Safe operation of complicated productions including hundreds and thousands of units of energy equipment is only possible with the information on its technical condition and available power being submitted to the company administration.
Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) represent a new class of production control systems that inseparably link all stages of diagnosing.
ACS SRSM™ realize a safe resource-saving technology (Safe Maintenance™ - SM™ - technology) for equipment condition control, which enables real-time condition monitoring of equipment and controllability of its quality at all stages of life cycle, stability, safety and efficiency of production process.
Kostyukov V.N., Naumenko A.P., Sinicyn A.A. Monitoring system of energy equipment // The problems of vibration, vibration adjustment, vibration monitoring and diagnostics: Collected reports, theses. - 2005. - pp. 110-114
The paper presents the results of theoretical and experimental investigations intended to justification of choice of the complex of diagnostic signals and features for evaluation and prediction of technical condition of rotor machines and units.
In the practice of vibration analysis and vibration control sometimes the signals of vibration acceleration and vibration displacement are not put to use because they are considered to be closely coupled with vibration velocity signal. In the course of repeated observation of vibration parameter trends accumulated by the systems for vibration analysis and vibration monitoring at a number of Russian plants more than once we evidenced the cases when only parameters of vibration acceleration and/or vibration displacement responded to the development of various defects of rotor assemblies.
These cases denote considerable narrowing of the range of diagnosed malfunctions with the use of parameters of only vibration velocity signal. Thus, the problem of independence degree of the signals of vibration acceleration, vibration velocity and vibration displacement arises.
Kostyukov A.V. Forming a vector of independent diagnostic features of technical condition of rotor assemblies // Collected articles on propulsion engineering dedicated to 175th anniversary of MSTU n.a. N.E. Bauman. - M.: MSTU n.a. N.E. Bauman, 2005. - pp. 26-30
Improving the quality and reliability of aviation equipment is impossible without correct information on its technical condition at all stages of equipment life cycle. Information on present, past and future technical condition of a product is obtained by the methods of technical diagnosis, genesis and prediction.
Regularities of machinery performance loss revealed during long industrial researches of thousands of machines and units in the field enabled to formulate a number of principles of the synthesis of continuous monitoring systems and Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™).
Realization of these and other principles enabled creation of new methods of diagnostics and prediction of the machinery service life without dismantling, which are invariant to equipment construction and form of connection between diagnostic features and structural parameters of technical condition applied in the COMPACS® systems and software.
Kostyukov V.N., Molteninov A.V. Diagnostics of technical condition of fuel pumps of gas turbine engines // Aircraft engines of XXI century: Collected theses of the II International Scientific and Technical Conference. - Volume III. - M.: Central Institute of Aviation Motors. - 2005. - pp. 69-73
We examined the principle of a spectral matrix which is based on the method of vibroacoustic diagnostics of batch-type equipment using synchronous comb filtering.
Modern computer aids enable realization of this method in the frequency domain, which increases precision of selection of multiple frequency components, and improves operation speed by ensuring the potentiality of work at the samples with limited length.
On the basis of the algorithms of a spectral matrix we developed the COMPACS® expert system that enables reasonably quick, complete and reliable diagnostics of technical condition without equipment dismantling.
Boychenko S.N. Spectral matrix of vibration in automatic diagnostics of batch-type equipment // Education through science: International Symposium. - M.: MSTU n.a. N.E. Bauman, 2005. - p. 63
The book deals with the theory of industrial engineering, resource saving and production management of enterprises with uninterrupted cycle. Business mechanism of equipment operation management by the example of refineries has been developed. The model of business process of safe resource-saving operation of equipment based on real-time condition monitoring of production factors has been suggested, the procedures have been detailed.
The book is meant for managers and chief specialists of the enterprises with uninterrupted cycle, researchers, post-graduates, students of economic specialties.
Kostyukov A.V., Kostyukov V.N. Increase of operational efficiency of enterprises based on real-time monitoring // M.: Mashinostroenie, 2009. - 192 p.
Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) enable automatic acquisition and use of reliable diagnostic information on the equipment condition in real-time mode. Such information represents a complex of diagnoses of condition of structures, machines, units and mechanisms that are collected on closely adjacent intervals of time so that the equipment condition varies insignificantly.
Nowadays about ten kinds of nondestructive testing (such as vibration, acoustic emission, thermal, electrical, etc.) are integrated in ACS SRSM™ COMPACS®.
Thus, the system enables continuous monitoring of production complex by the set of different methods of nondestructive testing on the basis of integrated hardware and software platform (COMPACS® distributed system for vibration analysis and computer monitoring), which enables diagnosing of condition of machine and columned-capacitive equipment, pipelines and tanks, furnaces and other equipment of petrochemical complex.
Kostyukov V.N., Kostyukov A.V. ACS SRSM™ COMPACS - the most important tool for equipping of refinery services that ensures safe and reliable operation of equipment // Proceedings of industry conference of chief mechanics of refineries and petrochemical plants. - 2005. - p. 218-221
Methodical instructions include two laboratory works by the course "Methods of technical diagnostics" containing the description of a test station of diagnosing tools, laboratory stand for wheel motor unit testing as well as implementation technology.
The instructions are meant for full-time five-year students of the speciality 190200 "Devices and methods of quality control and diagnosing" and the students of the Institute of Professional Development and Retraining.
Kostyukov V.N., Avilov V.D., Borodulin A.G., Koobar A.A., Abraamyan A.A. Diagnosing of the units of rolling stock. Part 1. Vibration analysis of wheel motor unit // Omsk: Publishing house of Omsk State Transport University, 2006. - 31p.
This standard is developed on the basis of the conclusions of the commission of State Technical Supervision Service of Russia carrying out acceptance tests of complex systems for monitoring of equipment of hazardous production facilities. This commission was created according to the decree № P-20 (02 December 2003) of Deputy Chief of State Technical Supervision Service of Russia. The conclusions reflect long-term experience of creation and implementation of comprehensive systems for real-time condition monitoring of machine and process equipment of hazardous production facilities in chemical, petrochemical, oil producing, oil and gas processing, mining industry, rail transport, public service, power engineering. This standard is recommended for expert, engineering companies and industrial enterprises as a guideline for selection and use of vibration indexes system for monitoring of machine unit condition in order to prevent technogenic accidents and ensure safe resource-saving operation of the equipment according to actual technical condition.
The standard has been developed by DYNAMICS SPC and the Scientific-and-Industrial Union "RISCOM".
Centrifugal pump and compressor units in hazardous industrial facilities. Operating standards for vibration (SА-03-001-05) Series 03 // The standard of Rostechexpertise. Moscow: Compressor and Chemical Equipment, 2005. - 24 p.
It was theoretically proved and practically confirmed that vibration parameter trends develop according to an exponential model on the areas of catastrophic wear of equipment. The practice of vibration analysis showed that different defects develop at different time intervals.
Consequently, the stage of catastrophic wear of different units takes different periods of time. Thus, the duration of exponential growth of vibration parameter trend is determined by the type of defect or malfunction associated with wear at a time (i.e., the type of wear process).
From the above reasoning it is possible to carry out vibration analysis of the equipment condition by determination of the rates of growth at different time intervals (at different areas of the trend), which correspond to different defects and stages of their development. Excess of the rate of growth at a certain area indicates hazardous development of corresponding defect or malfunction.
Kostyukov Al.V. Prediction of the equipment condition by the rates of change of vibration parameters // International Symposium "Education through science". Proceedings of the section "Internal Combustion Engines". - 2005. - p. 48-49