The paper dwells upon the basic concepts of choosing condition monitoring system for pump and compressor units of refinery production of various categories of hazard (according to GOST R 53563-2009), increasing units’ run-to-failure time and accident-free resource-saving operation.
The paper describes basic principles of monitoring and real-time diagnostics systems building, specifications of the system’s software and hardware based on selection and rationalization of classification factors according to GOST R 53564-2009. The correlation between failure skipping risk and system’s class is shown.
The main goal of equipping hazardous production facilities with a comprehensive monitoring system is to ensure safe resource-saving operation of machinery by means of preliminary control actions providing necessary stability margin, high-quality rates of its functioning and technological, ecological and economical safety.
Kostyukov V.N., Naumenko A.P., Tkachenko A.A. Concept of selection and rationalization of pumps condition monitoring system specifications // Increasing pump units’ reliability. Analysis of existing pump systems. Basic concepts of design and choice of pump units for refinery and petrochemical companies: from the expert meeting. – Moscow: Council of Chief Mechanical Engineers, 2014. - p. 81-101.
Main source of continuous production enterprise’s profitability comes from decreasing operational costs and losses due to accidents and production downtime caused by sudden breakdown of machinery units. Reliability analysis of oil and petrochemical companies shows that more than three forth of equipment failures are failures of machines and mechanisms, which often leads to accidents and production defects, downtime of production facilities and units. About 80% of mechanical equipment at refinery production today, are pumps and compressors. That is why condition of production facilities mostly depends on the condition of their pumps and compressors.
The solution for low-objective assessment of machinery condition in actual operation is condition monitoring with automatic expert systems providing decision-making on the basis of the machinery condition and repair time. Such an expert sub-system is an integral part of the COMPACS® automated control systems for safe resource-saving operation of machinery. The systems are implemented at dozens of oil and petrochemical companies of Russia.
The article describes methodical basis for providing safe operation of pumps and compressors at hazardous productions, an example of practical application of vibration-acoustic method of condition assessment and signal spectral analysis for machinery parts deterioration and early development of hydroshok.
Kostyukov V.N., Naumenko A.P., Boychenko S.N. Increasing reliability of pump and compressor units based on monitoring of failures and operation risks // Nasosyi i oborudovanie (Pumps and equipment). - 2014. №4-5, p.28-31.
The article is devoted to real-time monitoring of the equipment failure omission risk using data from computer systems for accidents prevention and machinery condition monitoring COMPACS®. To prove availability of connection between the equipment operating time in different states and the consequences that arise from adverse events, the necessity to determine such events and specify their consequences, as well as to calculate their occurrence frequency depending on operating time, has been shown.
The article includes assessment of possible and probable failures consequences for the units being operated in on unacceptable technical state according to results of the monitoring systems implementation.
The authors have concluded that the automatic calculation and real-time monitoring of the units failure omission risk of hazardous production facilities can be performed only by stationary systems for the equipment health monitoring and presented to all the refinery management levels. This allows the management not only to assume but to know exactly the existing risk level, which is conditioned by the prevailing housekeeping, as well as to make decisions aimed at risk decrease, i.e. to provide the most effective strategy of risk management.
The article describes the examples of the COMPACS® vibration monitoring system application for accident prevention of Reftinskaya GRES equipment: air-blowers, hot-blast fans, smoke exhausters, booster pumps, etc.
Equipping supplementary machinery with the COMPACS® condition monitoring stationary system eliminates accidents and converts “sudden failures” into “gradual” and “observable” and “controllable” by providing expert messages shown on the display covering all problems in diagnosed machinery. Due to that, machinery is ensured to be decommissioned for repair once it utilizes its full resource (reaching “Actions required” or “Unacceptable” condition) with full reparability. Automatic diagnostics provides after-repair commissioning of the machinery with objectively evaluated condition and ensured high quality of repair in “Acceptable” condition.
Application of a condition monitoring system allows to determine the causes of failure nucleation and development, as well as to find the fundamental causes of failures and help personnel to take precise actions for ensuring long-time accident-free operation of machinery.
Diagnostics of cavitation mode plays an important part in safe unit centrifugal pump operation, as soon as cavitation presupposes massive destruction of rotor wheel surface and pipe-lines, and additional vibration loads on unit construction. Currently, the main method of pump unit cavitation mode monitoring is spectral component analysis of case vibration signal. However, spectrum analysis requires precise data on pump unit construction (number of blades on rotor wheel, bearing types). Lack of such data or its irrelevance to the real one will lead to errors in cavitation mode measurements. Consequently, still, one of the urgent problems is development of new cavitation diagnostics methods using algorithms invariant to construction type of the unit.
The article dwells upon cavitation diagnostics of pump units by means of modern non-linear dynamics trend - fractal theory in which Hearst index related to a vibration signal dimension is used as a diagnostic feature. The main advantage of this feature is its invariance to the signal level and, consequently an independence from power and size characteristics of the unit.
The results of Hearst index usage during processes of pump unit testing and operation are also given in the article. It is shown that sensitivity of the feature equals or, in some cases, exceeded sensitivity of a spectral method.
Consequently, Hearst index allows to increase reliability rates of results issued by expert system of centrifugal pump unit health diagnostic system.
Kostyukov V.N. Production safety monitoring. Moscow: Mashinostroyeniye. 2002. 224 p.
Kostyukov V.N., Boychenko S.N., Kostyukov A.V. Automated systems for control of safe money-saving operation of oil-refinery and petrochemical productions (SMSRTM COMPACS®) [edited by. Kostyukov V.N.]. Moscow: Mashinostroyeniye. 1999. 163 p.
Kostyukov V.N. Synthesis of invariant diagnostic features and models of unit condition for diagnostic purposes// Omsk scientific bulletin 2000. Issue 12. p. 77-81.
Mandelbrot B.B. Fractals and chaos. Mandelbrot's set and other miracles. Moscow – Izhevsk: Research Center "Regulyarnaya i haoticheskaya dinamika" 2009. 392 p.
Feder E. Fractals – Moscow: Mir, 1991. 254 p.
Kostyukov V.N., Boychenko S.N. Real-time diagnostics and monitoring of pump unit cavitation mode // Condition Monitoring and Machinery Failure Prevention Technologies (СМ/MFPT 2014)
The authors assess the existing system of operation and maintenance of railway rolling stock in Russia; identify its main disadvantages and challenges. They argue that it is crucial to organize reliable condition monitoring of the most critical equipment.
Following the description of the features of transverter of electric train, they suggest a method of its troubleshooting which is based on monitoring of parameters of spectrum of three-phase alternating current. The method refers to both operational and pre-accident conditions of devices. Adequacy of the procedure is tested and confirmed on the basis of data obtained during the operation of the experimental unit.
Kostyukov V.N., Tsurpal A.E. Troubleshooting of transverter of electric train under operation conditions // Mir transporta. - 2014. - №4. - pp.46-53
Urge to improve the railway transport operation reliability makes it a serious concern – to solve a problem of observation and control over the equipment’s condition at any stages of its operation life. It is not a secret, that lack of objective assessment of manufacturing and repair of equipment, as well as not enough observability over real processes of condition deterioration at the operational stage may interfere with ability to make efficient, economically and technologically justified measures on sustaining high reliability rates for the equipment.
Great number of various diagnostic and control means available to industrial and service companies does not guarantee high-quality assessment of equipment condition. There is one more problem – practical application of diagnostic and control results requires their availability for all management levels. The solution for such problems may comprise an automatic system for continious monitoring and diagnostics.
Sizov S.V., Aristov V.P., Kostyukov V.N., Kostyukov Al.V., Kazarin D.V. Automated control system for safe resource-saving operation and maintenance of rolling stock – COMPACS // Delovaya slava Rossii: Interindustrial almanac. - 2014. - №3 (46). - pp. 14-16 (http://www.slaviza.ru/1406-cistema-monitoringa-sostoyaniya-oborudovaniya-elektropoezdov.html)
It has been almost 25 years since DYNAMICS SPC took up fundamental and applied research and development works, production and wide-scale implementation of the COMPACS® automatic diagnostic and condition monitoring systems into refinery and petrochemical companies.
The presented basic approach towards provision of petrochemical safety based on automated control systems for safe resource-saving operation of machinery – COMPACS® allows full utilization of each refinery enterprise and the whole company in general, and adopting the technology of safe resource-saving operation of machinery in real time which provides maximum possible run life at minimum operational costs. A perfect example of utilization of such approach is Syzran Refinery, JSC.
Kostyukov A.V., Sinitsyn A.A., Tkachenko A.A. General approach towards safety of refinery and petrochemical companies // Business&Class. - 2014. - June-August. - pp. 26-29.
The paper is aimed at determining possibility to provide reliable condition assessment of rotary units of mechanical part of rolling stock during operation and with acceptable cost of single diagnostic act. To reach that goal one need to develop a list of experimental researches of vibration acoustic processes and to create an experimental device for signal measurement.
The paper presents the results of development of the experimental device used within the framework of an integrated program of research of vibroacoustic processes to obtain data on vibration of mechanical components of rolling stock working in real operating conditions. The device enables prolonged continuous stream recording of signals from transmitters, in particular, from vibration sensors in the band to 900 kHz.
Results of the analysis of data obtained using the experimental device have been used as a basis for train component diagnosis algorithms, implemented in onboard condition monitoring systems COMPACS®-EXPRESS-3, installed on modern rolling stock.
Kostyukov V.N., Zaytsev A.V., Tsurpal A.E. A device for experimental studies of vibration of rolling stock components during operation // Transport of the Urals. - 2014. - №2. - pp. 77-80
The most important result of Soviet era of vibration monitoring development is a prove of considerable impact that errors in assembling and operation of machine have on its residual life, and also possibility of predicting the residual life span by the vibration diagnostics results.
For production and transport industries the fundamental reasons of high costs and losses are determined by subtle occurrence and development of faults, as well as poor observability of actual processes of machinery deterioration during its whole lifespan.
Stability can be achieved by means of observability and controllability, when all monitoring processes are coupled together and monitoring time does not exceed the shortest interval of machinery fault development.
The shortest monitoring period can be achieved by the in-built automatic expert system revealing all main problems to the personnel operating the machine and forwarding this information through the automatic diagnostic network to the managers and production heads.
Kostyukov V.N. Innovative technology for machinery “health” monitoring for accidents prevention and condition-based operation of machinery – Russian technological break-through // Modern approaches towards selection of equipment and materials during project development, building and operation of production facilities of refinery and petrochemical companies: proceedings of the Council of Chief Mechanics meeting