Condition monitoring of critical components is essential in ensuring the reliability of rolling stock. The condition of wheel-motor units is monitored using systems of vibroacoustic diagnostics. The effectiveness of diagnostic systems is determined by a combination of reliability, duration, and price. This study aims to develop engineering solutions for improving the efficiency of operation, repair, and maintenance of electric rolling stock. The studies were based on the methods of technical diagnosis, fuzzy logic decision-making techniques, reliability, and probability theories. Experimental studies were conducted on the basis of the experimental design theory. The in-site testing data were obtained during the diagnosis of the wheel-motor units in the railcar depots of the Moscow and October Railways. The use of fuzzy logic in the decision-making model on the technical condition of the wheel- motor units have been substantiated. The lognormal distribution law, which the vibration parameters of wheel-motor units of the electric rolling stock are subject to, has been established. An analytical model that provides the possibility to preset the values of the false alarm probability and the defect missing probability in the diagnosis of wheel motor units has been proposed. The paper offers a scientifically grounded engineering solution for improving the efficiency of operation, repair, and maintenance of electric rolling stock by increasing the diagnostic reliability to 99% and reducing the test duration by 20%.
V. N. Kostyukov, Al. V. Kostyukov, D. V. Kazarin, A.V. Zaytsev Vibration Monitoring of Wheel-Motor Units of Electric Rolling Stock // NDT World. - #3-2017, p.63-68
Equipment reliability is of high importance for companies of the processing and transport industries aimed at increasing their output and reducing unproductive downtime. Decrease in the equipment reliability is associated with progressive wear and negative impact of personnel who blindly, without knowing the real condition, control various production processes. This causes accidents, downtime, high repair costs, and significant loss of profit. The absence of critical progressive defects in equipment and conditions that accelerate their development or increase in the level of danger is called the equipment health. To make the health observed and predictable, the automatic defect and operation risk monitoring, so-called health monitoring, is used,
The purpose in view - improving the safety and efficiency of companies in the processing and transport industries by health monitoring of their equipment - is still a relevant problem to be addressed.
Technically the purpose is achieved by simultaneous monitoring of all equipment that makes up a processing complex using the COMPACS® machine monitoring systems. The monitoring result is a set of diagnoses made for all pieces of equipment at adjacent time intervals, when the health had not significantly changed. The diagnosis is formed based on the algorithms of the expert system, which provide an automatic detection of the type and danger level of equipment malfunctions, as well as the factors that cause destructive loads on it and accelerate the development of malfunctions. The expert system conclusions clearly indicate to the personnel the actions to be taken to eliminate the malfunction, and to overcome the disturbing factors.
The single platform COMPACS® systems monitor health of various equipment during its life milestones. Within one plant ali systems can be combined into a single automated control system providing safe resource-saving operation.
The paper has solved the following issues:
- the authors have developed the methodical backgrounds, and created hardware and software that ensure automatic monitoring of the plant health through the health of its equipment:
- a large number of health monitoring tools have been implemented and tested;
- the authors have created the technology of equipment operation according to its maximum running time with a minimum operational risk.
V. N. Kostyukov, Al. V. Kostyukov, E.V. Tarasov, D. V. Kazarin Automatic Health Monitoring of the Equipment for the Production and Transport Complex // NDT World. - #3-2017, p.19-22
At present time, widely used methods of vibration diagnostics cannot entirely provide required volume of diagnostics of machinery drivers. Specifically, such methods cannot determine condition of the machinery isolation. In order to solve the problem, it is suggested to use a partial discharge method during repair and maintenance of the machinery.
The up-to-date industry mainly uses the asynchronous motors as drivers of the machinery. One of the most common causes of failures is isolation damages. To prevent such failures, it is required to conquer and apply new diagnostics methods.
The purpose of the research is developing a technical solution. The solution, paired with vibration diagnostics, should provide more complete diagnostics of drivers' isolation systems. The partial discharge method was applied for solution of the problem. The method determines and traces the defects of isolation online without use of increased test voltage.
The undertaken study confirms applicability of the partial discharge method at the different stages of machinery operation. The method, as a part of the bench system tooling, controls condition of drivers' isolation of the equipment during its repair and acceptance testing of new equipment. As a part of the system, this method monitors condition of the isolation system of critical tags in real-time. This contributes machinery maintenance according to its actual condition instead of scheduled one. Due to the increase of completeness and profound diagnostics, and elimination of additional time and efforts, combining such methods as vibration diagnostics and partial discharge increases reliability and effectiveness of diagnostics of machinery.
А. V. Kostyukov, S. N. Boychenko, А V, Schelkanov, Е. A Burda Complex Application of Vibration Diagnostics and Partial Discharges Methods at Various Stages of Dynamic Equipment Operation // NDT World. - #3-2017, p.15-18
The stable operation of continuous technological processes directly depends on the accident-free operation of the dynamic equipment that ensures the output of products. On oil refineries, pumping, compressor units, smoke exhausters, air blowers, air cooling units equipped with rolling bearings are widely used. The rolling bearing is the main part, from the technical condition of which the working capacity of the entire unit depends. Monitoring vibration of dynamic equipment in operation allows you to monitor the degree of degradation of its components and parts. The purpose of the study is to develop a methodology for monitoring the process of stage-by-stage degradation of rolling bearings in operation and timely warning of the technological personnel of the oil refinery on the need to take measures to eliminate accidents and incidents.
The vibration monitoring of dynamic equipment in operation at oil refineries was carried out with the help of stationary monitoring systems for the technical condition and automatic diagnostics of COMPACS® and analysis of changes in the technical condition of the units. It is established that in some cases fatigue degradation and subsequent destruction of parts occur in stages. In this case, the vibration emissions reflect the stages of degradation. The developed technique for controlling emission amplitudes and intervals between vibration emissions allows us to detect in a timely manner the presence of a process of stage-by-stage degradation of parts in the operating unit, to warn personnel, to provide preparation for repair work and to prevent emergency situations.
V.N. Kostyukov, Е. V. Tarasov Fatigue Degradation Evaluation of Details and Substructures of Dynamic Equipment in Operation by Vibration Parameters // NDT World. - #3-2017, p.11-14
Integration of the results achieved by Russian scientific and technical institutions with developments in the same fields made by foreign countries gave rise to a conflict of interest and misunderstandings, particularly, in condition control, diagnostics and monitoring. The conflict of interest is, mostly, connected to commercial interests of certain firms and companies aimed at selling their product and, consequently, twisting technical diagnostic facts, deliberately or unintentionally. The misunderstanding is caused by foreign countries having a technological gap in certain scientific and technical fields, such as vibroacoustic diagnostics and health monitoring.
The paper is aimed at suggesting basic terminology for diagnostics, monitoring, and vibroacoustics and the method of their application in real technological decisions.
The terminology is suggested by regulatory and procedural documents, reference, scientific and guidance literature, including the researches carried out by the authors.
The analysis of terminology used in Russia and abroad revealed that there are differences in understanding the methods of technological solutions of tasks in the fields of technological control, diagnostics, and machinery condition observation. In particular, the term «condition monitoring» is intended to be understood as condition control, not condition observation.
It is shown that the vibration acoustic signal is a random process, and vibroacoustic diagnostics requires analysis of its stochastic characteristics. It is necessary to measure the acceleration, velocity and displacement, since the stochastic characteristics of these vibroacoustic oscillations parameters are statistically independent,
The researches have concluded that real-time condition monitoring systems should provide real-time diagnostics of machinery at such time intervals that machinery condition cannot change from normal to limiting. To minimize the chance of skipping a dangerous condition and ensure reliable by vibroacoustic parameters one should measure vibration acceleration, velocity and displacement with an error which does not exceed 5% in the frequency range of at least 3000Hz.
V. N. Kostyukov, A. P. Naumenko Vibroacoustic Diagnostics as the Basis of Machinery's Health Monitoring // NDT World. - #3-2017, p.4-10
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.
References:
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 article considers the issues of using different physical processes parameters in systems for real-time condition monitoring of reciprocating compressors.
The locations for sensors of absolute and relative vibration are defined.
Trends of parameters of absolute and relative vibration at emergence of malfunctions and defects are given.
Examples of diagnosing of reciprocating compressors in parameters of relative and absolute vibration are reviewed.
It is shown that real-time monitoring of the absolute vibration parameters and the relative position of rod provides observability of the piston compressors’ condition and, consequently, their safe operation.
Kostyukov V.N., Naumenko A.P. Real-time monitoring on vibration- based diagnostics of reciprocating compressors // Proceedings of The First World Congress on Condition Monitoring 2017. -152
The article considers the issues of using different physical processes parameters in systems for real-time condition monitoring of reciprocating compressors.
The locations for sensors of absolute and relative vibration are defined.
Trends of parameters of absolute and relative vibration at emergence of malfunctions and defects are given.
Examples of diagnosing of reciprocating compressors in parameters of relative and absolute vibration are reviewed.
It is shown that real-time monitoring of the absolute vibration parameters and the relative position of rod provides observability of the piston compressors’ condition and, consequently, their safe operation.
Kostyukov V.N., Naumenko A.P. Real-time monitoring on vibration- based diagnostics of reciprocating compressors // Proceedings of The First World Congress on Condition Monitoring 2017. -152
Condition diagnostics and monitoring of machinery by vibration-acoustic diagnostics methods is widely used nowadays in production industries, in order to quit the expensive preventive maintenance and implement an effective modern system of condition-based maintenance. The papers [1,2] show that the effectiveness of a condition monitoring system implementation is mainly determined by the value of the error of the result issued by the expert system. One of the components of the diagnostic errors is low resolution power of spectral analyzer which is currently the main instrument for vibration-acoustic signal analysis.
Kostyukov Al.V., Boychenko S.N. Improving reliability of vibration spectrum identification without increasing sampling rate using spectral interpolation algorithm // Proceedings of The First World Congress on Condition Monitoring 2017. -152
The article reviews and suggests certain results of an experimental analysis of low-frequency vibrations on a bench for rotor installed on plain bearings and having a residual deflection.
Kumenko A.I., Kostyukov V.N., Kuzminykh N.Yu., Timin A.V. Auto-oscillations and subharmonic vibrations as illustrated by an experimental rotor // Proceedings of the 7th international scientific and technical conference (Omsk, April 24-28, 2017). - Omsk: Publishing House of OmSTU, 2017. - p.186-187
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