The article presents the technology for safe resource-saving operation of equipment in real time mode (Safe Maintenance™ - SM™-technology) which was created on the basis of Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS®. The technology enables to increase the safety and efficiency of the plants with uninterrupted cycle with minimum cost of maintenance of process units.
The use of ACS SRSM™ COMPACS® makes the operation of fixed assets transparent and manageable, decreases capital output ratio, increases capital productivity and capitalization of business in whole.
Kostyukov V.N., Boychenko S.N., Kostyukov A.V. Manufacturing Execution System (MES) for safe resource-saving operation of equipment on the basis of ACS SRSM™ COMPACS // World of computer automation. - M.: 2004. - № 4. - p. 35-44
In most Russian fuel-and-energy companies considerable proportion of the investments in production process is spent on elimination of the accident consequences, production defects and unreasonable costs of repair of fixed production assets.
The emergence of Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS® and SM™-technology (Safe Maintenance™) for safe resource-saving operation of equipment enabled condition monitoring at all stages of its life-cycle by timely detection of malfunctions, supervision over malfunction development, provision the personnel with the instructions on the necessity of repair or emergency shutdown, and control of the timeliness of execution of above instructions.
Characteristic features of a new operation technology, which is being successfully implemented at refinery, petrochemical and other enterprises with uninterrupted cycle: significant economic effect tested through practice, short payback period and resource-saving safety.
Kostyukov V.N., Kostyukov A.V. New technology of operation of processing equipment - long-term goal of management of Russian fuel-and-energy companies // Proceedings of the meeting of chief mechanics of the enterprises JSC AK SIBUR. - Togliatti: 2004. - p. 58-62
The article presents the results of implementation of stationary systems for condition monitoring of equipment of drying department of one of the mine groups of the enterprise.
The article is concerned with several means of the system intended to implementation of high-performance safe resource-saving technology for equipment operation, which is based on timely, reliable and objective information on a current status of equipment generally determined by the human factor.
As experience has shown, the implementation of Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS® ensures resource-saving (anthropogenic, environmental, economical, etc.) production safety and timely targeting of limited financial resources to critical production areas with a guaranteed beneficial effect.
Balakin V.M., Vasiliev N.L., Kostyukov V.N., Naumenko A.P., Bortvin O.B., Kostyukov A.V. Experience of application of the COMPACS stationary system for equipment condition monitoring at JSC Silvinit // Mining machinery and automation. - M.: 2004. - № 10. - p. 23-26
The main source of reduction of production costs is resource-saving operation of equipment based on continuous condition monitoring in real-time mode that enables prevention of sudden malfunctions of equipment and production shutdowns, continuous automatic acquisition and use of objective information on equipment condition, real-time monitoring and correction of the personnel actions by integration of the COMPACS® system data into the single diagnostic network Compacs-Net®.
Thus, the COMPACS® system for vibration monitoring of technical equipment enables targeted and reliable condition monitoring of equipment of various types including reciprocating and centrifugal compressors.
Kostyukov V.N., Durosov V.M., Korenjakin A.F., Boychenko S.N., Naumenko A.P., Pidsadnij A.S., Sagirov V.H., Starikov V.A. COMPACS system for automatic condition monitoring of reciprocating and centrifugal compressors // Proceedings of X International Symposium "Consumers and manufacturers of compressors and compressor equipment". - St. Petersburg: 2004. - p. 154-164
Operation costs can be minimized by conducting timely and focused maintenance based on real-time condition monitoring, full using the equipment resource, and elimination of unscheduled shutdown and replacement.
Main causes of equipment operation problems at petrochemical enterprises are:
lack of observability of actual operation processes;
lack of quality control of the units and their assemblies during production and repair;
design errors in calculation of the required aggregate capacity;
lack of efficient control over the actions of the personnel responsible for conducting of the process and maintaining of equipment operability.
These problems often block timely and focused measures for maintaining a high degree of technical readiness of production. The problems above can be solved by the implementation of the COMPACS® stationary systems for vibration analysis and equipment condition monitoring at process units, at repair departments - stand systems for vibration analysis and repair quality control of the units and their assemblies, at whole enterprise - computer diagnostic network Compacs-Net® that enables direct management of the operation in real-time mode. The implementation of the systems for vibration analysis and equipment condition monitoring on the basis of Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS® enables high level of anthropogenic safety and production efficiency.
Kostyukov V.N., Kostyukov A.V. Real-time condition monitoring of equipment // Eurasia Processing. - 2004. - № 1. - p. 2-7
The article presents the analysis of implementation of the COMPACS® system for computer vibration monitoring of condition and accidents prevention, which enables condition diagnosing of reciprocating compressor valves, detection of malfunctions at early stage, registers and reflects overload of compressors and valves due to changes in operating practices, and ensures vibration monitoring of condition of reciprocating compressors in full compliance with Safety Norms 03-582-03.
Kostyukov V.N., Vostrikov I.Y., Zarudenskijj A.A., Pavlenko B.A., Naumenko A.P., Lvov O.S. Experience of diagnosing valves of reciprocating compressors // Consumers and manufacturers of compressors and compressor equipment: Proceedings of X International Symposium. - St. Petersburg: 2004
Efficient and reliable operation of rolling mills in many respects depends on reliability of direct current motors of primary drives, which is in large part determined by the conditions of commutation. Emergence of ring fire in the collector and increased sparking of the motor may cause the accident. Approximate cost of elimination of such accident may amount to tens of thousands rubles that convincingly confirms importance of vibration analysis and commutation adjustment of commutator electric machines of direct current.
The paper presents some results of examination of commutation conditions of motors of primary drives of finishing mill train 320 of JSC Metallurgical Plant in the Name of A.K. Serov and mill 800 of JSC Chusovoy Metallurgical Works.
We must conclude that the developed method of commutation adjustment in terms of operating conditions and application of a modern device system enables to reveal the reserve of use of the equipment installed. It results in the increase of productivity of rolling mills in whole or reliability of primary drive operation with lower operating costs.
Kostyukov V.N., Kovbasa N.I., Avilov V.D., Savelieva E.N. New technology for diagnosing and commutation adjustment of direct current motors of primary drives of rolling mills // Modern trends in development and construction of collector and other electromechanical energy converters. - Omsk: OSTU, 2003. - p. 203-208
DYNAMICS Scientific & Production Center (SPC) developed and implemented the COMPACS® stationary system for vibration analysis and computer polyvalent monitoring of the equipment condition at 70 petrochemical complexes and 12 factories. The COMPACS® system enabled complete elimination of sudden failures of equipment.
On the basis of the COMPACS® systems for vibration analysis and automatic condition monitoring DYNAMICS SPC specialists first in the world created and widely implemented a new class of Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) for hazardous industries.
The technologies for total resource-saving are successfully used in the COMPACS® systems for vibration monitoring which ensures reliable operation of equipment of hazardous petrochemical plants with minimum costs.
Kostyukov V.N., Boychenko S.N. Total resource-saving in the COMPACS systems for computer polyvalent monitoring of the equipment condition // Energy-saving and power engineering in Omsk region. - Omsk: 2003. - № 4(9). - p. 48-49
The paper presents the strategy of integrated continuous control of equipment condition that is based on real-time acquisition and analysis of objective instrumental data on actual technical condition of equipment. The data sources are the complexes of acoustic emission monitoring of capacitive equipment (vessels, instruments, pipelines, etc.) and the complexes of condition monitoring of rotating equipment (pumps, compressors, fans, smoke exhausters, etc.) by the parameters of vibration, current and temperature.
This strategy is implemented in the COMPACS® systems for computer monitoring of the machinery condition, which enables complete elimination of sudden failures, increase of safety and cost efficiency of operation of hazardous production facilities and comprehensive solution of a problem of increasing run-to-failure period of equipment provided transition to operation in accordance with the actual technical condition.
Problems associated with wear of basic production assets of hazardous production facilities of chemical, petrochemical and oil refining enterprises and actual condition of process equipment necessitate search, development and implementation of modern advanced technologies for monitoring of the equipment condition and systems for maintenance based on the principles of use of actual resources of safety. Experience of development and maintenance of modern control and diagnosing systems based on the methods of acoustic emission and vibration monitoring enables realization of the basic principles of the strategy of preventing maintenance, safety and resource-saving technologies.
Shatalov A.A., Razuvaev I.V., Kostyukov V.N. Experience of realization of the strategy of petrochemical plant safeguarding during operation in accordance with the actual technical condition // Chemical technique. - M.: 2003. - № 3. - p. 11-13
The COMPACS® complex of methodical means and firmware provides new technology of resource-saving and safe operation of equipment. Direct economic effect of the implementation of such technology at the enterprises is achieved by the saving through the elimination of accidents caused by machine equipment, reduction of losses caused by the downtimes of process complexes, and reduction of repair expenses.
The advantages of the COMPACS® systems: high reliability, comprehensive self-diagnostics of the firmware, comprehensive monitoring of the personnel actions, use of equipment during the whole operating life. That enables continuous elimination of major causes of equipment failures, minimization of flow of requirements for maintenance of equipment and systems.
Application of the COMPACS® technology makes the operation of fixed assets manageable, reduces losses, saves material, financial and human resources, and increases capitalization of overall business.
Kostyukov V.N. Profitability based on resource-saving safety in petrochemical industry // Branch meeting proceedings. - Perm: 2002