical companies // Business&Class. - 2014. - June-August. - pp. 26-29.
The paper is aimed at determining possibility to provide reliable condition assessment of rotary units of mechanical part of rolling stock during operation and with acceptable cost of single diagnostic act. To reach that goal one need to develop a list of experimental researches of vibration acoustic processes and to create an experimental device for signal measurement.
The paper presents the results of development of the experimental device used within the framework of an integrated program of research of vibroacoustic processes to obtain data on vibration of mechanical components of rolling stock working in real operating conditions. The device enables prolonged continuous stream recording of signals from transmitters, in particular, from vibration sensors in the band to 900 kHz.
Results of the analysis of data obtained using the experimental device have been used as a basis for train component diagnosis algorithms, implemented in onboard condition monitoring systems COMPACS®-EXPRESS-3, installed on modern rolling stock.
Kostyukov V.N., Zaytsev A.V., Tsurpal A.E. A device for experimental studies of vibration of rolling stock components during operation // Transport of the Urals. - 2014. - №2. - pp. 77-80
The most important result of Soviet era of vibration monitoring development is a prove of considerable impact that errors in assembling and operation of machine have on its residual life, and also possibility of predicting the residual life span by the vibration diagnostics results.
For production and transport industries the fundamental reasons of high costs and losses are determined by subtle occurrence and development of faults, as well as poor observability of actual processes of machinery deterioration during its whole lifespan.
Stability can be achieved by means of observability and controllability, when all monitoring processes are coupled together and monitoring time does not exceed the shortest interval of machinery fault development.
The shortest monitoring period can be achieved by the in-built automatic expert system revealing all main problems to the personnel operating the machine and forwarding this information through the automatic diagnostic network to the managers and production heads.
Kostyukov V.N. Innovative technology for machinery “health” monitoring for accidents prevention and condition-based operation of machinery – Russian technological break-through // Modern approaches towards selection of equipment and materials during project development, building and operation of production facilities of refinery and petrochemical companies: proceedings of the Council of Chief Mechanics meeting
One of the main components of safe accident-free operation of industrial facilities is its high-quality production and maintenance. Throughout the years a concept of increasing quality of production and repair by means of objective condition assessment of assemblies and machines is commonly used.
The concept is implemented on the basis of automated control system for safe resource-saving operation and repair of machinery – COMPACS®. The bench variant of the system operates successfully at dozens of repair productions of Russia and CIS.
One of the latest development of DYNAMICS SPC among the bench systems is a pump units diagnostic and testing control system COMPACS®-RPG. The system is implemented at Volgogradneftemash, JSC – the biggest Russian producer of pump units.
The system is intended for collaborative work with new diagnostic and test bench (DTB) for pump units produced by Volgogradneftemash, JSC in order to carry out hydraulic, quality assurance and periodic tests of pump units with full assessment of their quality after assembly.
Through the COMPACS-RPG system, specialists of DYNAMICS SPC solved the task of providing an automatic operation of the bench with real-time calculation of all required characteristics and test protocol printing.
The paper dwells upon the usage of the modern systems for diagnostics and comprehensive condition monitoring (DMS) for fuel and power industry machinery, which make an integral part of the reliability control system for comprehensive production facilities providing safe resource-saving operation.
The paper considers the basic principles and the most important properties and characteristics of such systems, as well as their classification by 13 main features, describes methods for DMS types determination. The paper shows the examples of system type calculation for various software and hardware, the systems’ application domains for implementation at power facilities according to the risk of fault skipping. The paper classifies the machinery by the risk matrix considering probability of a fault occurrence and its economic, ecological and technogenic consequences.
The paper suggests more detailed classification criteria for facilities targeted by technical regulation (FTR), hazardous production facilities (HPF) and critically important facilities (CIF). As an example of the first class DMS - the stationary condition monitoring system COMPACS® is described. The system comprises all general principles of the first-class DMS building according to GOST R 53564.
Kostyukov V.N., Boychenko S.N., Naumenko A.P., Kostyukov An.V., Kostyukov Al.V. Monitoring risks of fuel and power industry machinery // [Electronic source]//New on Russian electric power industry. 2014. №3, p. 30-44. - URL: http://energo-press.info/журнал-новое-в-российской-электроэне/архив-новое-в-российской-электроэнер/
Modern production facilities equipment operation and transport complex are unthinkable without the use of health monitoring systems. Currently, the production and transport facilities of the complex are distinguished by the degree of impact on the country’s security, economy and ecology: objects of technical regulation, hazardous production facilities, critical facilities, strategic facilities.
It is clear that various classes of systems should be used for these objects health monitoring. Principles of monitoring construction documented in the literature are reflected in the standards. Monitoring systems should provide information on the equipment (monitoring object) status in the required quantity and quality to provide observability of its technical state. Observation systems results should advance to take control actions, which provide the required stability margin processing facility, quality of its operation, create a necessary supply of technological, environmental and economic safety. These systems form the basis of automated control systems for the safe resource-saving operation of equipment in real time within the whole enterprise.
Risk decisions are determined by monitoring errors - static, dynamic, and those due to the influence of human factor. A significant effect of a static error detection on the magnitude of a dynamic error detection and of the failure omission risk due to the monitoring system has been shown. An equation of the static and dynamic errors relation, invariant to the nature of these processes and diagnostic features has been obtained.
There have been obtained numerical estimates of the dynamic error increase for linear and exponential trends of technical state degradation in the objects, invariant to their nature. Ways of improving the monitoring systems for malfunctions in objects of different responsibility depends on the basis of a modernized classification criterion.
Makhutov N. A., Technogenic safety: diagnostics and monitoring of potentially dangerous equipment and its operation risks// N. A. Makhutov, M. M. Gadenin, Digest: Federal
reference book, Vol. 26, Moscow, SP "Center of Strategic Partnership", 2012. – 496 p. pp. 307-314.
Kostyukov V. N., Monitoring of condition and operation risks of the equipment in real time as a basis of industrial safety// V. N. Kostyukov, N. A. Makhutov, A.V. Kostyukov. Digest: Federal reference book, Vol. 26, Moscow, SP "Center of Strategic Partnership", 2012. – 496 p. pp. 321-326.
Kostyukov V. N, Boychenko S. N, Kostyukov Al. V., Automated control systems for safe money-saving operation of equipment at refining and petrochemical plants (SMSRTM – COMPACS®), Moscow, Mashinostroenie, ISBN: 5-217-02971-4, 1999, 163 p.
Kostyukov A.V., Kostyukov V. N., Improving the operational efficiency of enterprises, based on real-time monitoring, Moscow, Mashinostroenie, 2009, 192 p.
Kostyukov V. N., Naumenko A.P., Bases of vibroacoustic diagnostics and monitoring of machinery: tutorial. Recommended by EMO of higher education institutions of the Russian Federation for students of higher education institutions studying in the field 200100 – "Instrument making". Omsk, OmSTU, 2011, 360 p.
Kostyukov V. N., Condition monitoring of the equipment in real-time technology of safe maintenance of the XXI century, Тhe 5th International Conference on Condition Monitoring and Machinery Failure Prevention Technologies CM 2008/MFPT 2008/ 15-18 July, 2008, Edinburgh, Scotland, UK, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-31-4, 2008, pp 785-793.
Kostyukov V. N, Real-Time Condition Monitoring of Machinery, The 6th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies,
CM 2009/MFPT2009/ 23-25 June, 2009, Dublin, Ireland, BINDT & Coxmoor Publishing Co., 2009, pp. 1161-1170.
Boychenko S. N., Kostyukov V. N., Equipment diagnostic expert system, The 6th International Conference on Condition Monitoring & Machinery Failure Prevention
Technologies, CM 2009/MFPT2009/ 23-25 June, 2009, Dublin, Ireland, BINDT & Coxmoor Publishing Co., 2009, pp. 1132-1135.
Kostyukov An. V., Increase of safety and operating efficiency of continuous production cycle enterprises based on real-time comprehensive condition monitoring of equipment, The 6th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2009/MFPT2009/ 23-25 June, 2009, Dublin, Ireland, BINDT & Coxmoor Publishing Co., 2009, pp. 1164-1179.
Kostyukov V. N., Real-time Condition Monitoring of Equipment, The 7th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies,
CM 2010/MFPT2010/ 22-24 June, 2010, Stratford-upon-Avon, England, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-33-8, 2010, Paper 236, 8 p.
Kostyukov V. N., Real-time Condition Monitoring of machinery by the recurrent selection of the noise and periodic components of vibration, The 8th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2011/MFPT2011/ 20-22 June, 2011, Cardiff, Wales, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2011, Paper 205, 13 p.
Kostyukov Al. V., Kostyukov V. N., Classification of vibration parameters trends for RTCM, The 8th International Conference on Condition Monitoring & Machinery Failure
Prevention Technologies, CM2011/MFPT2011/ 20-22 June, 2011, Cardiff, Wales, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2011, Paper 217, 10 p.
Naumenko A. P., Modern methods and means of on-line monitoring of parameters and realtime health monitoring of piston machines, The 8th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM2011/MFPT2011/ 20-22 June, 2011, Cardiff, Wales, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2011, Paper 209, 13 p.
Kostyukov V. N., Real-Time Condition Monitoring of gear pumps by the recurrent selection of the noise and periodic components of vibration, The 9th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2012/MFPT2012/ 12-14 June, 2012, London, England, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2012, Paper 259, 11 p.
Kostyukov V. N., Real-time Health Monitoring Systems of Machinery, The 10th International Conference on Condition Monitoring & Machinery Failure Prevention
Technologies, CM 2013/MFPT2013/ 18-20 June, 2013, Krakov, Poland, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-37-6, 2013, Paper 106, 10 p.
Kostyukov V. N., Naumenko A. P., Kostyukov An. V., Boychenko S. N., Kostyukov Al. V., Standards in the field of technical condition of hazardous facilities equipment, Industrial safety, Moscow, 2012, 7, pp. 30-36.
GOST R 53563-2010, Condition Control and Equipment Diagnostics. Condition Monitoring of Hazardous Production Equipment. The Order of the Organization, Moscow, STANDARTINFORM, 2010.
GOST R 53564-2010, Condition Control and Equipment Diagnostics. Condition Monitoring of Hazardous Production Equipment. Requirements to Monitoring Systems, Moscow, STANDARTINFORM, 2010.
GOST R 53565-2010, Condition Control and Equipment Diagnostics. Condition Monitoring of Hazardous Production Equipment. Vibration of Centrifugal Pumping and Compressor Units, Moscow, STANDARTINFORM, 2010.
Malov E. A., Bronfin I. B., Dolgopyatov V. N., Kostyukov V. N., Boychenko S. N., Implementation of COMPACS® systems – providing of safe operation at the plants with continuous production cycle, Industrial safety, Moscow, 1994, 8, pp. 19-22.
Kostyukov V. N., Boychenko S. N., Naumenko A. P., Tarasov E. V., Comprehensive monitoring of hazardous production facilities, Control. Diagnostics, Moscow, 2008, 12, pp.
Kostyukov V.N. Real-time health monitoring systems of machinery - risk assessment // Condition Monitoring and Machinery Failure Prevention Technologies (СМ/MFPT 2014)
The prime means of machinery operability support is preventive maintenance. The intervals between maintenance/repairs as well as their size and contents depend on the statistical data. That method does not consider special features of the particular assembly, its actual operation conditions, such as stochastic loads on the machines, or operation procedure, etc. A machinery maintenance system based on such approach has several disadvantages.
Switching from preventive maintenance to condition-based maintenance allows considerably (in a few times) increase run-to-failure period and decrease operational costs. The real-time condition monitoring of machines and their parts ensures an objective assessment of condition during operation. The second component of the innovative technology for maintenance, repair, run-to-failure growth and reduction of cost required for a demanded condition support is detection of faulty parts of the machine before repair and an accurate assessment of their condition after the repair.
Kostyukov V.N., Naumenko A.P., Kostyukov Al.V., Boychenko S.N. Real-time condition monitoring – innovative technology of maintenance and repair production // Territoriya NDT (NDT Territory). - 2014. - №1. - p.66-69.
Vibration analysis provides a comprehensive assessment of a piston machine’s condition by outer vibration of its casing, and makes an effective instrument for investigating dynamic processes’ quality during assembling, production, defects detection and their critical growth during operation. The highest efficiency rate can be reached by ensuring the condition monitoring of not only a piston machine, but all conjugated mechanisms and attached assemblies.
Internal combustion motors are the most important types of piston machines for which vibration-acoustic diagnostics allows to provide safe accident-free operation with the longest possible operating life.
A DMS is a system (or machine) which product is current information on the condition of the machinery and possible danger, with required commentary (prognosis of residual operating life, prompting on the nearest urgent actions to be made, etc.) and a set risk level.
Kostyukov V.N. Reliability increase of piston machines equipped with condition diagnostic and monitoring system (DMS) // Machine manufacturing. Encyclopedia. - Moscow: Mashinostroenie. Dvigateli vnutrennego sgoraniya. - 2013. - Vol. IV-14. – Annex, par.4. - p.775-781
Internal combustion motors are multifactor source of powerful vibration-acoustic signals. The motor’s vibrations are caused by unevenly rotating masses – inertia of reciprocating masses, centrifugal inertia and its moments, gas dynamic processes – power of gas pressure, inlet/outlet gas flow, fuel injection, and, also, impact and friction between elements and details of assemblies and mechanisms.
The paper consideres continuous condition monitroing and real-time automatic diagnostics of pump units at refinery and petrochemical facilities.
Using recommendations issued by the COMPACS® condition monitroing system with an automatic expert system, the maintenance personnel can ensure safe resource-saving operation of machinery of hazadours production facilities at refineries and petrochemical companies, search and correct errors in technology process, control operation procedure of machinery according to its condition.
Kostyukov V.N., Kostyukov An.V., Tarasov E.V. Advantages of real-time condition monitoring // Neftepererabotka i neftehimiya (Oil-refining and petrochemistry). - 2013. - №11. - p.44-51