The adequacy of the condition assessment of piston compressors of hazardous production, reliable and timely detection of faults and their causes, the risk rates of piston compressors safe operation are determined by the level of methodological basis development for the organization and operation algorithms of the soft-hardware of systems for piston compressors condition monitoring.
Nowadays, there are documents that define the basic requirements to the organization and the means of hazardous production facilities monitoring, but even for the experts in this field it is very difficult to orient oneself in the advertised capabilities of the systems. Thereby, there arises a need to range the methods and means of piston compressors condition monitoring and diagnostics.
The article dwells upon the development of condition and prospects of modern monitoring and diagnostic methods and means of piston compressors of hazardous process industries. The review of the condition control principles, implemented in nearly all the monitoring systems is made. The present article concentrates on technical means of monitoring systems.
The analysis of the methodology, techniques and principles of systems for real-time monitoring building is carried out. The article addresses the condition monitoring system of piston compressors in real-time COMPACS®.
Naumenko A.P. Modern methods and means of real-time condition monitoring of piston machines // Compressors and Pneumatics. - 2010. - №8. - pp. 27-34
Condition monitoring of the unit is an observation of the changing process of its capacity to warn personnel about the reaching of limit state. It allows transferring the majority of failures from the category of sudden-for-personnel to the category of gradual due to early detection and timely warnings.
The real-time monitoring has some significant differences from "on line/off line" monitoring, which consists in strict regulation of monitoring interval at the level of 10-20% from the fastest failure development of the equipment of production complexes. That is possible on the basis of automatic diagnostics and monitoring systems with functional uncertain structure, which does not depends on the design of the equipment for a wide range of units of production complexes and contains multi-level expert system.
Kostyukov V.N. Condition monitoring of equipment in real time // "Dvigatel-2010" ("Engine-2010"). - 2010. - pp.59-63
The real-time condition monitoring systems of acoustic emission impulses require flexible algorithms for the selection of acoustic emission impulse parameters. Therefore, the research of the characteristics of the acoustic signals, which are generated by the object in conditions close to real mechanisms of destruction, is an urgent task.
The results of acoustic emission signals research collected from the hydro test conducted to BGA 190 gas bottle, which were received by specialists of NTK "Cryogenic technique" together with the group of acoustic emission control of DYNAMICS SPC, are presented in the article.
The loading of the monitoring object was held in four stages. There was a crack at the fourth stage, and the tests were terminated.
Statistic characteristics are defined for each stage of acoustic emission signals, which are corresponded to the object destruction stages. The histograms of the values distribution of such acoustic emission signal parameters as amplitude, energy parameter and duration are constructed. The ranges of amplitudes, energy parameters and durations, corresponding to the destruction stages of the control object, were defined.
Kostyukov V.N., Naumenko A.P. Investigation of the characteristics of acoustic emission signals // Innovative technologies in the acoustic emission method. - 2010. - pp.1-13
The efficiency of oil-refining industry is determined in a great measure by the amount of material resources and labor force overhead for the repair of equipment and by the amount of losses from accidents and unit downtimes. The wear rate of the equipment is largely determined by the adequacy of impact on it from production and service personnel. It is necessary to control operating costs and equipment resources. For this effect it is essential to provide observability of the industrial complex condition through its monitoring, i.e. the monitoring of the equipment condition to determine the current condition and predict the moment of equipment`s transit to the limiting state.
The results of the monitoring present diagnoses, gathered from monitoring objects of the manufacturing complex, that are obtained by inseparably adjacent time intervals, when the condition of the equipment does not change significantly. Choice and substantiation of the monitoring object is carried out by analyzing the technological scheme of the plant and the scheme of process units, taking into account the impact of their failure (shutdown or power reduction) on the technological process and the explosion and fire risk across the enterprise. As a result we can define the hazard categories, which are subjected to be equipped with the condition monitoring system in accordance with our program of equipping the enterprise with monitoring systems and the transition to condition-monitored operation of the equipment.
The process equipment of refinery units includes dynamic (pumps, compressors, blowers, air coolers, etc.) and static (columns, tanks, pipelines, etc.) equipment, different technical means are often used for its diagnosis and monitoring. The global trend to use the overspecialized technology of stationary and portable diagnostic tools for the specific type of equipment has led to the creation of a large variety of systems produced by different companies and almost incompatible with each other, that does not allow to integrate them into one information space - ACS of enterprise.
An example of a comprehensive approach to condition monitoring of process units refinery equipment is the COMPACS® system, which provides observability of dynamic and static equipment of essential main process units of "Angarsk Petrochemical Company" JSC on an one hardware and software platform with the transfer of the results of monitoring into an integrated diagnostic network Compacs-Net®.
Kostyukov V. N., Kostyukov A.V., Serdyuk F.I., Yolshin A.I., Kuks I.V., Makhonkin B. N., Mayler V. B., Mukhin S.V., Aktuganov A.N., Dvornikov A.A. Monitoring system COMPACS is the basis of many years of safe resource-saving equipment operation at the "Angarsk Petrochemical Company" JSC // Nefteperepabotka & Neftekhimiya (Oil Processing and Petrochemistry). - 2010. - № 6. - pp. 40-46
The article dwells upon the equipment condition monitoring practice by means of vibration diagnostic systems COMPACS®:
sleeve assembly detail malfunctions;
crank-slide mechanism detail malfunctions;
base bearing malfunctions;
Also, the article gives the specifics of diagnostic and monitoring systems' realization.
Kostyukov V.N., Naumenko A.P. The modern methods and means of condition monitoring and diagnostics of piston compressors. Part 2 // Maintenance and Repair (“Tekhnicheskoye obsluzhivanie i remont”). - 2010. - №2. - p. 16-21
Safety level at piston compressors units operation is determined by the reliability of their condition control, trustworthiness and timeliness of malfunctions and their causes detection. Today there are a lot of technical means which are developed and produced for monitoring and diagnostics of piston compressors and generally offered by the foreign companies. However, a question of adequacy of carried-out measurements to real conditions of piston compressors is opened.
The article reveals criteria of the equipment condition. As a rule, there are four categories of such conditions: "good", "acceptable", "measures required" and "unacceptable".
The article dwells upon the choice criteria of diagnostic signals for condition monitoring, gives the sources of a vibroacoustic signal.
The methodology and algorithms of piston compressors diagnosing are revealed. The distinctions between systems for real-time monitoring and on-line monitoring are listed.
Kostyukov V.N., Naumenko A.P. The modern methods and means of condition monitoring and diagnostics of piston compressors. Part 1 // Maintenance and Repair ("Tekhnicheskoye obsluzhivanie i remont"). - 2010. - №1. - p. 28-35
Revolutionary increase the repair quality of motor driven rolling stock (MDRS) and simultaneously reduce duration and laboriousness of obligatory after-repair control is possible by means of automatic systems for comprehensive diagnostics with automatic expert system of malfunctions detection, excluding subjective diagnose errors and providing reliable assessment of the most complex and critical systems of an EMU-train.
The article describes the system for comprehensive diagnostics of EMU-train sections COMPACS®-EXPRESS-TR3, which includes 7 sub-systems for the diagnosing of the most complex and damageable assemblies and units – wheel-motor units, isolation of high-voltage electric circuits, pantographs, compressed-air braking system control circuits, power and auxiliary electric circuits.
Due to the usage of the sub-system for electric circuits diagnostics, which is the part of the COMPACS®-EXPRESS-TR3 system, for the first time a possibility to detect details and devices, which condition leads to the decrease of a train productiveness and deterioration of operation conditions of electric machinery and a switchgear, to make the personnel’s work to be aimed at the liquidation of the particular defects, and not all the probable malfunctions, increase of the particular elements’ repair quality, reduction of the train after-repair control and checkout operations in more than 6 times.
The developed methodology of electric circuits diagnostics on the basis of the COMPACS®-EXPRESS-TR3 system allows to make EMU-train electrics checkout faster and easy during the commissioning with the help of prompt, timely and qualitative assessment of control, power and auxiliary electric circuits’ condition.
Sizov S.V., Aristov V.P., Kostyukov V.N., Kostyukov Al.V., Kazarin D.V. Automatic diagnostics of motor driven rolling stock electric circuits // Railway transport ("Zheleznodorozhny transport"). - 2010. - №5. - p. 56-58
Safe and resource-saving operation of machinery is provided by the machinery degradation process control, which allows to carry out all condition-monitored repairs of units, according to the schedule providing 100% exception of emergency repairs. Resource-saving is to be defined as not only reduction of material recourses, but reduction of labour and financial expenses of the enterprise on elimination the consequences of emergency, breakdowns, and losses caused by production shutdown.
The key component of calculations of condition monitoring system economic efficiency and conversion to safe recourse-saving production operation is an increase of the production length. Cost of the addition products not only covers costs of systems acquisition and provides their payback within several days, but also is the main source of increase of repair fund means which are aimed at providing longer non-stop work of the equipment and units of refineries.
The only means in Russia, really providing safe and resource-saving operation of the equipment, is diagnostic and monitoring systems - COMPACS®, successfully operating at many Russian enterprises for already more than 20 years. The systems implementation gives a real increase in the run-to-failure operation periods of units up to 2-5 years, and that is a modern requirement for plants.
Ionova Yu.B., Kostyukov V.N., Kostyukov An.V., Boychenko S.N. COMPACS monitoring systems // Scientific and technological center of the Council of chief mechanical engineers. - 2010. - p. 258-262
Machinery health monitoring – is supervision of its operation process changes in order to warn the personnel about unit reaching its critical state. It allows to make the most of the sudden failures gradual, due to their early detection and timely prevention.
Real-time monitoring – RT-Monitoring has a few essential differences from on-line/off-line monitoring. They consist in a strict regulation of an monitoring interval at the level of 10... 20% of an interval of the fastest development of malfunctions of the industrial complexes equipment.
That becomes possible on the basis of automatic systems with functionally uncertain structure, which does not depend on the equipment construction for the wide class of industrial complex units and contains a multilevel expert system. This allows to implement systems for real-time diagnostics and monitoring in case of prior uncertainty, when types of bearings, number of impeller blades, etc., can be unidentified, as well as to minimize static and dynamic errors and risk of failure omission.
The article dwells upon the main propositions of real-time health monitoring and the differences from on-line and off-line monitoring. There given rated correlations for certainty indexes and monitoring systems speed rate identification. The necessity of diagnostic features changes speed usage is shown. Definitions of monitoring, equipment condition danger, static error, dynamic error, zero-monitoring are given.
Kostyukov V.N., Kostyukov Al.V. Real-time Condition Monitoring of Equipment // Testing. Diagnostics. - 2010. - №3. - pp. 43-50
The article dwells upon the criteria of the equipment condition. The selection of diagnostic methodology and parameters, which not only detects condition but allows to carry out diagnostics with the required operation conditions and maintenance depth. Among the big variety of measured parameters the most informative are acoustic vibrations, which sources are cinematic pair impacts (piston-cylinder, pin-sleeve, etc.)
The sources of vibration acoustic signals of piston machines are given in the article:
Unbalance of the moving and rotating masses – inertial force of reciprocal moving masses, centrifugal force of inertia and the moments of the force.
Gasdynamic processes – pressure force of gases, gas flow during an admission and release.
Impacts and friction between elements and details of assemblies and mechanisms.
The methodology and algorithms of diagnosing of piston machines in real-time monitoring systems are described in the article. Also, the article gives the examples of a proper response of vibroacoustic signals’ various parameters to the condition changes of various piston compressor assemblies.
Kostyukov V.N., Naumenko A.P. Analysis of modern methods and means for piston compressors monitoring and diagnostics. Part 2. Real-time monitoring systems // NDT world. - 2010. - №2. - pp. 28-35