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
Safe operation of the compressor units with reciprocating compressors (CU with RC) operating on explosive and noxious gases is possible only by continuous monitoring of their technical condition.
At most enterprises of oil-refining industry CU with RC are almost beyond their service life, and it is necessary to make an examination of industrial safety in order to prolong their service life. In addition, schedule-based preventive maintenance and repair are not economically feasible and efficient, and more than once it was proven in practice and examples of centrifugal equipment. The only way out is equipping of CU with RC with condition monitoring systems using various methods of nondestructive testing and process variables and transition to operation, maintenance of reciprocating compressors by their actual technical condition. Therefore, the development of methodology and systems for condition monitoring of CU with RC is a topical problem.
The article gives scientific definitions of condition monitoring, technical diagnostics, technical diagnosis, diagnostic feature; it presents the principles of monitoring system structure, data collection, data analysis and processing, time selection of the signals, spectral analysis, envelope analysis, trends, pattern identification, emergency shutdown and presentation of monitoring results.
Kostyukov V.N., Naumenko A.P. System for condition monitoring of reciprocating compressors of oil-refining industries // Refining and petrochemistry. - M.: 2006. - № 10. - p. 38-48
The process of coking is widely used for processing of heavy still bottoms. It enables to improve the depth of oil refining and thus increase the enterprise profitability.
21-10/ZM unit releases through the complicated process involving hundreds of units of machine and columned-capacitive equipment. The failure of any element of a technological cycle may not only cause the decrease of quality and output but also result in emergency shutdown.
In order to ensure reliability of production it is necessary to know technical condition of equipment in operation, timely detect assemblies with critical technical condition and prevent emergencies.
Equipping of the machinery of Omsk Refinery with the COMPACS® stationary system enabled accident elimination. So-called sudden failures stopped. 'Suddenness' occurs in case of absence of the supervision over the processes of defects emergence or development, and consequently their growth to a critical level up until the accident.
Kostyukov V.N., Shatalov A.A., Anisimov V.F., Tarasov E.V. There are no sudden accidents: Improving of the efficiency of 21-10/ZM unit operation on the basis of equipment condition monitoring // Oil of Russia. - M.: 2006. - №7. - p.78-81
The necessity of accident-prevention protection of powerful compressors and other unique equipment has never raised doubts of the experts. In order to ensure technological system tolerance for disturbances, including failures of process and pump-and-compressor equipment, it is necessary to trace external and internal factors that influence the system and characterize its technical condition.
In order to manage the system condition it is necessary to take technical and organizational measures. Equipment accidents at Omsk Refinery caused safety decrease, loss of efficiency and downtime of process equipment and thus inflicted economic damage, exacerbated environmental problems.
Under the circumstances in the late 1980s the company administration had decided to implement stationary systems for equipment condition monitoring and first of all stationary vibration analysis of machinery. The specialists of Minaviaprom engine research institute, who developed and implemented the devices and systems for vibration analysis of aircraft units, got involved in the work. Later these specialists formed the main body of Scientific Production Company "Dynamics".
Kostyukov V.N., Pidsadnij A.S., Sagirov V.H. Safe resource-saving operation and repair as a part of economic policy of the plant // Refining and petrochemistry. - M.: 2005. - № 18. - p. 45-49
Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS® solve the following problems: vibration analysis and prediction of major malfunctions of equipment with early detection, full use of resources and retention of maintainability; monitoring of execution of diagnostic instructions and personnel actions through network (Internet) engineering; elimination of design and installation mistakes; optimization of flow charts and configuration; keeping of the databases of diagnostics, works, equipment replacement and service life; reporting at all control levels of the enterprise.
The Compacs-Net® network for vibration analysis is of service in on-line monitoring of execution of instructions of automatic systems for vibration analysis. The central element of the CompacsNet® network for vibration analysis and the collector of diagnostic information is the server that periodically examines the COMPACS® stations connected to a diagnostic network and saves the findings as SQL-database.
Internet-based technologies integrate various systems for vibration analysis of equipment condition, which are located hundreds of kilometers apart, into single information complexes used in ACS SRSM™ COMPACS®, improve observability and controllability of equipment, and increase the systems efficiency by significant reduction of maintenance costs.
Kostyukov V.N., Boychenko S.N., Kostyukov Al.V. Internet technology in the COMPACS control systems for safe resource-saving operation of equipment // Oil Industry. Innovative Technologies in Oil and Gas Industry. - M.: 2005. - № 10. - p. 104-107
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