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Real-time vibration diagnostics
of machinery with probability close to 1
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In 2001 the quality management system of SPC Dynamics was put through facultative certification. In 2016 it was recertified for compliance with standards ISO 9001:2008. Its results confirmed a high level of goods and services quality management. In 2001 the quality management system of SPC Dynamics was put through facultative certification. In 2016 it was recertified for compliance with standard GOST ISO 9001-2011. Its results confirmed a high level of goods and services quality management.
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Self-diagnostics of piezoelectric transducers

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Equipment technical state monitoring systems contain hundreds of vibration and temperature sensors for real-time condition monitoring of machinery.

Monitoring systems reliability should significantly exceed the units stock reliability, being protected from accidents and incidents.

The paper considers the approach to monitoring systems reliability growth, primarily by means of providing control (monitoring) of measuring-converter path technical condition.

Sensors are the weakest point, due not only to wear, but also to damage, caused by repair personnel when servicing equipment.

The self-diagnostics method for channels with piezoelectric transducers and the choice of optimal self-diagnostics circuits parameters have been suggested.

The results of practical implementation have been provided as well.

References:

  1. V. Donskov, A. Ivanov, V. Zagorodniy, V. Kostyukov, Vibration Transducers for Industrial Application, Foreign Radioelectronics. 9 (1996) 65-67.
  2. V. Kostyukov, S. Morozov, Certificate of authorship 1740994, Device for Machines Diagnostics, International classification of inventions, GO1M15/00, USSR (1992).
  3. V. Kostyukov, S. Bojchenko, A. Kostyukov, Automated Control Systems for Safe Resource-Saving Operation of Equipment at Refineries and Petrochemical Plants, Moscow, Mashinostroenie, 1999.
  4. V. Kostyukov, Monitoring of Industrial Safety, Moscow, Mashinostroenie, 2002.
  5. V. Kostyukov, Certificate for useful model 1537, The System for Machines Diagnostics on Their Body Vibration, International classification of inventions, G01M15/00, Russian Federation (1996).
  6. Computer Aided Maintenance, Rules for Selection and Use of Systems, Maintenance Management, 4 (1997) 15-19.
  7. Computer Aided Maintenance, Champion the maintenance cause internally, Lack of formal strategy and performance, Look after your assets, Maintenance Management, 5 (1997) 23-27.

 

Kostyukov V.N., Kostyukov Al.V. Self-diagnostics of piezoelectric transducers // Key Engineering Materials. - 2014. - Vol. 613: Measurement Technology and Intelligent Instruments XI. - P.204 - 212 (http://www.scientific.net/kem.613.204)

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Tags: condition monitoring diagnostics reliability vibration analysis non-destructive testing Date: 27.10.2017
Views: 155
 

Vibration-activity analysis of mechanical parts of electric trains

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Improving techniques for condition assessment of mechanical parts of electric trains in operation is an ongoing challenge.

The paper presents the results of researches aimed at establishment of a range of vibration parameters change for mechanical part of electric trains, in order to provide requirements for the dynamic range of measurement channels when developing an on-board system for vibration analysis and condition monitoring of mechanical parts of electric trains.

 

Tsurpal A.E., Basakin V.V., Ilyushin M.S. Vibration-activity analysis of mechanical parts of electric trains // Dinamika sistem, mehanizmov i mashin (Dynamics of systems, mechanisms and machines). - Omsk: OmSTU, 2014. - Iss. 4. - p. 164-167.

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Tags: condition monitoring diagnostics vibration analysis rolling stock non-destructive testing EMU-train Date: 24.10.2017
Views: 139
 

Diagnostics of shafting lines assembly in large power turbo-units using shaft sensors

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Satisfying operation of a turbo-unit can be reached by elimination of unacceptable values of defects, good alignment of details in hot position, stable position of supports in the turbo-unit, i.e. absence of considerable damages in their base or support shift during the change from cooling or cold condition to hot condition.

The article touches upon operational detection of various defects of big power turbo-units’ shaft lines assembly, made during repair works. Specifications of rotor movements and variable stress in rotor journals, weld joints and half-coupling bolts are shown by the numerical defect modeling. The examples and basic causes of half-coupling bolts operational distortion are revealed. Also, the article shows specifications of automatic diagnosing and quantitative measurement of defect parameters in turbo-unit condition monitoring systems.

 

Kumenko A.I. Diagnostics of shafting lines assembly in large power turbo-units using shaft sensors // Dinamika sistem, mehanizmov i mashin (Dynamics of systems, mechanisms and machines). - Omsk: OmSTU, 2014. - Iss. 4. - p. 161-164.

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Tags: condition monitoring diagnostics vibration analysis non-destructive testing diagnostic features machinery Date: 17.10.2017
Views: 117
 

Method for diagnostics of electro-pneumatic systems of electric trains

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Higher intensity of suburban railway line transportation and provision of its safety in conditions of simultaneous reduction of operational costs for railway-yard maintenance have even requirements towards  reliability level and maintenance quality provided for rolling stock.

Statistically, an electro-pneumatic system and its parts is highly vulnerable to the impact of human factor during maintenance and repair and damageable during operation. It’s about 80% of all damages and at least 75% of all costs for maintenance and repair.

The article presents the results of studies on the development for diagnostics of electro-pneumatic systems, which allows to increase the accuracy by increasing the depth and completeness of the diagnostics.

 

Kostyukov Al.V., Kazarin D.V., Schelkanov A.V. Method for diagnostics of electro-pneumatic systems of electric trains // Dinamika sistem, mehanizmov i mashin (Dynamics of systems, mechanisms and machines). - Omsk: OmSTU, 2014. - Iss. 4. - p. 158-161.

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Tags: condition monitoring diagnostics vibration analysis rolling stock non-destructive testing EMU-train Date: 10.10.2017
Views: 164
 

Reliability assessment of safe operation of petrochemical facilities

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Solution for the problem of safe and reliable operation of machines of hazardous petrochemical facilities is directly related to the monitoring of their operational risks.

To monitor risks of hazardous production facilities one need to assess the performance of equipment reliability in real operating conditions, to know the mean time of machinery operation before defect nucleation and occurrence of a dangerous technical condition (emergency).

In addition, the reliability analysis of machinery units of petrochemical facilities shows that dynamic equipment accounts for more than 70% of failures.

Thus, the solution for the most important problems of safe and reliable operation of machines of continuous hazardous productions of petrochemical facilities is to determine the mean time of the machinery operation considering different technical conditions.

 

Kostyukov V.N., Kostyukov A.V., Sinitsyn A.A., Tarasov E.V. Reliability assessment of safe operation of petrochemical facilities // Dinamika sistem, mehanizmov i mashin (Dynamics of systems, mechanisms and machines). - Omsk: OmSTU, 2014. - Iss. 4. - p. 154-157.

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Tags: condition monitoring diagnostics reliability vibration analysis non-destructive testing machinery Date: 03.10.2017
Views: 168
 

Risk assessment for establishing standard values of diagnostic features

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In general case, using a combination of diagnostic features, with each feature characterizing the diagnostic object’s condition with a certain probability, it would be correct to establish a critical rule by which the combination of features would be considered to be related to one of the possible states (diagnoses). In particular case, it is important to distinguish two diagnoses (differential diagnostics or dichotomy), such as “good condition” and “faulty condition”.

Methods of statistics decisions, such as minimal risk method, minimal faulty decision method, minimax method, Neumann-Pearson method, maximum likelihood method allow to choose the critical rule using optimum conditions, such as minimum risk condition, reducing chance of a diagnostic error at a set level of another error.

The paper considers selection of a method for establishing standard values of diagnostic features using a theory of statistic decisions-making. The paper dwells upon calculation of probability of defect skipping and false alarm, as well as failure skipping risk while establishing a standard feature value by various methods of decision-making.

 

Kostyukov V.N., Naumenko A.P. Risk assessment for establishing standard values of diagnostic features // Dinamika sistem, mehanizmov i mashin (Dynamics of systems, mechanisms and machines). - Omsk: OmSTU, 2014. - Iss. 4. - p. 150-154.

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Tags: condition monitoring diagnostics vibration analysis non-destructive testing diagnostic features machinery Date: 26.09.2017
Views: 168
 

Measuring system for broadband vibration-acoustic processes

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The paper dwells upon the development results of an experimental unit intended to be used as a part of a comprehensive program to study vibration-acoustic processes in order to obtain data on vibration of mechanical parts of a rolling stock in operation.

 

Kostyukov V.N., Kostyukov Al.V., Boyarnikov A.V., Schelkanov A.V., Kazarin D.V., Tsurpal A.E., Yudin K.V., Aleksandrov I.V., Melk V.V. Measuring system for broadband vibration-acoustic processes // Dinamika sistem, mehanizmov i mashin (Dynamics of systems, mechanisms and machines). - Omsk: OmSTU, 2014. - Iss. 4. - p. 146-149.

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Tags: condition monitoring diagnostics vibroacoustic signal vibration analysis vibration non-destructive testing machinery Date: 19.09.2017
Views: 158
 

Technology of piston compressors real-time diagnostics and monitoring

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Development of methodology and technology for piston compressors health control, diagnostics and monitoring by means of vibration analysis, as well as algorithms of automatic systems for piston compressors monitoring which provide their fault-free operation, is an actual problem.

Data collection and processing is the basis of piston compressors monitoring and diagnostics technology, thus providing compressors defects and malfunctions detection with a specified depth of their detailing and reliability and a hazard level.

Realization of monitoring and diagnostics technology is based on application of vibration-acoustic signals structure models upon occurrence of various defects and malfunctions in piston compressors components, set of malfunctions and standard values diagnostic features, methods of vibration-acoustic signals transformation and a system for their parameters estimation.

The paper considers methodology of the diagnostic signal processing and the monitoring system functional diagram.

The proposed monitoring and diagnostics methodology is based on measurement of vibration-acoustic oscillations parameters and characteristics, as well as measurement of direct structural and thermodynamic parameters.

The structure and functioning principles of the expert system for decision-making support have been  presented.

Functioning algorithm of the automatic expert system includes calculation of the diagnostic features values based on their normative ones, formation of the diagnostic features sets which correspond to individual malfunctions classes and formation of the expert system messages.

The scheme of the system for piston compressors real-time condition monitoring has been considered.

The system has a series-parallel structure of a data-measuring complex for data collection and processing, which allows to measure the vibration-acoustic signals parameters for piston compressors and their operating modes monitoring. Besides, the system allows to measure other physical processes parameters, for example, for monitoring and diagnosis-making purposes it has been provided to measure and apply pressure in decreasing spaces (an indicator diagram), gas temperature, a rod position, leakage through stuffing boxes and others.

References:

  1. GOST R 53563-2009. Condition monitoring and diagnostics of machines. Monitoring the condition of the equipment hazardous. Order organization - DYNAMICS SPC, Russian Technical Expertise, Scientific-and-Industrial Union "RISCOM", NPO "RDC CD", – Introduced on 01/01/2011, Moscow, "Standardinform" - 2010 – 5 p.
  2. Naumenko A.P., Vibration-acoustic model of piston compressor diagnostic signal // Dynamics of systems, mechanisms and machinery systems: materials of VII International Scientific and Technical Conference, 10-12 November 2009, Omsk. Omsk Technical State University, 2009. Vol. 2. P. 39-44.
  3. Naumenko A.P., Methodology of vibration-acoustic diagnostics of piston machinery // Bauman’s MSTU Reporter. Special edition. Mechanical engineering series. Moscow, Moscow State Technical University n.a. N.E. Bauman. 2007. p. 85-95.
  4. Naumenko A.P., Models of piston compressor vibration-acoustic signals // Science, Education and Business: materials of regional scientific and practical conference devoted to Radio day. Omsk, KAN, 2010, p. 114-120.
  5. Naumenko A.P., On some models of piston machinery vibration-acoustic signal structure // Dvigatel – 2010: International Scientific conference, devoted to the 180-Anniversary of Moscow State Technical University n.a. N.E. Bauman [edited by N.A.Ivashchenko, V. A. Wagner, L.V.Grekhov]: Moscow State Technical University n.a. N.E. Bauman, 2010. С. 75-79.
  6. Kostyukov V.N., Industrial safety monitoring (monograph), V.N. Kostyukov, Moscow, Mashinostroenie, 2002, 224 p.
  7. Kostyukov V.N., Synthesis of invariant diagnostic features and the units health models for diagnostic purposes (article), V.N. Kostyukov, Omsk Scientific Bulletin, 2000, №12, pp. 77-81.
  8. Kostyukov V.N., Naumenko A.P., Practice of piston machines vibration-acoustic diagnostics (article), V.N. Kostyukov, A.P. Naumenko, Collected works on engine building problems, devoted to the 175th Anniversary of Moscow State Technical University n.a. N.E. Bauman, Moscow, 2005, pp. 30-33.
  9. Kostyukov V.N., Naumenko A.P., Problems and solutions of piston compressors safe operation (article), V.N. Kostyukov, A.P. Naumenko, Compressor Techniques and Pneumatics, 2008, №3, pp. 21-28.
  10. Kostyukov V.N., Naumenko A.P., Solution for problems of piston compressors safe operation (article), V.N. Kostyukov, A.P. Naumenko, Assembling in Mechanical Engineering and Instrument-Making, 2009, №3, pp. 27-36.
  11. Naumenko A.P., On vibrational diagnostic parameters’ choice// Science, Education and Business: materials of regional scientific and practical conference devoted to Radio day. Omsk, KAN, 2010, p 106-115.
  12. GOST R 53565-2009. Condition monitoring and diagnostics of machines. Monitoring the condition of the equipment hazardous. Vibration centrifugal pump and compressor units - DYNAMICS SPC, Russian Technical Expertise, Scientific-and-Industrial Union "RISCOM", NPO "RDC CD", - Introduced on 01/01/2011, Moscow, "Standardinform" – 2010 - 8 p.
  13. Kostyukov V.N., Rationing of vibration parameters within piston compressors diagnostics (article), V.N. Kostyukov, Consumers – manufacturers of compressors and compressor equipment, 7th International Symposium, Proceedings, Saint-Petersburg, 2001, pp. 90-93.
  14. Kostyukov V.N., Naumenko A.P., Regulatory and methodological support of piston compressors health monitoring (article), V.N. Kostyukov, A.P. Naumenko, Testing. Diagnostics, 2005, №11, pp. 20-23.
  15. Naumenko A.P.,  Modern methods and means of real-time piston machinery health monitoring / Compressor machinery and pneumatics. №8, 2010. p. 27-34.
  16. Kostyukov V.N., Naumenko A.P., Boychenko S.N.. Method of vibration diagnostics of machinery: pat. 2 314 508 Russian Federation. 2006135874/28; declared 10.10.2006; published 10.01.2008. Bulletin No. 1.
  17. Kostyukov V.N., Naumenko A.P., Boychenko S.N.. Method of vibration diagnostics of piston cars’ condition by spectral invariants: pat. 2 337 341 Russian Federation. No. 2007113529/28; declared 11.04.2007; published 27.10.2008. Bulletin No. 30.
  18. Kostyukov V.N., Naumenko A.P., Method of vibration diagnostics of objects: pat. 2 363 936 Russian Federation. 2008121486/28; declared 27.05.2008. published 10.08.2009. Bulletin No. 22.
  19. GOST R 53564-2009. Condition monitoring and diagnostics of machines. Monitoring the condition of the equipment hazardous. Requirements for monitoring - DYNAMICS SPC, Russian Technical Expertise, Scientific-and-Industrial Union "RISCOM", NPO "RDC CD", - Introduced on 01/01/2011, Moscow, "Standardinform" - 2010 – 20 p.
  20. Kostyukov V.N., Boychenko S.N., Kostyukov Al.V., Automated control systems for safe money-saving operation of refineries and petrochemical plants equipment (ACS SMSPM - COMPACS®) (monograph), V.N. Kostyukov, S.N. Boychenko, Al.V. Kostyukov, Moscow, Mechanical Engineering, 1999, 163 p.
  21. Kostyukov V.N., Naumenko A.P., Health monitoring system for reciprocating machines (article), V.N. Kostyukov, A.P. Naumenko, Testing. Diagnostics, 2007, №3 (105), pp. 50-59.
  22. Naumenko A.P., Real-time condition monitoring of reciprocating machines (full report text) // CM2009/MFPT2009 (The sixth international conference on condition monitoring and machinery failure prevention technologies): materials of a conference (June 23-25, 2009). Irish, Dublin, 2009. Pp. 1202-1213.
  23. Naumenko A.P., Research on vibration-acoustic parameters of piston units // Dvigatel – 2007: materials of International Scientific and Technical Conference [edited by N.A.Ivashchenko, V. A. Wagner, L.V.Grekhov] М.: Moscow State Technical University n.a. N.E. Bauman, 2007. P. 518-525.
  24. Naumenko A.P. Diagnostics and Condition Monitoring of piston compressors // CM2010/MFPT2010 (The Seventh International Conference on Condition Monitoring and Machinery Failure Prevention Technologies) (June 22-24, 2010): materials of a conference. England, Stratford-upon-Avon, 2010. Pp. 1-11. 1 CD-disk (CD-ROM).
  25. Vibration in Technic: Reference book in 6 volumes. [edit. council: V.N. Chelomey]. Moscow, Mashinostroenie, 1981. Vol. 5. Measurings and testings [under edit. Of M.D. Genkin]. 1981. 496 p.

 

Kostyukov V.N., Naumenko A.P. Technology of piston compressors real-time diagnostics and monitoring // Condition Monitoring and Machinery Failure Prevention Technologies (СМ/MFPT 2014)

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Tags: condition monitoring diagnostics expert system piston compressor vibration analysis vibration signal non-destructive testing Date: 15.09.2017
Views: 165
 

Diagnostics of rolling bearings by characteristic function parameters

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Analysis of accidents and machinery comprising rotating parts has revealed that a considerable amount of shutdowns is caused by the destruction of rolling bearings (40-50 %). To solve the problem of preventing sudden failures of the bearings one shall implement vibration monitoring of bearings condition during operation and switch from PPM to a condition-based maintenance and repair system.

Almost all existing methods of rolling bearing condition diagnostics deal with analysis of vibration-acoustic signals in time or frequency domains. But since operation of bearings within the machinery unit sometimes produces a lot of noise, there is a chance of a second-kind error occurrence.

That is why an increase of reliability of diagnostic results due to new method development is an urgent task. In that connection, a study of changes in characteristic function parameters of vibration-acoustic signals of bearings during condition measurement arouses a great interest.

 

Kostyukov V.N., Naumenko A.P., Kudryavtseva I.S. Diagnostics of rolling bearings by characteristic function parameters // Dinamika sistem, mehanizmov i mashin (Dynamics of systems, mechanisms and machines). - Omsk: OmSTU, 2014. - Iss. 4. - p. 142-145.

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Tags: condition monitoring diagnostics vibration analysis vibration signal non-destructive testing rolling bearings machinery Date: 12.09.2017
Views: 186
 

The technology for comprehensive condition assessment of depot trains

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Solving the task of increasing transport volumes at suburbian railway lines and their quality in conditions of transportation safety provision with simultaneous reduction of operational costs requires automatic systems for rolling stock diagnostics in depot.

The technology of electric train condition assessment by means of the COMPACS®-EXPRESS-TR3 system described in the paper, which does not cancel the order existing in the Russian Railways regulating the PPM and repair process, allows significantely speed-up and simplify train maintnance in depot in case when large amounts of machines require maintnance. It is possible by the timely accurate and high-quality codition monitoring of the main sub-systems of electric trains in depot.

Such decision also alows to reduce non-productive downtime of train units waiting for train to be assembled, adjusted and run-in; obtain almost full elimination of defects and operational failures due to maintnance staff‘s incompetence, i.e. reduce equipment‘s damagebility by at least 50-60%, providing high level of safety and uninterrupted operation of suburbian railway lines.

 

Kostyukov Al.V., Kazarin D.V., Serov A.A. The technology for comprehensive condition assessment of depot trains // Dinamika sistem, mehanizmov i mashin (Dynamics of systems, mechanisms and machines). - Omsk: OmSTU, 2014. - Iss. 4. - p. 139-142

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Tags: condition monitoring diagnostics vibration analysis rolling stock non-destructive testing EMU-train Date: 05.09.2017
Views: 172
 
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