The article examines the features for evaluation of class of a monitoring system for production and transportation purposes, shows a necessity of meticulous consideration of factors correlation and inner classification in order to determine the power industry facilities liable to the particular diagnostic and monitoring systems.
The article specifies the criteria for classification of facilities targeted by technical regulation, hazardous production facilities, critically important facilities and strategically important facilities.
The author shows a significant impact of type 1 error of machinery condition static recognition on type 1 dynamic recognition error, which is developing in inverse relation to decrease of ratio of diagnostic signs critical values (“Unacceptable” and “Actions required” conditions).
It is shown in the article, that implementation of diagnostic and monitoring systems is advisable even in case of high risk of failure skipping, since when the risk to skip a failure is more than 30% - time of accident-free operation of hazardous production facilities increases not more than twice.
Kostyukov V.N., Boychenko S.N., Naumenko A.P., Kostyukov An.V., Kostyukov Al.V. Risk Evaluation for FPC Facilities Condition Monitoring // Problems of vibration, vibration alignment, vibration monitoring and diagnostics of power stations: proceedings of the VIII International Scientific Conference - Moscow, JSC "VTI", 2013. – p. 225-235
DYNAMICS SPC produces systems for vibration analysis and monitoring of accident prevention and condition control - COMPACS®, which are applied in upstream, downstream, power industry and various engineering industries.
The systems are designed for measuring the vibration parameters, rotation frequency, A/C and D/C, temperature, level, pressure, and the most important value is vibration.
The main task of the vibration channel tuning is to determine the coefficients of frequency and amplitude range. That can be done manually by connecting to a channel of the sensor mounted at the test vibration unit, as well as by calculating coefficients separately for each channel.
The general idea of the process automation is in replacing the test vibration unit by the controlled signal generator which output is connected to the measuring channels instead of a vibration sensor.
The signal generator is included into a test bench, which is a multi-functional software-and-hardware complex operating on the basis of various text signals reproduction and registration of the system’s readings.
Using of test vibration unit is necessary only for the bench calibration, while the system’s tuning is automatic and does not require any calibrating device.
Kostyukov V.N., Kostyukov Al.V., Boychenko S.N., Pavlenkov D.V. Automatic Tuning of Vibration Analysis System Channels by Vibration Parameters // Devices and techniques for measuring, quality control and diagnostics in industry and transport: refer to. 2nd All-Russian scientific and technology conference with international participation. - Omsk: OSTU, 2013. - P. 352-356
The condition of bearing assemblies included into wheel-motor unit (traction electric motor and gear, axle bearings) impacts directly on its resource.
The major technique for specified assemblies’ condition is carried out using vibroacoustic diagnostics. This technique allows measuring vibrations on the specified rotating frequency of the shaft, comparing obtained diagnostic signs readings to corresponding critical values. Basing on the obtained results the diagnosis is to be made considering defect appearance.
The disadvantage of the technique is non-stationary appearance of incipient defect in vibration signals on low rotating frequencies (180-210 r/min).
In order to assess appropriately the bearings’ condition it is required taking into account the impact of rotating frequency and type of defect appearance on different speed.
The mathematical model was developed and approved by test data. The model connects the level of rotation bearing vibration signal with linear dimensions of the defect and bearing rotating frequency. This illustrates that the vibration amplitude is proportional to rotating frequency and defect dimension.
Kostyukov V.N., Zaitcev A.V., Teterin A.O. The Research of Wheel-Motor Unit Condition Diagnostics Fault // Devices and techniques for measuring, quality control and diagnostics in industry and transport: refer to. 2nd All-Russian scientific and technology conference with international participation. - Omsk: OSTU, 2013. - P. 132-136
Trends are used in machinery condition monitoring for its vibration analysis. The trend means change of vibration parameter variation in time.
There are two criteria for assessing the machinery condition in hazardous industry according to GOST R 53563-2009:
Absolute parameter creation (vibration velocity, vibration acceleration and vibration displacement);
Growth rate of the parameters per hour creation.
The machinery condition is assed according to any of the parameters with the worst condition.
The vibration measured by the sensor located on the housing of the diagnosing machinery has irregular shape. The shape consists of the useful and noise components. When the machinery is in unsteady mode the noise components prevail in vibration signal. This contributes to the increase of vibration parameters values. So the threshold values are exceeded accidentally.
As a result the task of trends processing appears for the minimization of noise impact on trend change assessment.
In order to analyze the impact of smoothing technique the article considers the vibration displacement of the front bearing of the ventilator in intermittent mode.
Kostyukov A.V., Boychenko S.N., Kondratenko E.V. Smoothing Technique Impact on Trends Retard // Devices and techniques for measuring, quality control and diagnostics in industry and transport: refer to. 2nd All-Russian scientific and technology conference with international participation. - Omsk: OSTU, 2013. - P. 122-126
Continuous and sustainable signals recording (without data omission) is a distinctive feature of 3541 measuring module developed by DYNAMICS SPC.
The article is devoted to the module results. The works result is vibration signal sampling of traction motor of electric train and 250 sec duration and 65 kHz sampling frequencies are shown as a spectrogram.
The spectrogram shows two sympathetic vibration zones of vibration sensor used for the signal obtaining. The peaks, frequencies and their levels which do not depend on electric train speed (rotational frequency) and perturbation action availability (available even when the electric train is stopped) are also marked on the spectrogram.
Harmonic components of vibration signal spectrum are in range from 0 to 10 kHz, in speed rage from 0 to 120 km/h. The frequencies of harmonic components vary directly electrical train speed. The zones showing the electric train speed-up and running-out are clearly distinguished on the given data visualization form.
The system based on 3541 module allows executing vibroacoustic and acoustic emission diagnostics in real-time of machinery including machineries in non steady conditions.
Kostyukov A.V., Zaytsev A.V., Melk V.V., Shchelkanov A.V., Tcurpal A.E. Measuring System for Broadband Vibroacoustic Processes // Devices and techniques for measuring, quality control and diagnostics in industry and transport: refer to. 2nd All-Russian scientific and technology conference with international participation. - Omsk: OSTU, 2013. - P. 26-30
Existing documents in the field of piston machines vibration rationing, in particular standards VDI 2056, ISO 2372, ISO 10816-6, the draft standard ISO 10816-8, as well as commercial standards, do not provide diagnostics and a safe, fault free compressors operation. Moreover, the draft standard ISO 10816-8 is not intended to be used in monitoring systems, since it does not guarantee the compressors safe operation as well. In 2011 in Russia the industry standard STO 03-007-11 has been adopted; it allows to carry out a vibration analysis monitoring of the piston compressors crucial components and ensures the compressors safe operation.
The standard applies to stationary piston compressors, operating on explosive and hazardous gases and sets the vibration standards for assessing their condition during operation and acceptance tests after mounting and repair.
The vibration parameters rates, specified in STO 03-007-11, are of advisory nature for all the machines which are not enumerated in the machinery list, supplied in the standard appendix.
These rates can be adjusted according to resolutions of the enterprise responsible technical services as bringing the diagnosed equipment to the required reliability activities, guaranteeing safety and fault-free operation of the hazardous facilities. The standard specifies the vibration parameters rates and prescribes their use for the arrangement of vibration monitoring, vibration analysis, condition monitoring and operational risks for stationary piston compressor units.
This document determines the frequencies ranges of measurement for each vibration parameter and proposes to measure not only the mean square values of acceleration, velocity, displacement, but their amplitudes, as well. The vibration rates are given for the five compressors constructive groups with unit capacities from 0,02 to 2 MW. The paper considers the standard STO 03-007-11 main issues.
Kostyukov V.N., Naumenko A.P. Rationing of piston machines vibration // X International Conference Condition Monitoring and Machinery Failure Prevention Technologies - СМ/MFPT 2013
The studies have shown that existing diagnostic techniques for the pneumatic system within an electric train have low reliability, completeness and diagnostic depth.
To identify the diagnostic features that characterize different types of faults and the degree of their development, a large number of test data for each type of fault needs to be collected. In practice to do this work within a reasonable period of time is not possible. This raises the problem of modeling dynamic processes in the pneumatic system of the electric multiple unit with different types of faults.
As follows from the analysis of possible methods it was decided to model gas-dynamic processes in the pneumatic system of the electric multiple units using the combined method, i.e. some parts of the pneumatic system would be described analytically, the other parts – algorithmically. Modeling the system as a whole will be done by numerical method of finite differences.
The resulting model accurately describes the gas-dynamic processes in the pneumatic system of the electric multiple unit. After being improved with regard to pipelines it can be applied for modeling various types of faults in the pneumatic system.
Kostyukov V.N., Schelkanov A.V. Model of Electric Train Pneumatic System // Engineering Support of Railway Rolling Stock Maintenance and Dynamics Improvement: proceedings of the 2nd All-Russian Scientific and Technical Conference with International Participation. - Omsk: Omsk State Transport University, 2013. - pp. 67-75
The wheel-motor unit is the most important section of an electric train, which fault-free operation affects the safety of railway transport.
The aim of this work is to increase the reliability of wheel-motor unit diagnostics.
To ensure the most reliable diagnostics the test hardware should:
Make a clear health diagnostics of the tested assemblies;
Eliminate an opportunity for the diagnostic operator to make decision on the wheel-motor unit health on his own;
Provide automatic acceleration of the drive motor maintaining the predetermined speed;
Provide automatic consistently-set adjustable rotation of the wheel pair in forward and reverse directions;
Simultaneously measure vibration in all tested assemblies;
Detect vibration signals from the selected tested assemblies.
The COMPACS®-EXPRESS vibroacoustic monitoring system meet most of the requirements. The system is designed to monitor health of wheel-motor units of railway rolling stock. The system measures the vibration parameters, generates expert reports and displays them on the monitor, as well as provides automatic acceleration of the drive motor maintaining the predetermined speed of the wheel pair. Test results are generated in the form of reports on technical condition for each wheel-motor unit and the railcar as a whole.
Zaytsev A.V. Improvement in Techniques of EMU-Train Wheel-Motor Unit Diagnostics // Engineering Support of Railway Rolling Stock Maintenance and Dynamics Improvement: proceedings of the 2nd All-Russian Scientific and Technical Conference with International Participation. - Omsk: Omsk State Transport University, 2013. - p.60-67
It is known that the lack of fact-based equipment quality control during production and service, as well as the lack of in-service observation over the real health degradations do not allow us timely take cost-effective and technically efficient measures to maintain a high level of equipment reliability.
The problem of diagnostics reliability and guaranteed delivery of the diagnostics data to the executives and managers of different responsibility levels is solved by automatic condition monitoring and creation of automated control systems.
DYNAMICS SPC expertise in monitoring and diagnostics of critical equipment at various industries and railway transport made possible to create innovative health control technology for rolling stock on the basis of real-time monitoring that is Automated Control System for Safe-Money-Saving Real-Time Maintenance of equipment (ACS).
The purpose of introducing ACS into railway transport is to increase the safety and smooth functioning of the transport through the effective health monitoring of rolling stock and infrastructure facilities on the basis of continuous automatic real-time monitoring.
Kostyukov V.N., Kostyukov Al.V., Kazarin D.V., Schelkanov A.V. Resource-Saving Operation and Maintenance of Motor-Driven Rolling Stock // Eurasia Vesti. - 2013. - August. - p.20.
DYNAMICS Scientific & Production Center (DYNAMICS SPC) was founded in June 11 in 1991 by Vladimir Kostyukov in Omsk.
The crucial moment for the company was a successful implementation of the first computer monitoring system for pump units developed by the DYNAMICS SPC specialists for the 36/1-3 deasphalting unit and AVT-10 atmospheric and vacuum crude unit of Omsk refinery.
Over 2 years there were more than 6 systems on the refinery. The systems were protecting about 138 machines of the 6 most important plants from the breakdowns. Also, there was the diagnostic network Compacs-Net® used for issuing voice announcements for the specialists.
In 1994 the preventing shutdowns and condition computer monitoring system COMPACS® was approved by Ministry of Fuel and Power and State Committee for Industrial and Mining Safety Supervision of Russian Federation.
Today more than 500 systems are implemented in Russia and other countries in 12 industry branches: petrochemical, oil-refining, mining, metallurgic, railway transport and community facilities, etc.
Kostyukov V.N. DYNAMICS Scientific & Production Center // Success as a lifestyle. - 2013 - September. - P.38-39