The COMPACS® system for computer monitoring carries out vibration monitoring and analysis of centrifugal compressors by means of the sensors of absolute and relative vibration installed on the outside (on the housing of each compressor bearing) and inside (above the rotor shaft) in orthogonally related directions in order to measure and control radial displacements and axial shift of the shaft.
The sensors of temperature, rotational speed and current consumption are used additionally. It enables diagnosing of technical condition and mode of operation of the compressors. Continuous vibration analysis and monitoring of technical condition of the units have positive results.
Every unit may become "good" in case of timely repair and estimation of its quality according to the unit condition by means of the COMPACS® system for vibration monitoring (both stationary and personal - COMPACS®-Micro), which enables to collect vibrations from all points of the compressor unit and transmit them to COMPACS-NET® diagnostic network of engineering supervision or to the Internet in order to analyze and control safe resource-saving operation.
Kostyukov V.N., Starikov V.A., Tarasov E.V. Monitoring and diagnostics of centrifugal compressors // Proceedings of VI International Symposium 'Consumers and manufacturers of compressors and compressor equipment'. - St. Petersburg, 2000. - p. 174-177
The report deals with the problems of vibration analysis of machine equipment on the basis of the analysis of vibration parameter trends. Main modern methods of machine vibration analysis are based on the evaluation of vibration parameters and on the analysis of vibration signal spectra.
Harmonic analysis of the spectrum usually requires knowledge of an exact construction of a machine; and existing methods of vibration analysis and prediction of technical condition do not take into consideration harmful effect of the human factor. Reliability of evaluation of machine equipment condition can be increased considerably by the use of the laws of processes of destruction and operability loss.
The processes of pump-and-compressor unit degradation were researched at a number of Russian refineries by means of the COMPACS® stationary systems for vibration monitoring. The researches concerned showed that rates of operability loss differ at various machine assemblies.
Kostyukov A.V. Evaluation of machinery performability by vibration parameter trends // DYNAMICS OF MACHINE AGGREGATES: Proceedings of the 5th International Conference. - Gabcikovo (Slovak Republic), 2000. - p. 101-104
In order to ensure failure tolerance of a process system it is necessary to monitor the equipment degradation, diagnose and control the equipment condition by giving the personnel notifications concerning urgent immediate actions.
Reliability and service life of the units depend heavily on their vibration; and vibration, in turn, is determined by the errors in manufacture, assemblage, repair and mounting at the unit as well as by operational defects caused by wear, mistakes of maintenance personnel and faults of operating conditions of the unit. That determines the necessity of vibration analysis of equipment condition at all stages of its life-cycle: for evaluation of workmanship, repair and mounting at the unit, for evaluation of technical condition in operation due to wear, mistakes of maintenance personnel and violation of operating conditions of the unit.
During vibration analysis of even one process unit diagnostic information should be collected, processed, presented and transmitted to the personnel in appropriate form during short interval of time (5-10 minutes) determined on the one hand by the maximum speed of malfunction development, and on the other hand – by the necessity of timely detection of mistakes or negligence of maintenance personnel and violation of operating practices which causes the unit failure. Considerable information scope requires the use of only stationary systems for continuous vibration monitoring.
Kostyukov V.N. Vibration analysis and monitoring of the units of plants with uninterrupted cycle // DYNAMICS OF MACHINE AGGREGATES: Proceedings of the 5th International Conference. - Gabcikovo (Slovak Republic), 2000. - p. 95-100
The main types of vibration signals used in the systems for equipment vibration analysis are the signals of vibration acceleration, vibration velocity, and vibration displacement. The parameters of these signals (RMS value, peak value) are in common use in different diagnostic and vibration-survey systems for equipment condition control.
In order to receive the required signal it is allowed to use appropriate sensor as an end device: piezoaccelerometer – for vibration acceleration parameter, inductive sensor of vibration velocity - for vibration velocity, displacement sensor – for vibration displacement.
But most devices and systems for vibration measurement use vibroaccelerometer as an end device, and the integration operations are used for acquisition of the signal of vibration velocity and vibration displacement.
Boychenko S.N. Algorithms for spectral integration of vibroacoustic signals for equipment vibration analysis // DYNAMICS OF MACHINE AGGREGATES: Proceedings of the 5th International Conference. - Gabcikovo (Slovak Republic), 2000. - p. 34-37
Russian refineries are used groups of ten thousand pumping units, basically centrifugal pumps, both Russian and foreign production. It’s power ranges from tens kilowatts to tens megawatts.
Technological settings of primary oil processing, catalytic cracking, catalytic reforming and others contains a different number of units, which ranges from groups of ten to hundred units depending on powers of settings. Specialists never raised doubts the necessity an anti-accident protection a powerful compressor and other unique machines, but not a pumps, which high concentration in modern technological settings however offen was reason of damages and other production troubles.
Really, if we take probability of pump trouble-free operation in day equal 0.99, then for the group of machines, containing 100 units, refusal probability close to 1, and the technological system herewith practically disabled. For reaching stability of a technological system to different perturbations, including failures of motor pumps, it is necessary to provide overseeing with the exterior on it exterior and interior factors describing its availability index of product, and control by its state by means of opportune acceptance of engineering and organizational measures.
Kostjukov V. N., Boychenko S.N., Kostjukov A.V. Vibration monitoring of pumps in Russian refineries // Mimosa Meeting 17, Scottsdale, Arizona, April 12-16, 1999
The introduction of ecologically clean resourse-keeping technology is the main demand of modern production especially in dangerous branches of industry such as oil-gas-refining, oil-chemical etc.
It's impossible to imagine oil-chemical production without reliable accident-free work of technological equipment. By means of computer vibration monitoring COMPACS® system we provide fundamentally new level of safe processes and machine maintenance based on the latest information technologies, saving large financial and personnel resourses.
Kostjukov V. N. Safe Maintenance of The Equipment is The Technology of The XXI Century - Russian Experience // Mimosa Meeting 17, Scottsdale, Arizona, April 12-16, 1999
Researches of the processes of degradation of technical condition of pump-and-compressor units, which were carried out at Omsk Refinery by means of the COMPACS® stationary systems for vibration monitoring, showed that velocities of performability loss widely differ at various unit assemblies.
Therefore, vibration analysis should be carried out in terms of development of the destruction processes; and as far as possible vibration analysis should be invariant to the equipment construction. The accidents of centrifugal pumping units can be prevented by reduction of time required for construction of trends of changes of vibration parameters and for detection of defects of certain elements by the trends concerned.
Vibration of the set of the unit elements, pump and motor rotors, supporting bearing assemblies, coupling, suction and pressure pipelines, and a base supporting the unit should be measured simultaneously during operation of the unit.
Kostyukov V.N., Kostyukov A.V., Boychenko S.N. Diagnostics of pump-and-compressor units by monitoring of vibration parameter trends // Diagnostics of equipment and pipelines: Proceedings of XVII International Theme Workshop. - M: Gazprom, 1997. - p. 187-194
Complexity of reciprocator vibration analysis consists in the cyclicity of operation of moving parts. Vibration signal is almost periodic process, and the wear rate of the unit influences vibration signal level under certain values of crankshaft rotation angle.
However, it is hard to recognize the worn part corresponding to vibration signal change because clearances of different details may cause change in vibration signal value under the same values of crankshaft rotation angle.
The problem concerned can be solved by the following: firstly, 'competent' choice of the number of points for vibration sensors installation; secondly, 'fortunate' location of the sensors on the unit; and thirdly, 'reliable' algorithm for the signal processing. The only criterion for solving of these problems is field experience of the analysis of reciprocating compressor malfunctions at the moment of their repair, and comparison of malfunctions with accumulated data.
Kostyukov V.N., Naumenko A.P. Condition monitoring of reciprocating compressors // Consumers and manufacturers of compressors and compressor equipment: Proceedings of III International Symposium. - St. Petersburg, 1997. - p. 254-256
The paper presents the results of long researches of the authors in the field of development and industrial implementation of the systems for vibration analysis of machines and processes on the basis of measurement of the parameters of secondary static and dynamic (mainly vibroacoustic) processes accompanying technological system operation.
We formulated a number of aufbau principles of measurement and diagnostic systems (MDS) for machines and equipment, which were proven in practice. MDS concerned laid the groundwork for wide implementation of such systems. We showed that the use of IBM-compatible computers enable to simplify the sensors and secondary equipment, improve metrological characteristics of the systems, ensure structural flexibility in coordinates "Cost - Capacity", create an unique man-machine interface (MMI), which exempts the operator from routine reading of indications of hundreds of devices and studying figures on the screen and clearly notifies of necessary targeted actions with minimum requirements to the personnel qualification.
We considered MDS software (SW) structure by example of SW of the COMPACS® system of computer vibration monitoring for accident prevention and condition control; SW concerned was compared with well-known SCADA-systems. In addition, we discussed the results of wide-ranging implementation of the COMPACS® MDS at Russian petrochemical enterprises.
Kostyukov V.N., Kostyukov A.V., Boychenko S.N. Principles of construction of measurement and diagnostic systems for machines and equipment. Actual problems of electronic instrument engineering - 1996 // Measurement in Electrical Engineering: Proceedings of the Third International Scientific and Technical Conference. - Novosibirsk, 1996. - V. 5. - P. 81-86