The COMPACS® system
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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Standards in the field of condition monitoring and diagnostics of hazardous production facilities

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Low observability of hidden destruction processes of production facilities condition caused by wear and wrong actions taken by the maintenance personnel is a fundamental reason of hazardous production facilities operational problems. The analysis of reliability of technological units of modern refinery and petrochemical complexes shows that more than ¾ of failures are machinery unit failures, high concentration of which often appears as a reason of accidents and production faults which cause unit downtime and reduce coefficients of technical use and readiness.

In order to fix this problem it is necessary to provide observability and assessment of unit condition during the manufacture and acceptance at the consumer plants, during repair in special departments of enterprises, during the assembly of units and their operation. The observability of failure development requires constant diagnostics with an automatic delivery of objective results independently from the will of executive personnel to the personnel responsible for the machinery operation. The condition diagnostic and monitoring system should reveal the failures and provide supervision for their development and timely warn the personnel about the necessity of machinery decommissioning for repair or its emergency shutdown.

The article reviews the current state standards of the Russian Federation, and the standards of the professional public organizations developed by the authors. These standards define the basic requirements for condition monitoring of the equipment at hazardous production facilities which can underlie the transition to risk monitoring of hazardous production facilities.

 

Kostyukov V.N., Naumenko A.P., Kostyukov An.V., Boychenko S.N., Kostyukov Al.V. Standards in the field of condition monitoring and diagnostics of hazardous production facilities // Safety of industry labor. - 2012. - № 7. - pp. 30-36

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Tags: condition monitoring diagnostics standard accidents prevention Date: 24.04.2015
Views: 858
 

From monitoring systems to safe resource-saving operation of machinery. Results of implementation for 20 years

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The burst out economic crisis, mainly caused by non-objective assessment of real processes undergoing in global economy, points out the urgency of development and implementation of systems for economic condition monitoring in all economic braches. The development of such system allows to carry out an objective assessment of real processes undergoing at enterprises and timely inform concerned parties (management, consumers, shareholders, suppliers) about their current efficiency. In case of condition worsening it points out the main factors having harmful influence on the economy. Consequently, the task of provision of guaranteed production safety level and getting the planned results with minimum expenses is very urgent for Refinery and Petrochemical companies.

Efficiency of Refineries and Petrochemical companies mostly determined by value of material and human resource expenses for the machinery repair and losses due to accidents and downtime. Machinery wear rates are significantly determined by the adequacy of production and maintenance personnel work.

On the modern stage of effective management of machinery condition monitoring, we developed a new product - Compacs Asset Management (САМ™), which works on the bases of the COMPACS® system data and allows to make reports on the machinery operation for any time period, calculate efficiency index of technological complex machinery operation management in real time (САМ™ Index), and to make the process of decommissioning for repair automatic by means of the COMPACS® system data integration into the TORO-module of the enterprise management system (ERP, ЕАМ).

 

Kostyukov V.N., Kostyukov A.V. From monitoring systems to safe resource-saving operation of machinery. Results of implementation for 20 years // Council of Chief Mechanics. - 2012. - p.67-74

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Tags: COMPACS condition monitoring diagnostics resource-saving accidents prevention Date: 10.04.2015
Views: 923
 

System for comprehensive condition monitoring of equipment of hazardous production facilities – ways and technologies of realization

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To ensure the reliability of production it is necessary to be acquainted with technical condition of operated equipment in any time, to know exactly the assemblies with critical technical condition and to assume the measures in time to prevent emergency situations. Production output of petrochemical enterprises makes comprehensive technological process, which includes a few hundred units of technological equipment. Failure of any elements operation in the process flow can lead not just to quality or production volume decrease, but to emergency breakage.

Prediction of such failures can be carried out just in the case of comprehensive monitoring of a whole unit, including monitoring of dynamic equipment (pumps, compressors) and static equipment (columns, reactors, reservoirs, furnaces).

The COMPACS® system uses widespread methods of non-destructive testing: vibration, acoustic emission, thermal, electrical, vortex-current, acoustic, optical, and, in automatic mode, carries out the assessment of machinery equipment technical condition, and so ensuring displaying current technical condition by color pictogram, gives warning to the personal with speech transaction and recommendations for the nearest urgent actions, which have to be carried out to ensure equipment operation without breakdowns. Usage of these methods together, not separately, allows to control any equipment.

Machinery equipment with the stationary system COMPACS® allowed to eliminate breakdowns and exclude "sudden" failures, occurred in the places, where the nucleation and development of the malfunctions up to its critical level can`t be traced and, as a result, causes an emergency situation.

 

Kostyukov V.N., Kostyukov A.V. System for comprehensive condition monitoring of equipment of hazardous production facilities – ways and technologies of realization // Kompleksnaya bezopasnost (Complex safety). - 2012. - pp. 45-47

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Tags: COMPACS diagnostics vibration analysis industrial safety monitoring Date: 27.03.2015
Views: 876
 

Modern methods and means of on-line monitoring of parameters and real-time health monitoring of piston machines

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The paper is devoted to the current development and prospect development of modern methods and means of condition monitoring and diagnostics of reciprocating compressors in hazardous industries. The analysis of well-known monitoring systems enables determination of points for installing sensors in compressors and their assemblies including the controlled assemblies. The principles of condition control presented in monitoring systems have been studied. Technology of condition monitoring systems was examined.

The most systems receive diagnostic signals by means of stationary systems called on-line monitoring systems, in which equipment condition is estimated at the moment of signal receipt according to the measured parameter value without analyzing the causes of its change. In addition, the lack of automatic expert systems of diagnostics and lengthy diagnostic period exceeding the time of defect development testify that the examined on-line monitoring systems are parameter monitoring systems.

Methodology, implementation technology and principles of construction of real-time condition monitoring systems have been analyzed. The methodology of real-time condition monitoring and diagnosing is based on measurement of parameters of indirect processes (vibroacoustic oscillation) that requires installation of 5 sensors or less in a cylinder. The measurement of direct structure and thermodynamic parameters is provided as well.

The condition monitoring system is based on algorithms of real-time decision-making expert system with automatic detection (i.e. diagnostics during measurement of diagnostic signals) of more than 23 malfunctions of compressor assemblies and a hazard degree. The system also provides personnel with the instructions on compensatory control. Scientifically grounded diagnostic period enables reduction of static and dynamic errors by 5% that enables condition monitoring of the most significant equipment and overall production complex.

 

Naumenko A.P. Modern methods and means of on-line monitoring of parameters and real-time health monitoring of piston machines // The Eighth International Conference on Condition Monitoring and Machinery Failure Prevention Technologies (CM-2011/MFPT-2011)

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Tags: condition monitoring diagnostics piston compressor vibration analysis Date: 20.03.2015
Views: 888
 

Developing and realization of condition monitoring for rotor systems in oil-and-gas industry

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One of the types of high-risk machinery of oil-and-gas facilities is rotor units: pumps, compressors, separators with wide range of power, pressure, speed, costs, working environments, temperatures and operational resources. Failures and accidents of such machinery can be connected with considerable economic losses and possibilities of severe emergencies.

In order to ensure and increase the resource and safety of rotor machinery for the last twenty years the member-companies of Scientific and Production Unit "RISKOM" were developing methods and systems:

  • prompt discrete condition diagnostics of the equipment according to the requirements of normative-technical documentation;
  • continuous condition diagnostics of supporting elements by the common criteria and vibration activity parameters;
  • continuous and discrete monitoring of rotor units condition based on the results of the current diagnostics and forecast of dangerous conditions (accidents, failures).

These developments allowed for the first time to shape and begin the implementation of a new stage – risk monitoring of rotor units for petrochemical industry. Its methodological nature is the following: by the current condition diagnostic and monitoring data there are quantitative evaluation of accident risk occurrence rates, growth of economic expenses and risks caused by the equipment degradation, reduction of safe run-to failure operation and growth of expenses for diagnostics, monitoring, and reasoning of safe residual life prolonging.

 

Makhutov N.A., Kostyukov V.N., Leshchenko V.V., Kostyukov A.V. Developing and realization of condition monitoring for rotor systems in oil-and-gas industry // Kompleksnaya bezopasnost (Complex safety). - 2012. - p. 35

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Tags: diagnostics pump-and-compressor units accidents prevention monitoring Date: 13.03.2015
Views: 872
 

Research of dependence of current consumption parameters of electric motor on its health

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Operation of motors in unsatisfactory technical condition leads to financial losses, connected with unpredictable equipment breakdown and caused by this violation of technological process. And also, it leads to considerable electric energy expenditure, caused by an increased current consumption.

In some cases, the diagnostics by the current or consumption capacity, perhaps, is the only one method of non-dismountable diagnostics of electric equipment. Such problem occurs during the diagnostics of air coolers and wind-powered generators. Such facilities have restricted access in terms of vibration sensors mounting, at the same time the mounting of current consumption sensors and control of consumed and outputted electric power do not involve any difficulties.

Spectrum-current analysis is the procedure of monitoring of current and voltage signals on motor terminals and their further analysis aimed at detection of electric and mechanical malfunctions (defects) of electric motors.

 

Boychenko S.N., Tkachenko A.A. Research of dependence of current consumption parameters of electric motor on its health // Nauka, obrazovanie, biznes (Science, education, business). - 2012. - pp. 199-200

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Tags: electric motor diagnostics Date: 24.02.2015
Views: 920
 

Selection of method for diagnostics of auxiliary machine system of electric trains

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Operation of electric motors in unacceptable condition leads to material loses connected with unpredictable failure of the equipment and technological process breakdown produced by this failure, and also considerable expenditures of electrical energy, caused by increased power consumption.

One of these methods is based on that fact that the auxiliary machine systems of each section are independent in terms of ranked measured values. It allows to mark out sections with current references deviation from train`s average values, thereby it points out the section with developing malfunction in the supporting machine system.

It is perspective to develop method for condition diagnostics of electric trains based on spectral analysis of consumption/ generated current. This analysis allows to specify the condition of machine`s different elements and detect specific types of malfunctions.

Physical principle lying in the basis of this method is that any disturbance in the operation of electric and mechanical parts of the machine leads to change of magnetic flux in air gap and, consequently, to a change of a momentary electric current value. Accordingly, the presence of particular frequencies of fixed value in a current of a spectrum of three-phase feed system of auxiliary machines testifies the development of particular malfunctions of a unit.

Thus, for the continuous monitoring of auxiliary machine system it is enough to install three current sensors to the corresponded line conductors of transformation generator.

 

Tsurpal A.E. Selection of method for diagnostics of auxiliary machine system of electric trains // Nauka, obrazovanie, biznes (Science, education, business). - 2012. - pp. 202-205

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Tags: diagnostics electric multiple unit MDRS Date: 13.02.2015
Views: 879
 

Condition monitoring and diagnostics of rolling bearings of high-voltage electric motors during their operation

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During the operation of high-voltage motors at hazardous industries, it has been proved that, bearings do not work out the operating time assigned by the manufacturer. The report covers issues on the condition monitoring and diagnostics of the defects in rolling bearings of a high-voltage motors during theirs operation, defines the causes of a premature emergence and development of the defects as well the measures worked out for ensuring safe and prolonged operation of the rolling bearings of high-voltage motors.

The collection and analysis of vibration parameters of electric motors during their operation is performed by means of the real-time condition monitoring system. A spectral matrix of defects frequencies has been developed on the basis of the analysis of rolling bearings vibration source. The spectral analysis of vibration parameters showed the presence of frequency components that reveal defects of the bearings. As a result of vibration analysis, a number of defects in the rolling bearings have been revealed and proved during the motor repair and inspection of its bearings for likely defects.

The condition monitoring and diagnostics of the rolling bearings during the operation of the electric motors have allowed:

  • timely decommissioning of the motor with the damaged bearings as well as prevention of accidents which may have occurred with the unit that dispenses fire explosive products;
  • detection of the principal cause of frequent failures of the rolling bearings, which is application of the bearings in inappropriate working conditions and non-fulfillment of auxiliary measures recommended by manufacturers of bearings to prolong lifetime of the equipment;
  • submitting of recommendations on use of the bearings in the motor.

 

Kostyukov V.N., Tarasov E.V. Condition monitoring and diagnostics of rolling bearings of high-voltage electric motors during their operation // Condition Monitoring and Diagnostic Engineering Management (COMADEM-2011), pp. 824-833

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Tags: vibration analysis rolling bearings electric motor diagnostics Date: 06.02.2015
Views: 861
 

Condition monitoring and diagnostics of rolling bearings of high-voltage electric motors during their operation

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During the operation of high-voltage motors at hazardous industries, it has been proved that, bearings do not work out the operating time assigned by the manufacturer. The report covers issues on the condition monitoring and diagnostics of the defects in rolling bearings of a high-voltage motors during theirs operation, defines the causes of a premature emergence and development of the defects as well the measures worked out for ensuring safe and prolonged operation of the rolling bearings of high-voltage motors.

The collection and analysis of vibration parameters of electric motors during their operation is performed by means of the real-time condition monitoring system. A spectral matrix of defects frequencies has been developed on the basis of the analysis of rolling bearings vibration source. The spectral analysis of vibration parameters showed the presence of frequency components that reveal defects of the bearings. As a result of vibration analysis, a number of defects in the rolling bearings have been revealed and proved during the motor repair and inspection of its bearings for likely defects.

The condition monitoring and diagnostics of the rolling bearings during the operation of the electric motors have allowed:

  • timely decommissioning of the motor with the damaged bearings as well as prevention of accidents which may have occurred with the unit that dispenses fire explosive products;
  • detection of the principal cause of frequent failures of the rolling bearings, which is application of the bearings in inappropriate working conditions and non-fulfillment of auxiliary measures recommended by manufacturers of bearings to prolong lifetime of the equipment;
  • submitting of recommendations on use of the bearings in the motor.

 

Kostyukov V.N., Tarasov E.V. Condition monitoring and diagnostics of rolling bearings of high-voltage electric motors during their operation // Condition Monitoring and Diagnostic Engineering Management (COMADEM-2011), pp. 824-833

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Tags: vibration analysis rolling bearings electric motor diagnostics Date: 06.02.2015
Views: 57
 

Analysis of malfunctions of wheel-motor units of motor-driven rolling stock for the purpose of their diagnostics

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One of the most important assemblies of electric rolling stock is a wheel-motor unit. Its faultless operation determines abilities of transport to fulfill their main functions.

One of the main requirements to the wheel-motor units is a set operational resource. Operation of rolling and sliding friction systems, such as ball- and roller-bearing assemblies, traction gears, commutator-and-brush device and other devices, which are the elements limiting the train resource in general, and depend on the vibration condition, quality of manufacture, repair and assembly.

It is reasonable to carry out the diagnostics of these facilities both during operation and maintenance with the required diagnostic depth.

Typical for these malfunctions is high level of noise, vibration, impact sound. By the deviations and higher levels of these parameters with the help of vibration analysis means it is possible to trace the defect development up to the moment when the usage of defected element is inexpedient or impossible in terms of operation.

Vibration analysis is based on the analysis of vibration process features changes, presupposing that the vibration signal of the operation unit contains all the information on the interactions of its details.

 

Basakin V.V. Analysis of malfunctions of wheel-motor units of motor-driven rolling stock for the purpose of their diagnostics // Nauka, obrazovanie, biznes (Science, education, business). - 2012. - pp. 136-140

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Tags: diagnostics wheel motor unit vibration analysis rolling stock MDRS Date: 23.01.2015
Views: 929
 
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