In modern conditions, the growth of refinery production efficiency can be reached mostly by increasing machinery operation time between repairs and decreasing operation costs for machinery maintenance and repair which is impossible without its high operational reliability.
Traditional methods of maintaining machinery operability based on PPM are low-effective and do not ensure the required time between repairs and production safety rates. In that connection, for the last 25 years, the COMPACS Systems has been implemented nation-wide to ensure safe resource-saving operation of machinery by means of real-time condition monitoring.
Kostyukov V.N., Boychenko S.N., Kostyukov A.V. Automated control systems for safe resource-saving operation of equipment for oil refining and petrochemical industries (ACS SRO) / Ed. V.N. Kostyukov. Moscow: Mashinostroenie, 1999.163 p.
Kostyukov V.N. Production safety monitoring. Moscow: Mechanical engineering. 2002.224 s.
Kostyukov A.V., Kostyukov V.N. Improving the operational efficiency of enterprises based on real-time monitoring. Moscow: Mashinostroenie, 2009, 192 p.
Kostyukov V.N., Naumenko A.P. Fundamentals of vibroacoustic diagnostics and monitoring of machines: a textbook. Novosibirsk: Publishing house of the SB RAS, 2014; 378 p.
Chepurnov P.E., Kudryashov V.A., Berezhnoy A.N., Kostyukov V.N., Kostyukov A.V., Sinitsyn A.A. Innovative highly efficient resource-saving technology for operation of rotating equipment of process units of JSC Kuibyshevsky Refinery based on condition monitoring systems // Chemical Engineering. 2015. No. 12. P. 16-20.
Kostyukov A.V., Sinitsyn A.A., Kazarin D.V., Zarubina D.S. Maintenance of Safe Resource-Saving Operation of Equipment Under The Control of The COMPACS Systems // Improving the reliability and safety of the equipment of refinery production units. - Moscow: OOO "Council of Chief Mechanics", (December 5-6, 2016, Moscow) - 2017 .—512p., p. 192-198.
The aim of this work is to study the applicability of an automated stand for testing of machinery monitoring and diagnostics systems.
The work covered determination of algorithms and principles that this stand is based on.
Using the data of requirements and criteria, we developed a stand for automated testing of monitoring and diagnostics systems for pumps and compressors during a facility acceptance test.
The obtained results indicate the feasibility of application of such stands. Applying the stands allows to reduce labor costs while making the testing more full and accurate.
Kostyukov Al.V., Kazarin D.V., Efimov A.V. Automated testing stand for machinery diagnostic and monitoring systems // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2015. – p.124-131.
The work aimed at studying into applicability of control methods for partial discharges parameters for induction motors with an operating voltage of 380 V.
The study identified the theoretical background of possibility for the partial discharges inception at low supply voltage. Using existing methods of the partial discharges parameters recording, the measurements were carried out on a large number of low voltage electric motors.
The obtained results confirm the partial discharges presence in the low voltage motors and point to the feasibility of the partial discharges monitoring methods application in insulation of the critical low-voltage motors.
Kostyukov Al.V., Boychenko S.N., Schelkanov A.V., Burda E.A. Study of electric discharges activity in induction motors with an operating voltage of 380 V // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2015. – p.96-101.
The features of Real-time condition monitoring of machinery and the differences from On-line and Off-line condition monitoring are considered. Taking into account a human factor, the monitoring system model has been reviewed. This model shows that observability of the units state and the entire production complex equipment can be provided by measuring the diagnostic signals (vibration parameters) and rate of their change, which show accurately within scale the generalized units errors and rates of their growth, as well as residual life and its reducing, and the whole complex safety.
Determinate partial ageing functions and their rates, defined by the generalized errors, structural parameters and rates of their growth are offered to be used as variables of the unit’s state. Regularities for petrochemical complex units operation based on a sporadic character of control actions, which are the framework of the monitoring system generalized model, are identified taking into account the human factor.
Technical state of the production complex and correspondingly the risk of its operability loss are offered to be evaluated according to a minimum residual operability and a maximum rate of its loss, observed by the diagnostic and monitoring systems among the units group composing the complex. The required operational speed of the diagnostic and monitoring systems (DMS) is offered to estimate the maximum rate of the petrochemical complex residual operability loss according to the observability criteria of the monitoring theory Conclusions:
Monitoring allows to transfer the equipment and production complexes failures from a “sudden” to a “gradual” category;
Necessity of the failures reduction by ten times and corresponding increase of the equipment run-to-failure requires decrease of the monitoring mistakes to minimum (zero);
Decrease of a statical error and the implementation period reducing up to some months requires development of diagnostic methods and standard techniques invariant to the equipment type diagnostic features formation;
Decrease of a dynamic error requires a significant excess of the monitoring pace over pace of failures development at the production complexes, thus excluding a manual labor by means of automation of all monitoring processes: from parameters measurement and automation of a diagnostic output of information on the equipment state up to its unhampered and timely delivery and presentation to all levels of the production complex control.
Kostyukov V.N, Kostyukov A.V. Real-time health monitoring of machinery malfunctions // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.83.
Current Russian and International standards in the field of standardizing parameters for piston machines vibration including piston compressors are reviewed. It is shown that the current standards do not meet the requirements for the piston compressors safe operation at hazardous production facilities. The article describes the Russian Federation National Standard "Condition monitoring and diagnostics of machines. Hazardous equipment monitoring. Vibration generated by rotodynamic pump and compressor units".
Kostyukov V.N, Naumenko A.P. Standardization in vibration monitoring of piston compressors // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.82-83.
Operation experience and results of the COMPACS® stationary system for machinery health monitoring and automatic diagnostics are given. The system manufactured by DYNAMICS SPC is intended to prevent sudden failures and breakdowns of the CDU-VDU equipment, shifting them from the sudden to the observed category. The system warns the staff about changes in the equipment technical state, giving recommendations to take urgent actions in order to lead the equipment into "acceptable" technical state.
Description of the system operation in real conditions is given, and analysis of the dynamic equipment operation is carried out. Reasons of the equipment failures are described, and recommendations for improving technical and economic parameters of the equipment operation and maintenance cycle optimization are offered.
Kostyukov An.V., Kostyukov Al.V., Tarasov E.V., Putintsev S.L., Chatkin A.P. Operation of equipment for primary oil processing under control of the COMPACS stationary system for health monitoring and automatic diagnostics // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.81.
The efficiency of malfunction detection for machinery protected by diagnostic and condition monitoring systems is strongly dependent from quality of their tuning, full and objective examination during post-production acceptance tests. However, the task of minimizing the influence of human factor on design quality check-up and tuning process can be successfully solved by automatic test benches.
A test bench provides automation of the most laborsome tasks, such as:
Diagnostic feature calibration in measuring channels;
Metrological check-up for measuring channels;
Expert system check-up, including defect signal formation and registering of the expert system messages;
Automatic formation and printing of a test report, as well as database storage of the results.
Tarasov E.V., Kazarin D.V., Zaytsev A.V., Pavlenkov D.V., Kostuykov V.N. Automatic test bench for machinery diagnostic and condition monitoring systems // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.80-81.
The research is based on the data obtained by an on-board monitoring system COMPACS®-EXPRESS-3 and aimed mostly at increasing reliability of machinery diagnostics of rolling stock units (in electric trains) by finding codependences in changes of vibration diagnostic features during condition degradation process from analyzing statistic properties of their distribution.
At the same time, the results obtained during the course of work are invariant to the diagnostic subject and can apply to machinery in hazardous production facilities in FEC.
The completed research allowed to establish the criteria according to which the cases of defect development were found using trends of vibration diagnostic features.
Tsurpal A.E., Kazarin D.V., Dederer Ya.V., Kostuykov V.N. The research of vibration activity of machinery units by vibration parameter trends // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.78-79.
The paper is aimed at researching the influence of rotation frequency and condition of rolling bearings on the level of vibration spectrum components which corresponds to the frequencies of rolling element bearing defects exposure.
The research is based on a theory of experimental planning using an experimental stand to assign frequency and record vibration signals. Different types of bearings have been subjected to the experiment: regular rolling bearings as well as rolling bearings with artificiality created defects and bearings with defects obtained during long-term operation.
The obtained results show the direct dependence between the level of spectrum components corresponding to the frequencies of rolling bearing defect exposure and rotation frequency. It should be noted, that such sensitive dependence is directly connected with condition of the rolling bearing under analysis
These results laid a foundation for creating mathematical models of rolling bearings vibration used in automatic expert systems for rolling bearing diagnostics.
Basakin V.V., Kazarin D.V., Zaytsev A.V., Teterin A.O., Kudryavtseva I.S. The research of rotation frequency influence and technical state condition upon the level of vibration spectrum components of rolling bearings // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.79-80.