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
Experience of long-term operation of the COMPACS® systems for automatic vibration analysis and computer monitoring of technical condition of machinery enabled to accumulate the data on the diagnostics of reciprocating compressors.
In order to make the analysis vibration sensors were installed at different points. Vibration examination of the compressor with the COMPACS®-micro portable system usually preceded the mounting of sensors.
Thus far the information has been accumulated, and the algorithms of operation of expert system for diagnostics of hydraulic impacts, loosening of piston nut, wear of rod seals and babbit layer of the slider have been developed.
Kostyukov V.N., Naumenko A.P. Vibration analysis of reciprocating compressors // Compressors and pneumatics. - M.: 2002. - № 3. - p. 30-31
Energy-saving and reduction of power consumption of equipment are vital problems for modern businesses. One of the ways to solve them is equipment operation in conditions ensuring energy-saving.
The analysis of operation of equipment most accepted by the enterprises - pumps, compressors, fans, electric motors - showed that electricity consumption may be reduced by 15-25% by improvement of its technical condition, which requires timely determination of equipment condition and unfavorable operating conditions, informing service and managing personnel in case of degradation of technical condition and violation of operation conditions in order to take urgent measures.
The assigned task is successfully solved by various systems: the COMPACS® system for vibration monitoring and vibration diagnostics, the COMPACS®-micro personal system, vibration diagnostics systems for repair departments integrated into diagnostic network Compacs-Net®. The analysis of sources and reasons for immediate effect after the system implementation permits to affirm that real-time vibration monitoring of equipment complexes enables company profitability on the basis of resource-saving safety.
Kostyukov V.N., Kirillov V.I. Energy-saving based on real-time condition monitoring of equipment // Energy-saving and energetics in Omsk region. - Omsk: 2002. - № 4 .- p. 95-98
Self-diagnostics of the firmware is the most important feature of modern systems for vibration diagnostics and vibration monitoring containing thousands of measuring channels and tens of thousands of diagnostic features.
We have developed the system for vibration diagnostics and vibration monitoring with self-diagnostics of overall measuring and transforming channel, which is realized by the signal injection into the circuit of detecting element of the sensor and its further analysis by the firmware.
The system ensures reliable diagnosing of failure of the sensor or cable routings. The system displays a message in the form of a "blue" corner at operator's desk situated in petrochemical complex, and at the stations of users of vibration diagnostic network, including the specialists of control equipment and automatics. This solution ensures quick elimination of causes of malfunction and failure, high metrological reliability, high availability, possibility of trailbuilder operation by actual technical condition.
Kostyukov V.N. Self-diagnostics of vibration diagnostic systems // Control. Diagnostics. - M.: 2002. - № 9. - p. 18-22
Operation of complicated productions including hundreds and thousands of units of machine and process equipment is only possible with the information on its technical condition being submitted to the company administration. Repair and modernization of equipment, reconstruction of sections, shops and factories require reasoned decisions based on reliable information on the causes of insufficient productivity, frequent repairs, downtimes, production malfunctions and emergency situations.
Information on the equipment condition (diagnosis) is obtained through the means of technical diagnosing, and their reliability is determined by the prescribed methods of diagnosing, measurement precision, diagnostician skills and quality of adjustment of devices to informative characteristics of the signals of diagnosed object.
The article presents some results of development and application of the systems for vibration analysis and monitoring of assembling and mounting of machines and units. Their use has prospects for engineering because it enables to increase reliability and service life of output products without significant reconstruction of manufacturing and process base and subsequent huge expenses.
Kostyukov V.N. Diagnostics of quality of assembling and mounting of equipment // Assembling in mechanical and instrument engineering. - M.: 2002. - № 7. - p. 25-32