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.
The book presents various aspects of safe operation of the complexes of oil-and-gas enterprises, reconstruction and creation of new equipment based on conversion technologies and targeted programs.
It was shown the necessity and perspective of solving the problems of increase of production safety and efficiency on the basis of modern computer systems for vibration analysis and monitoring of equipment condition during its operation based on multiple-recognition methods by the use of the systems that measure the parameters of different physical processes: absolute and relative vibration, acoustic emission, temperature, electrical current, pressure, levels, etc.
Static and dynamic models, the methods of vibration analysis and vibration monitoring, the structure of expert systems, firmware of computer monitoring systems and automated control systems for safe resource-saving operation of equipment (ACS SRSM™) were presented.
The book is concerned with the problems of metrological support, the quality of the systems and technologies, personnel training, technical and economic efficiency of ACS SRSM™ and safe resource-saving (Safe Maintenance Technology) equipment operation.
Kostyukov V.N. Monitoring of production safety // M.: Mashinostroenie, 2002. - 224 p.
The report is concerned with the COMPACS® complex of methodical means and firmware providing new technology of resource-saving and safe operation of equipment. The systems implement vibroacoustic, thermal, acoustic emission, current and parametric (pressure, level, consumption, temperature) methods for diagnostics of machinery, vessels and equipment, which are protected by the patents for inventions, production prototypes and trademarks.
Built-in expert system carries out fully on-line automatic vibration analysis of the equipment malfunctions. This expert system is invariant to equipment construction and forms of connection between diagnostic features and structural parameters of the objects diagnosed.
At repair departments stationary systems for vibration analysis ensure output of 'nonvibrating' pumps and motors, which have the minimum dynamic loads and the maximum potential life, with 'one-time' assembling and commissioning.
COMPACS®-micro personal systems (automated working station of a diagnostician) ensure (off line) objective vibration monitoring of quasistatic equipment, transmit information to the stationary systems of vibration analysis for general announcing and reminding the personnel of condition of quasistatic equipment, realize the advantages of WINDOWS 95/98.
All these systems are integrated into a diagnostic network Compacs-Net®, they present diagnostic information according to the principle of MIMOSA standard ('look&feel') that considerably simplify training process.
Kostyukov V.N. Monitoring of safe operation of equipment // Proceedings of industry conference of chief mechanics of refineries and petrochemical plants. - Kirishi, 2002. - p. 269-270
The COMPACS® complex of methodical means and firmware provides new technology of resource-saving and safe operation of equipment. Direct economic effect of the implementation of such technology at the enterprises is achieved by the saving through the elimination of accidents caused by machine equipment, reduction of losses caused by the downtimes of process complexes, and reduction of repair expenses.
The advantages of the COMPACS® systems: high reliability, comprehensive self-diagnostics of the firmware, comprehensive monitoring of the personnel actions, use of equipment during the whole operating life. That enables continuous elimination of major causes of equipment failures, minimization of flow of requirements for maintenance of equipment and systems.
Application of the COMPACS® technology makes the operation of fixed assets manageable, reduces losses, saves material, financial and human resources, and increases capitalization of overall business.
Kostyukov V.N. Profitability based on resource-saving safety in petrochemical industry // Branch meeting proceedings. - Perm: 2002
Experience of long-term operation of the COMPACS® systems for automatic vibration analysis and computer monitoring of technical condition of machinery enabled to accumulate the data on the diagnostics of reciprocating compressors.
In order to make the analysis vibration sensors were installed at different points. Vibration examination of the compressor with the COMPACS®-micro portable system usually preceded the mounting of sensors.
Thus far the information has been accumulated, and the algorithms of operation of expert system for diagnostics of hydraulic impacts, loosening of piston nut, wear of rod seals and babbit layer of the slider have been developed.
Kostyukov V.N., Naumenko A.P. Vibration analysis of reciprocating compressors // Compressors and pneumatics. - M.: 2002. - № 3. - p. 30-31
Energy-saving and reduction of power consumption of equipment are vital problems for modern businesses. One of the ways to solve them is equipment operation in conditions ensuring energy-saving.
The analysis of operation of equipment most accepted by the enterprises - pumps, compressors, fans, electric motors - showed that electricity consumption may be reduced by 15-25% by improvement of its technical condition, which requires timely determination of equipment condition and unfavorable operating conditions, informing service and managing personnel in case of degradation of technical condition and violation of operation conditions in order to take urgent measures.
The assigned task is successfully solved by various systems: the COMPACS® system for vibration monitoring and vibration diagnostics, the COMPACS®-micro personal system, vibration diagnostics systems for repair departments integrated into diagnostic network Compacs-Net®. The analysis of sources and reasons for immediate effect after the system implementation permits to affirm that real-time vibration monitoring of equipment complexes enables company profitability on the basis of resource-saving safety.
Kostyukov V.N., Kirillov V.I. Energy-saving based on real-time condition monitoring of equipment // Energy-saving and energetics in Omsk region. - Omsk: 2002. - № 4 .- p. 95-98
Self-diagnostics of the firmware is the most important feature of modern systems for vibration diagnostics and vibration monitoring containing thousands of measuring channels and tens of thousands of diagnostic features.
We have developed the system for vibration diagnostics and vibration monitoring with self-diagnostics of overall measuring and transforming channel, which is realized by the signal injection into the circuit of detecting element of the sensor and its further analysis by the firmware.
The system ensures reliable diagnosing of failure of the sensor or cable routings. The system displays a message in the form of a "blue" corner at operator's desk situated in petrochemical complex, and at the stations of users of vibration diagnostic network, including the specialists of control equipment and automatics. This solution ensures quick elimination of causes of malfunction and failure, high metrological reliability, high availability, possibility of trailbuilder operation by actual technical condition.
Kostyukov V.N. Self-diagnostics of vibration diagnostic systems // Control. Diagnostics. - M.: 2002. - № 9. - p. 18-22