Urge to improve the railway transport operation reliability makes it a serious concern – to solve a problem of observation and control over the equipment’s condition at any stages of its operation life. It is not a secret, that lack of objective assessment of manufacturing and repair of equipment, as well as not enough observability over real processes of condition deterioration at the operational stage may interfere with ability to make efficient, economically and technologically justified measures on sustaining high reliability rates for the equipment.
Great number of various diagnostic and control means available to industrial and service companies does not guarantee high-quality assessment of equipment condition. There is one more problem – practical application of diagnostic and control results requires their availability for all management levels. The solution for such problems may comprise an automatic system for continious monitoring and diagnostics.
Sizov S.V., Aristov V.P., Kostyukov V.N., Kostyukov Al.V., Kazarin D.V. Automated control system for safe resource-saving operation and maintenance of rolling stock – COMPACS // Delovaya slava Rossii: Interindustrial almanac. - 2014. - №3 (46). - pp. 14-16 (http://www.slaviza.ru/1406-cistema-monitoringa-sostoyaniya-oborudovaniya-elektropoezdov.html)
It has been almost 25 years since DYNAMICS SPC took up fundamental and applied research and development works, production and wide-scale implementation of the COMPACS® automatic diagnostic and condition monitoring systems into refinery and petrochemical companies.
The presented basic approach towards provision of petrochemical safety based on automated control systems for safe resource-saving operation of machinery – COMPACS® allows full utilization of each refinery enterprise and the whole company in general, and adopting the technology of safe resource-saving operation of machinery in real time which provides maximum possible run life at minimum operational costs. A perfect example of utilization of such approach is Syzran Refinery, JSC.
Kostyukov A.V., Sinitsyn A.A., Tkachenko A.A. General approach towards safety of refinery and petrochemical companies // Business&Class. - 2014. - June-August. - pp. 26-29.
The paper is aimed at determining possibility to provide reliable condition assessment of rotary units of mechanical part of rolling stock during operation and with acceptable cost of single diagnostic act. To reach that goal one need to develop a list of experimental researches of vibration acoustic processes and to create an experimental device for signal measurement.
The paper presents the results of development of the experimental device used within the framework of an integrated program of research of vibroacoustic processes to obtain data on vibration of mechanical components of rolling stock working in real operating conditions. The device enables prolonged continuous stream recording of signals from transmitters, in particular, from vibration sensors in the band to 900 kHz.
Results of the analysis of data obtained using the experimental device have been used as a basis for train component diagnosis algorithms, implemented in onboard condition monitoring systems COMPACS®-EXPRESS-3, installed on modern rolling stock.
Kostyukov V.N., Zaytsev A.V., Tsurpal A.E. A device for experimental studies of vibration of rolling stock components during operation // Transport of the Urals. - 2014. - №2. - pp. 77-80
The most important result of Soviet era of vibration monitoring development is a prove of considerable impact that errors in assembling and operation of machine have on its residual life, and also possibility of predicting the residual life span by the vibration diagnostics results.
For production and transport industries the fundamental reasons of high costs and losses are determined by subtle occurrence and development of faults, as well as poor observability of actual processes of machinery deterioration during its whole lifespan.
Stability can be achieved by means of observability and controllability, when all monitoring processes are coupled together and monitoring time does not exceed the shortest interval of machinery fault development.
The shortest monitoring period can be achieved by the in-built automatic expert system revealing all main problems to the personnel operating the machine and forwarding this information through the automatic diagnostic network to the managers and production heads.
Kostyukov V.N. Innovative technology for machinery “health” monitoring for accidents prevention and condition-based operation of machinery – Russian technological break-through // Modern approaches towards selection of equipment and materials during project development, building and operation of production facilities of refinery and petrochemical companies: proceedings of the Council of Chief Mechanics meeting
Ensuring the safe operation of machine units such as pumps, compressors and other production equipment has always been one of the most relevant tasks in the industry. Failures of the mentioned machinery can often lead to malfunctions and accidents, causing losses and damaging the environment. For example, the analysis of statistics on oil refining and petrochemical industries shows that failures of machine units account for more than 70% of the total number of equipment failures in these industries.
The wide application of electric motors, including electric motors with a working voltage of 380 V, as part of machine units, necessitates the development and use of new methods for monitoring their technical condition, which allow detecting emerging defects at early stages and preventing their further development.
To assess the insulation condition of electrical machine windings, methods for controlling the parameters of partial discharges occurring in the insulation of windings are being increasingly used, which is caused by the improvement of technical and instrumental diagnostics, which allow to register and analyze such discharges.
Kostyukov V.N., Burda E.A. Study of the applicability of the partial discharge measurement method for diagnostics of insulation condition of stators of asynchronous electric 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, 2014. – p.228-233.
The main diagnostic task is to recognize condition of machines and units, classify them as faultless or faulty ones. The task is closely connected to false alarm or defect skipping risks.
When a method for axle equipment of wheel-motor units diagnostics is utilized there is always a chance of defect skipping or false alarm.
In rolling stock operation conditions, skipping a defect may lead to unit’s destruction, which cause not only an expensive unscheduled repair, train schedule failure, but also a technogenic hazard and transport accident.
False alarm may lead to additional repairs for units which does not require maintenance, and, consequently, make their condition even worse and decreasing rolling stock’s operating availability rates.
The paper is aimed at increasing diagnostic reliability with minimum expenses for testing procedures.
Kostyukov V.N., Zaytsev A.V., Teterin A.O. Increasing diagnostic reliability of axle equipment of wheel-motor units in electric trains // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2014. – p.183-190.
The paper is aimed at finding dependency between the RMS value of vibration parameters of rolling bearings in different conditions and the axial load.
he research is carried out by means of an experimental unit based on the COMPACS®-RPP system using drive 1602 which allows to set axial and radial load values and measure vibration radially.
The subject of research is an operable bearing, bearings with seeded defects of inner and outer race, and a bearing with rolling elements defect which occurred due to long-term service.
From the analysis of the obtained results one can make a conclusion on a rolling bearing condition having a considerable impact on RMS values’ dependency on an axial load.
The operable bearing and bearings with seeded defects of inner and outer race are lacking or have non-considerable amount of such dependency. That may testify that such seeded defects have no considerable impact on dependency between bearing vibration and an axial load.
Bearings with rolling element defects which occurred due to long-term service have RMS value considerably dependent on the applied axial load. The most sensitive to changes in axial load are RMS values of vibration displacement and vibration acceleration.
Kostyukov V.N., Boychenko S.N., Basakin V.V., Teterin A.O., Kudryavtseva I.S. Research on dependency of bearing vibration parameters on axial load // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2014. – p.123-127.
Rolling bearings are the most common and important elements applied in modern engineering. For rotary mechanical equipment – rolling bearings are node points limiting machinery operational resource in general.
The most effective method, which allows to detect both – nucleating and developed defects of rolling bearings, are vibration-acoustic method of NDT.
To make a valid assessment of rolling bearings condition – it is required to know how various factors are influencing vibration level.
The paper is aimed at studying a dependency between the RMS value of vibration parameters of rolling bearings in different conditions and the radial load.
Kostyukov V.N., Boychenko S.N., Basakin V.V., Teterin A.O., Kudryavtseva I.S. Research on dependency of bearing vibration parameters on radial load // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2014. – p.118-123.
One of the main components of safe accident-free operation of industrial facilities is its high-quality production and maintenance. Throughout the years a concept of increasing quality of production and repair by means of objective condition assessment of assemblies and machines is commonly used.
The concept is implemented on the basis of automated control system for safe resource-saving operation and repair of machinery – COMPACS®. The bench variant of the system operates successfully at dozens of repair productions of Russia and CIS.
One of the latest development of DYNAMICS SPC among the bench systems is a pump units diagnostic and testing control system COMPACS®-RPG. The system is implemented at Volgogradneftemash, JSC – the biggest Russian producer of pump units.
The system is intended for collaborative work with new diagnostic and test bench (DTB) for pump units produced by Volgogradneftemash, JSC in order to carry out hydraulic, quality assurance and periodic tests of pump units with full assessment of their quality after assembly.
Through the COMPACS-RPG system, specialists of DYNAMICS SPC solved the task of providing an automatic operation of the bench with real-time calculation of all required characteristics and test protocol printing.
The paper dwells upon the usage of the modern systems for diagnostics and comprehensive condition monitoring (DMS) for fuel and power industry machinery, which make an integral part of the reliability control system for comprehensive production facilities providing safe resource-saving operation.
The paper considers the basic principles and the most important properties and characteristics of such systems, as well as their classification by 13 main features, describes methods for DMS types determination. The paper shows the examples of system type calculation for various software and hardware, the systems’ application domains for implementation at power facilities according to the risk of fault skipping. The paper classifies the machinery by the risk matrix considering probability of a fault occurrence and its economic, ecological and technogenic consequences.
The paper suggests more detailed classification criteria for facilities targeted by technical regulation (FTR), hazardous production facilities (HPF) and critically important facilities (CIF). As an example of the first class DMS - the stationary condition monitoring system COMPACS® is described. The system comprises all general principles of the first-class DMS building according to GOST R 53564.
Kostyukov V.N., Boychenko S.N., Naumenko A.P., Kostyukov An.V., Kostyukov Al.V. Monitoring risks of fuel and power industry machinery // [Electronic source]//New on Russian electric power industry. 2014. №3, p. 30-44. - URL: http://energo-press.info/журнал-новое-в-российской-электроэне/архив-новое-в-российской-электроэнер/