Machinery operation is often connected with professional risks. It is counter-productive to reach absolute safety with economical means, because it leads to irrational expenditures. That’s why to control the safety one requires efficiency using systems of analysis methods and assessment of possible dangers with quantitive risk factors.
The paper briefly shows real-time monitoring of machinery failure skipping risk using the COMPACS systems of computer monitoring for accident prevention and condition control.
Kostyukov V.N., Kostyukov A.V., Kostyukov Al.V. Real-time Monitoring of Machinery Operation Minimize Risk of Accidents // Economy and life. – 2015. – №24 (9590) (http://www.eg-online.ru/article/284218/).
The COMPACS® systems is a 100% innovative Russian product, implemented at more than a hundred enterprises in Russia and abroad, and the basis of technology for safe resource-saving operation of machinery.
Such systems provide timely personnel warning on the unacceptable condition of the diagnosed technical facilities by providing instructions indicating a malfunction or defect to be eliminated and, as a result, to avoid accidents, production failures and downtime.
Kim V.E. The resource-saving operation is a key to a highly effective policy of an advanced enterprise // Tehnadzor. – 2015. – №5. – p. 65.
Problems of technical safety and resource-saving in production and transport industries were always topical, but recently, need in their solution became more urgent. This is due both to the growth of volumes and complexity of production, and to a significant decrease in the level of personal responsibility and qualification of personnel of enterprises operating hazardous production facilities.
Besides, there are fundamental reasons of the existing machinery reliability problems at facilities, which mostly comprise hidden nucleation and development of machinery failures, as well as subjective and not timely assessment of machinery condition in real operational processes. That does not allow the personnel to carry out timely and efficient procedures in order to support high technical readiness level of the production. Consequently, the enterprise bear significant operating costs and losses from accidents and downtime of production associated with the sudden failure of process equipment.
The above-listed factors cause an urgent need for general application of automated control systems for safe resource-efficient operation and equipment repair at the hazardous production facilities.
Kostyukov V.N., Kostyukov An.V., Kostyukov Al.V. Automated control systems for safe resource-saving operation and maintenance COMPACS // Glavniy mehanik (Chief Meachnical Engineer). – 2015. – №4. – P. 66-73.
The paper dwells upon the method of calculation of guideline values of diagnostic signs in terms of statistical decision-making theory. It gives an example of calculation of the probability of the defect skipping and false alarms, the risk of the failure skipping while selecting the size of the regulatory characteristic of different decision-making methods.
It is shown that it is reasonable to use a method of minimum number of false decisions if the costs of false alarms and defect skipping are comparable. If the defect skipping cost is considerably higher than the cost of the false alarm it is advisable to use method of Neumann-Pearson. Selection of threshold values of diagnostic signs according to their distribution functions for different states of a machine under diagnostics should be made when the probability rates are >0.93 and <0.95.
Kostyukov V.N., Naumenko A.P. Risk assessment of selection of guideline values of diagnostic signs // Condition Monitoring and Machinery Failure Prevention Technologies (СМ/MFPT 2015)
The paper dwells upon new approaches towards imbalance diagnostics for both – separate rotors and shaft rotors. The methods are based on comprehensive usage of sensors for absolute support displacement and relative/absolute shaft displacement.
There are a lot of tasks to be solved with such sensors’ application, but the main one is the diagnostics of imbalance and its spreading area. The present paper covers only that one task.
Along with minimizing the absolute radial vibrations of journals and supports, it is also suggested to minimize turning angles of journals and consequently decrease the residual rotor vibration. The method can be utilized witht the COMPACS® system and intended for morden systems of imbalance monitroing and diagnostics and its automatic detection.
Kumenko А.I. Balancing of flexible rotors and shafting systems based on the COMPACS systems with the use of shaft sensors // Neftegaz.ru. – 2015. – №3. – p. 58-61.
Safe resource-saving operation of the machinery of the industry and transport branches is a very urgent task. Real-time condition monitoring of the machinery provides observability and allows to implement safe resource-saving technology of the machinery maintenance and repair. This paper considers the experience in operation of systems for health monitoring of hazardous production facilities and the machinery of energy sector and rail transport in case of smooth or discontinuous changes in vibration diagnostic features that reflect the corresponding multi-stage processes of destruction machines generating multimodal trends vibration parameters.
The paper proves that real-time condition monitoring systems increase diagnostics productivity in million times in comparison to "manual" tools, and provide economical effect for a consumer due to:
Increase of technogenic safety and machinery run-to-failure in dozens and hundreds of times.
Increase of readiness coefficient and main production assets usage coefficient.
Kostyukov V.N., Tarasov E.V. Real time vibration-diagnostic condition monitoring of production and transport complex machinery // Condition Monitoring and Machinery Failure Prevention Technologies (СМ/MFPT 2015)
The paper dwells upon the results of implementation of the stationary system of condition monitoring and automatic vibration analysis COMPACS® for elimination of sudden failures of thermal power station units. A description of the system’s functions, capabilities and application advantages are presented in the paper. There are detailed examples of the operation of auxiliary equipment, mainly, rotating aggregates, under the system’s control.
Kostyukov V.N., Tarasov E.V., Putintsev S.L. Safety operation monitoring of thermal station facilities // New in Russian Power Industry (Novoe v rossiyskoy elektroenergetike). 2015. – #2. – p. 6-13.
PJSC Enel Russia has been cooperating with DYNAMICS SPC since 2009. Current situation at the power industry enterprises is that the control and emergency shutdown systems are equipped in operation only at the main power mechanisms – turbine units. At the same time, several dozens of auxiliary machines (mills, blowers, smoke exhausters, power, condensate, circulating, network pumps, cooling towers) are used to support the operation of one turbine. Also, there are a lot of auxiliary machines that are operated without a reserve, and their sudden failure leads to reduction of volume and quality of the generated electric power and, consequently, to a complete shutdown of the turbine.
In this connection, PJSC Enel Russia has begun stage-by stage procedure of equipping the auxiliary machines of thermal power stations with the COMPACS® systems.
Equipping the auxiliary machines of Reftinskaya State District Power Station with a stationary condition monitoring and automatic diagnostic system COMPACS® has allowed to eliminate accidents and, so called, “sudden failures”, to make them “gradual”, “observable” and “controlled” by timely warnings for the personnel. Thanks to that, machinery units are decommissioned for repair only after full usage of their resources and with full reparability. The automatic diagnostics carried out by the COMPACS® system ensures the after-repair commissioning of the unit with an objective assessment of its condition and guaranteed quality repair with the "Acceptable" technical condition.
Kostyukov V.N., Tarasov E.V., Putintsev S.L. DYNAMICS SPC: On Safety Guard // TOP Energoprom. - 2014. - November-December. - p. 28
All major factors causing high operational expenses and losses due to failures are revealing in machinery operation life, when cumulative damage directly depends on timeliness of failure detection and adequacy of personnel actions depending on various speed of resource losses due to wear of machinery elements. The later the personnel reacts to worsening of machinery condition the greater resources are required to restore it, and if the situation is critical the total costs may exceed the ones enough for building a new facility. In turn, personnel’s reaction rate is determined by two main factors: machinery condition observability and adequacy of reaction to its worsening which mostly is influenced by manager’s being demanding and aware of the situation’s criticality level.
Thus, it is necessary to ensure failure skipping risk monitoring in real-time, i.e. provide managers of all levels with financial assessment of the current rates of possible costs and losses to the company in existing operational conditions of hazardous production facilities. Observability of the machinery degradation process in real time and good labour discipline allow to avoid the risk of accidents.
Data on machinery condition and its malfunctions and developing defects of the most critical parts of a machine are presented by the COMPACS® systems to all levels of production management. The systems automatically, without involving diagnostic specialists, detect all major classes of machinery malfunctions and for each of them issues several prescriptions automatically diagnosing defects of centrifugal and piston compressors, pumps, air-coolers and other machinery. Multiple analysis of maintenance works carried out by system’s prescriptions has revealed that all shutdowns of machines in “Unacceptable” state due to the system’s prescriptions were really necessary. In 100% of cases not only the necessity of maintenance works, but the machinery defects detected by the COMPACS® system were proved to be real.
Kostyukov V.N., Kostyukov Al.V., Kostyukov A.V. Real-time condition monitoring of machinery // Controlling. - 2014. - №4. - P. 44-49.
It is shown in the article, that losses due to machinery operation may be reduced to the minimum by timely and well-aimed maintenance based on real-time condition monitoring and diagnostics of machinery. That allows to use full resource of machinery and to bar its unscheduled (accident-based) repairs. That can be achieved by means of automated control systems for safe resource-saving operation and maintenance of machinery - COMPACS®.
Kostyukov V.N., Kostyukov A.V. Automated control systems for safe resource-saving operation and maintenance of machinery // Modern methods of technical diagnostics and non-destructive testing of details and assemblies - 2014. - №2. - P. 37-43.