The main challenges of the company services responsible for production maintenance are:
maximizing of process units run-to-failure period by eliminating of accidents and downtimes due to equipment failures;
minimizing of the stopping repair duration through targeted repairs of the equipment;
reduction of maintenance costs and losses by eliminating of inefficient unscheduled and schedule-based preventive repairs.
Thus, a key performance indicator of various technologies of equipment operation (equipment maintenance strategies) is the extent of their ability to solve each of the problems mentioned above.
The analysis of ten-year experience of operation of Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS® at eight largest petrochemical and oil-and-gas processing enterprises shows that COMPACS® is a reliable tool for protection from technogenic accidents, which are mainly caused by the mistakes of manufacturing personnel, and an indispensable tool for prompting of efficient decisions during the planning of the scope and terms of repairs, equipment replacement and estimation of its results.
The systems are an ideal tool for monitoring of performance discipline and workmanship of the personnel. They ensure observability of condition of manufactured, repaired and exploited equipment, controllability of its quality at all stages of life cycle, stability, safety and efficiency of production.
Kostyukov V.N., Kostyukov A.V. Resource-saving and safe operation of equipment - the strategy of XXI century // NEFTEGAZ. - 2007. - p. 36-37
The paper presents the results of development and application of the systems for diagnostics and monitoring of the quality of assembly and mounting of machines and assemblies, which are in general use at oil-and-gas enterprises. These systems are potentially productive for engineering because they are an effective tool of increasing the reliability and service life of the products without important reconstruction of industrial and technological basis and, consequently, huge expenditures. The advances have come about through the fact that the cost of diagnosed processes and equipment is way above the cost of the monitoring systems, which is especially important for a national economy today.
Kostyukov V.N., Boychenko S.N., Kostyukov Al.V., Kostyukov A.V. Monitoring of the quality of assembly, mounting and operation of units of fuel and energy complexes // Technologies of Fuel and Energy Complexes. - 2007. - №2. - p. 60-65
We offer a revolutionary approach to operation management which was developed in Russia and approved at the largest oil-and-gas enterprises of Russia and abroad. This approach is realised by means of human factor elimination from the process of technical state evaluation of equipment for control of its safe maintenance on the base condition monitoring in real time. It allows establishing an actual feedback from the sources of control - equipment of production complex and operating personnel. This technology is especially actual at present stage when essential increase of production processes at different branches of oil-and-gas complexes in the vast expanses of Siberia and the Far East is planned.
The given SM™-Technology is provided by implementation of Automatised Control Systems for Safe Maintenance and Resources Saving™ COMPACS® during all stages of lifetime of the equipment: from the development stage up to utilisation. Systems ensure monitoring of the equipment state and efficiency of the maintenance and operating personnel actions and represent in real time current information to the work places of technical personnel and engineering managers responsible for an operational multiplier of the enterprise business-process.
Kostyukov V.N., Kostyukov A.V. Increase of Oil-and-gas Enterprises Efficiency on the Basis of Safe Maintenance // World finance review. - 2007. - p. 48-49
The implementation of the COMPACS® stationary systems for monitoring and automated control systems of safe resource-saving operation of equipment on their basis (Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment - ACS SRSM™) enabled transfer to the operation of machine equipment according to its actual condition in real-time mode, extension of run-to-failure of process units, significant increase of reliability and technical readiness of equipment in view of almost 100% use of production capacities.
The main advantage of the systems is absolute elimination of "a human factor" influence on the process of monitoring of equipment condition, quality, timeliness and purposefulness of the personnel actions of safe resource-saving operation of a process unit.
The implementation of the systems for automatic vibration analysis and monitoring of equipment condition not only produced significant economical effect but also substantially increased industrial safety owing to elimination of stress emergencies, which often caused inadequate actions of the personnel.
The attitude of the personnel (primarily the chief operator directing the process) is a key factor of safe resource-saving operation of the unit. That is why the knowledge of actual equipment condition provided by the COMPACS® systems for vibration monitoring is the best way to cost effective industrial safety.
Kostyukov V.N., Kostyukov A.V., Vostrikov I.Y. A new high-performance saving technology of operation of Syzran Refinery equipment complexes on the basis of the COMPACS system for condition monitoring // Chemical Technique - M.: 2007. - № 3. - p. 14-20
Condition monitoring ensuring profound diagnostics of the assemblies and mechanisms of reciprocating equipment and first of all compressor units with reciprocating compressors and internal combustion engines is one of the most important problems solvable through the diagnostics by vibration signal parameters.
Development of the methodology and systems for reciprocator condition monitoring is an actual problem.
The paper presents the methodology for monitoring, gives definition of the following terms: condition monitoring of the units, technical diagnosing of the unit, technical diagnosis, diagnostic feature. In addition, it presents the guidelines for monitoring system construction and specifies the main parameters characterizing and accompanying reciprocating compressor work.
For equipment condition monitoring the following parameters are used (depending on diagnostic tasks): vibration acceleration, vibration velocity, vibration displacement, temperature, pressure, radial clearance, current consumption, shaft speed, fluid (condensate) level, the signal of acoustic emission sensor, the parameters of alternating/direct current and voltage.
Kostyukov V.N., Naumenko A.P. System for condition monitoring of reciprocating equipment // Control. Diagnostics. – M.: 2007. - № 3(105). - p. 50-59
Analysts estimate that from 30 to 70% of the companies qualify the results of Enterprise Resource Planning (ERP) system implementation as partly failed (objectives have not been completely gained, terms and budgets of the projects have been exceeded, total cost of ownership of a system turned out unreasonably high, difficult maintenance etc.)
Along with above reasons we can note another two which are not often mentioned, but connected with the realities of operating enterprise:
transformation of the enterprise structure and the rules of its operation, which requires change of ERP-system configuration and consequently significant financial and time costs;
manual data input by the operator.
MES-systems (systems for process control) are intended to reduce or eliminate manual data input to ERP-systems. Such systems are intermediate between SCADA (Supervisory for Control And Data Acquisition) and ERP-systems. When solving the control problems at a certain level (department of power engineer, mechanic, technician, supply etc.) provided interaction with ERP they are able to minimize human factor influence during the data acquisition.
Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment ACS SRSM™ COMPACS® are MES-systems based on automatic acquisition and practical use of diagnostic information on the equipment condition in real-time mode.
Kostyukov V.N., Malov E.A., Ryabov V.A., Shatalov A.A., Kostyukov A.V. Compass in the world of security and efficiency: Benefits of Manufacturing Execution System (MES) for safe resource-saving operation of equipment which is based on ACS SRSM COMPACS // Oil of Russia. - M.: 2006. - № 4. - p. 100-103
An adaptive algorithm for measuring and processing of the signals in a wide frequency range, which use pipelining of the channel selection at the lines level, at the level of analog-to-digital converter structure, and paralleling of the measurement processes at different lines, has been developed and realized in the article.
Application of these algorithms enables to increase the productivity considerably and to bring the frequency of measurement and diagnostics within the scope of a certain fieldbus up to 7,5 acts per second in case the selection length equals 400 ms and the hardware is absolutely self-supervisory. Consequently application of these algorithms enables reduction of time of response of statistical delta modulation to the change in diagnosed equipment condition.
Developed algorithms have been applied in the COMPACS® systems used at dozens of Russian enterprises. These systems have established a reputation as fast and high-reliability measurement complexes to solve the problems of diagnostics and monitoring.
Kostyukov Al.V. Adaptive pipelining of vibroacoustic signals in the problems of equipment condition monitoring // Actual problems of piezoelectric instrument engineering and nanotechnologies. - M.: 2006. - p. 104-108
Despite normal rotation frequencies and equipment degradation rates are relatively low there is still demand for equipping of mining industry machinery, which is most important for manufacturing process, with the systems for equipment condition monitoring. This demand is determined by the security requirements and significant reduction in costs of maintenance of the machinery equipped with the systems for monitoring and diagnostics.
There is positive experience of operation of stationary systems for equipment condition monitoring in mining and mining-chemical industry. Mining plants are equipped with the systems for condition monitoring including those based on the methods of nondestructive testing. These systems can evaluate technical condition of process equipment during operation and provide the personnel with the information on technical condition of process equipment in real-time mode, as in many enterprises of oil and gas processing industry.
The article deals with the approaches to condition monitoring of working machines of mining industry. As mentioned in the article, the use of technology developed by DYNAMICS Scientific & Production Center (SPC) using the COMPACS® systems enables application of the most significant process and low-charged equipment in the optimum way and cost-effectively. Fail-safety of the enterprise increases along with the decrease in the cost of fixed assets maintenance. That results in capitalization and increase of profitability of the company.
Kostyukov V.N., Tarasov E.V., Bortvin O.B., Shhelkanov A.V., Cepelev S.M., Pancheha P.G. Experience of equipment condition monitoring in mining and mining-chemical industry // Mining Equipment and Electromechanics. - M.: 2006. - № 7. - p. 18-20
Fan plants for central ventilation of a mine are the most important element that ensures operation and safety of mine production. Long shutdown of the fan is utterly unacceptable because it may cause danger to life and health of the workers at the mine.
Reliable information on technical condition of the fans helps to reduce the probability of their sudden failure. It enables early planning of repair work and stand-by fan starting. Timeliness and reliability of the information helps personnel, which services the fans, to find a proper solution.
The COMPACS® system enables detection of fan plant malfunctions (bearing defects, imbalance, misalignment, unfastening) and violation of operating practices (aerodynamic defects that increase overall level of vibration loading on bearing supports).
Timely detection of developing defects enables to schedule preventive and repair work, which significantly increases level of equipment use. In addition the use of information on the fan condition enables reduction of the probability of a sudden failure and associated emergencies in the mine. Consequently fail-safety of the enterprise increases. All that leads to capitalization and increase of JSC "ALROSA" profitability.
Starikov V.A., Tarasov E.V., Cepelev S.M. Equipping fan plant for central ventilation with the COMPACS stationary system for vibration analysis // Mining Journal - M.: 2006. - № 6. - p. 26-27
In 1980s a lot of cryogenic tanks with thermo-insulating housing (GHK, CTK, TRZHK types) have been produced. Nowadays most of them have already worked for designated lifetime (20 years). However, it is still possible to operate these items for a long time. And it is important for most companies because new items are rather expensive.
In this connection it is necessary to carry out technical diagnosing and examination of industrial safety (EIS) of the equipment. The cost of technical diagnosing and EIS is much lower than the cost of new item, and their positive results enable extension of operation life of the equipment which has worked for designated lifetime. Therefore the development of the techniques for condition control of the vessels after their repair, after the assigned resource completion and periodically during operation (particularly by acoustic emission method of nondestructive testing) becomes a topical problem.
In terms of the gathered experience a standard program for technical diagnosing of cryogenic tanks and vessels, which determines conditions and basic requirements for acoustic emission control, has been developed. This program provides for pneumatic testing with acoustic emission maintenance and enables not to disturb the hermeticity of thermo-insulating housing. That enables significant reduction of costs of diagnosing, retention of the housing integrity and condition monitoring of the inner vessel on-site.
The developed method of cryogenic tank technical diagnostics enables condition monitoring of the inner vessel during the test and operation of the tanks.
Kostyukov V.N., Naumenko A.P., Chikarin V.A., Shakirzyanov M.G. Diagnosis of cryogenic tanks with thermo-insulating housing // Chemical technique. - M.: 2006. - № 5. - p. 7-9