The problem of increase of anthropogenic safety and profitability is urgent for oil and gas industry in whole and especially for modern refineries with high concentration of power-intensive and potentially hazardous equipment.
One of the most promising ways to solve this problem is implementation of the technology for safe resource-saving operation of equipment on the basis of vibration analysis and real-time condition monitoring based on the new class of systems - Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS®.
Kostyukov V.N., Boychenko S.N., Bezzubov A.V., Mikerin O.B., Fedorinov I.A., Durosov V.M., Lvov O.S. The COMPACS saving system ensures safe resource-saving operation of equipment at OOO LUKOIL-Volgogradneftepererabotka // Automation and information technology. Special edition of 'Oil of Russia' journal. - M.: 2005. - № 4. - p. 101-105
The paper presents the results of long experience of vibration analysis and condition monitoring of reciprocating compressors.
On the basis of the collected data the principles and methodological support for data collection and analysis, which enable vibration analysis and condition monitoring of reciprocating compressors, have been developed in order to determine normative values of the measured parameters.
The paper also presents some results concerning the ways to measure the parameters, collect data, and diagnose the compressors, as well as data processing scheme and some normative values.
Kostyukov V.N., Naumenko A.P. Regulatory and methodological support of reciprocating compressor condition monitoring // Control. Diagnostics. - M.: 2005. - № 11. - p. 20-23
The paper presents statistical analysis of distributions of characteristics of a spectral matrix of vibrations of batch-type equipment by a centrifugal pump unit.
The results of work have been used in the construction of automated expert system (ES) for diagnostics and decision-making in respect of technical condition.
The developed ES is integrated into the software of the COMPACS® stationary system for continuous vibration monitoring and vibration diagnostics, stand systems and Compacs®-micro portable device. Thus, it integrates into the system that provides measurement, storage of the measurements, ES measurements processing and automatic instructions – without the personnel being involved. Consequently, it helps to avoid subjective errors and expenditure of time.
Boychenko S.N. Normalization of characteristics of a spectral matrix of vibrations of batch-type equipment // Collected articles on propulsion engineering dedicated to 175th anniversary of MSTU n.a. N.E. Bauman - M.: 2005. - p. 22-25
Operative reciprocating compressors and those put into operation are almost indispensable equipment of processing trains of petrochemical enterprises. Reciprocators operating for a long time especially require condition control due to the termination of service life of some units and parts with different operating lives.
Automated Control System of Safe Resource-saving operation and Maintenance of equipment of refineries and petrochemical plants (ACS SRSM™) COMPACS® is the most optimized system in terms of the cost of a single channel and explosion safety. ACS SRSM™ COMPACS® realizes the strategy of the minimum cost of the systems for vibration analysis and vibration monitoring.
The COMPACS® system for vibration monitoring of technical equipment enables focused and reliable condition control of the equipment, including reciprocating compressors, prevention of sudden malfunctions and shutdowns, real-time control and correction of the personnel actions by integration of the data from the systems of a single diagnostic network Compacs-Net® with a single database of the monitoring parameters. Thus, the COMPACS® system provides vibration monitoring of equipment condition and promotes transition to operation in accordance with the actual technical condition. Consequently, it reduces material costs of maintenance.
Durosov V.M., Kostyukov V.N., Naumenko A.P., Pidsadnij A.S. Сondition monitoring of reciprocating compressors // Chemical technique. - M.: 2004. - № 6. - p. 6-12
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