Improving the quality and reliability of aviation equipment is impossible without correct information on its technical condition at all stages of life cycle: in developing in design office, at the manufacturing stage and in operation. Information on present, past and future technical condition of a product is obtained by the methods of technical diagnosis, genesis and prediction.
The quality of these methods is characterized by PD probability of acquisition of correct information on the product condition at a time. Vibration monitoring of condition integrates these methods into a single continuous process by the elimination of passing through the time intervals with unobserved changes of the condition.
Reliability of the results of monitoring (PM) is determined not only by the reliability of vibration analysis (PD), but also by the frequency of vibration control (TK) that should be considerably smaller than duration of malfunction development (TN) because it determines the probability of detection (PT) of a critical malfunction.
Kostyukov V.N. Condition monitoring of aircraft units // Collection of reports of scientific and technical conference "Sensors and detectors for aviation equipment "DDAT-2003". - Penza, 2003. - p. 87-95
Efficient and reliable operation of rolling mills in many respects depends on reliability of direct current motors of primary drives, which is in large part determined by the conditions of commutation. Emergence of ring fire in the collector and increased sparking of the motor may cause the accident. Approximate cost of elimination of such accident may amount to tens of thousands rubles that convincingly confirms importance of vibration analysis and commutation adjustment of commutator electric machines of direct current.
The paper presents some results of examination of commutation conditions of motors of primary drives of finishing mill train 320 of JSC Metallurgical Plant in the Name of A.K. Serov and mill 800 of JSC Chusovoy Metallurgical Works.
We must conclude that the developed method of commutation adjustment in terms of operating conditions and application of a modern device system enables to reveal the reserve of use of the equipment installed. It results in the increase of productivity of rolling mills in whole or reliability of primary drive operation with lower operating costs.
Kostyukov V.N., Kovbasa N.I., Avilov V.D., Savelieva E.N. New technology for diagnosing and commutation adjustment of direct current motors of primary drives of rolling mills // Modern trends in development and construction of collector and other electromechanical energy converters. - Omsk: OSTU, 2003. - p. 203-208
The COMPACS® system for automatic vibration analysis is the firmware complex providing new technology for safe operation and maintenance of mechanical equipment. The COMPACS® system falls into the category of the systems for measurement and diagnostics; it is intended to solve the problems of vibration monitoring of process equipment condition.
The hardware of the COMPACS® systems for automatic vibration analysis is constructed with the most advanced components; the characteristics of the COMPACS® systems constantly improve. In addition, the systems have a flexible structure at the expense of microprocessor control. All modern systems have a backbone network of the links between modules and diagnostic controller by control and signal lines; also they correspond to all fundamental principles of construction of the COMPACS® measurement and diagnostic systems.
The hardware structure of the COMPACS® system for vibration monitoring includes:
distributed system of end devices which control major parameters of the equipment;
distributed system of portable modules which enable initial conversion of the signals from the sensors and their translation to a diagnostic controller as well as control over the integrity of the sensors and communication lines;
vibration analysis station that control portable modules and ensure data collection and processing.
Starikov V.A. COMPACS system hardware // Collection of reports of scientific and technical conference "Sensors and detectors for aviation equipment "DDAT-2003". - Penza, 2003. - p. 18-21
DYNAMICS Scientific & Production Center (SPC) developed and implemented the COMPACS® stationary system for vibration analysis and computer polyvalent monitoring of the equipment condition at 70 petrochemical complexes and 12 factories. The COMPACS® system enabled complete elimination of sudden failures of equipment.
On the basis of the COMPACS® systems for vibration analysis and automatic condition monitoring DYNAMICS SPC specialists first in the world created and widely implemented a new class of Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) for hazardous industries.
The technologies for total resource-saving are successfully used in the COMPACS® systems for vibration monitoring which ensures reliable operation of equipment of hazardous petrochemical plants with minimum costs.
Kostyukov V.N., Boychenko S.N. Total resource-saving in the COMPACS systems for computer polyvalent monitoring of the equipment condition // Energy-saving and power engineering in Omsk region. - Omsk: 2003. - № 4(9). - p. 48-49
The necessity of creation of an expert system (ES) for automatic vibration analysis and prediction of technical condition of electric drives is conditional on a high speed of the degradation processes and a large number of the units in petrochemical industry.
ES use enables to copy and spread the knowledge, and thus makes a unique experience of several highly skilled professionals available for a number of specialists. The COMPACS® ES enables reasonably quick, complete and reliable vibration analysis of technical condition of an electric motor without dismantling since it detects the following malfunctions:
unfastening of a motor to a base;
dog leg and unbalance of revolving parts;
inadmissible oscillations of a base;
inadmissible temperature of machine units;
frequency content and amplitudes of current of drive electric motors.
Kostyukov V.N., Boychenko S.N. Use of spectral matrix algorithms for vibroacoustic analysis of electric drives of centrifugal pumps of petrochemical production // Proceedings of 8th All-Russian Scientific and Technical Conference "Modern development trends of construction of collector and other electromechanical energy converters". - Omsk, 2003 .- p. 239-243
The article presents the results of research of orthogonality of the signals of vibration acceleration, vibration velocity and vibration displacement in the course of the defect development by means of numerical simulation of defects and correlation analysis.
Orthogonality of diagnostic features is an important condition that significantly simplifies the process of vibration analysis of the equipment condition. The more independent characteristics form a vector of diagnostic features, the easier to relate it to the vector of the equipment condition.
The dependence of the equipment condition is simplifying if all diagnostic features of a vector are orthogonal.
Kostyukov A.V., Kostyukov V.N. Experimental unit for research of vibroacoustic processes in electromechanical units on the basis of Agilent VEE software suite // Proceedings of 8th All-Russian Scientific and Technical Conference "Modern development trends of construction of collector and other electromechanical energy converters". - Omsk, 2003. - p. 226-239
We developed resource-saving technology for production and repair of electric machines with the quality diagnostics at all stages: vibration analysis of the components quality, build quality of the units, quality of assembled machines and units in running and during acceptance test.
The technology is based on stand systems for vibration analysis of technical condition of rolling and plain bearings, dynamic balancing of rotors, build quality of bearing supports and rotary assemblies in own supports, comprehensive diagnostics of assembled machines and units.
This technology is realized on the basis of the COMPACS® stationary system – the system of computer monitoring for accidents prevention and condition control of machine equipment.
Kostyukov V.N., Karpov S.Y., Kovbasa N.I. Resource-saving technology for production and repair of electric machines on the basis of condition diagnostics // Proceedings of 8th All-Russian Scientific and Technical Conference "Modern development trends of construction of collector and other electromechanical energy converters". - Omsk, 2003 .- p. 214-219
The analysis of failure level of process equipment (furnaces, columns, machinery, etc.) shows that machine equipment failures make up about 70% of all failures. Thus, the automation of control over equipment operation on the basis of real-time vibration monitoring of the equipment condition is an actual problem.
Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™), which were developed by DYNAMICS Scientific & Production Center (SPC) for vibration analysis and control over safe resource-saving operation on the basis of real-time condition monitoring of equipment, solve the following problems:
vibration analysis and prediction of major malfunctions (> 95-98%) of equipment with early detection, full use of resources and retention of maintainability;
notification to the personnel of urgent immediate actions intended to control the equipment condition;
monitoring of execution of diagnostic instructions of the systems and the personnel actions through network (Internet) engineering;
development of the plans of targeted repairs in accordance with the actual technical condition of equipment;
elimination of design and installation mistakes;
optimization of flow charts and equipment configuration;
keeping the databases of diagnoses, works, replacements and service lives of equipment, reporting at all control levels of the enterprise.
Naumenko A.P., Boychenko S.N., Kostyukov Al.V. Condition monitoring of machine equipment is a solution to the problems of safe operation // Workshop meeting "Problems of safety, ecology and automation of shipment operations and storage of oil and oil products". - 2003. - p. 85-91
The paper presents the strategy of integrated continuous control of equipment condition that is based on real-time acquisition and analysis of objective instrumental data on actual technical condition of equipment. The data sources are the complexes of acoustic emission monitoring of capacitive equipment (vessels, instruments, pipelines, etc.) and the complexes of condition monitoring of rotating equipment (pumps, compressors, fans, smoke exhausters, etc.) by the parameters of vibration, current and temperature.
This strategy is implemented in the COMPACS® systems for computer monitoring of the machinery condition, which enables complete elimination of sudden failures, increase of safety and cost efficiency of operation of hazardous production facilities and comprehensive solution of a problem of increasing run-to-failure period of equipment provided transition to operation in accordance with the actual technical condition.
Problems associated with wear of basic production assets of hazardous production facilities of chemical, petrochemical and oil refining enterprises and actual condition of process equipment necessitate search, development and implementation of modern advanced technologies for monitoring of the equipment condition and systems for maintenance based on the principles of use of actual resources of safety. Experience of development and maintenance of modern control and diagnosing systems based on the methods of acoustic emission and vibration monitoring enables realization of the basic principles of the strategy of preventing maintenance, safety and resource-saving technologies.
Shatalov A.A., Razuvaev I.V., Kostyukov V.N. Experience of realization of the strategy of petrochemical plant safeguarding during operation in accordance with the actual technical condition // Chemical technique. - M.: 2003. - № 3. - p. 11-13
The book presents the basic principles of practical analysis of vibroacoustic signal parameters in order to determine technical condition of machine equipment and the main diagnostic features of malfunctions and defects. Special attention is paid to practical methods of equipment condition diagnostics on the basis of the analysis of vibroacoustic signal.
The book conforms to State Educational Standard of the disciplines 'Automated systems for quality monitoring and diagnostics' and 'Methods of technical diagnostics' (engineering education course 190200 "Devices and methods of quality control and diagnostics").
The book is intended for four-year and five-year students of a Radiotechnical Faculty studying the discipline 'Automated systems for quality monitoring and diagnostics' within the framework of engineering education. Also this book may be useful for post-graduates and the specialists engaged in condition diagnostics of machine equipment.
Kostyukov V.N., Naumenko A.P. Practical fundamental of vibroacoustic analysis of machine equipment // Omsk: Publishing house of Omsk State Technical University, 2002. - 108 p.