The paper presents the method of adaptive standardless vibration analysis of equipment on the basis of the analysis of vibroacoustic signals associated with unobserved errors of machines and units, which arise during the manufacturing process and in operation. Part of these errors is not presented adequately in ratio and interval scales.
We derived a canonical equation of links between diagnostic features of the signal and structural parameters of the machine condition, which represents the bisector of the first angle of information plane. The results of simulation for normal distribution are presented as well.
Kostyukov V.N. Adaptive method of vibroacoustic diagnostics // Actual problems of electronic instrument engineering: Proceedings of V International Conference. - Novosibirsk, 2000. - V.6 - p. 142-147
Trouble-free operation of equipment of petrochemical plants - one of the main factors determining production quality and output, technical and environmental safety.
The COMPACS® system enables automatic vibration analysis and monitoring of development of defects and malfunctions without dismantling of machinery of petrochemical and other fire explosive factories.
The maximum effect is achieved by comprehensive equipping of a number of units with the COMPACS® systems for automatic vibration analysis afterwards integrated into computer network of vibration diagnostics for supervision over the departments of chief mechanic and chief power engineer.
In estimating of saving rate of the system implementation at the refinery the following components are taken into consideration: increase of productivity and reliability of measurements and diagnostics, reduction of equipment repair costs, saving of the time of commissioning, number and length of emergency situations, number of production defects and downtimes.
Kostyukov V.N., Kostyukov Al.V., Shatalov A.A., Serdyuk F.I., Mahonkijj B.N., Makler B.V., Yolshin A.I., Aktuganov A.N., Mukhin S.V., Zyuzin A.V. Trouble-free operation - the way to increase the profitability // Chemistry and Technology of Fuels and Oils. - № 3 (501). - M.: 2000. - p.9-13
The COMPACS® system for computer monitoring carries out vibration monitoring and analysis of centrifugal compressors by means of the sensors of absolute and relative vibration installed on the outside (on the housing of each compressor bearing) and inside (above the rotor shaft) in orthogonally related directions in order to measure and control radial displacements and axial shift of the shaft.
The sensors of temperature, rotational speed and current consumption are used additionally. It enables diagnosing of technical condition and mode of operation of the compressors. Continuous vibration analysis and monitoring of technical condition of the units have positive results.
Every unit may become "good" in case of timely repair and estimation of its quality according to the unit condition by means of the COMPACS® system for vibration monitoring (both stationary and personal - COMPACS®-Micro), which enables to collect vibrations from all points of the compressor unit and transmit them to COMPACS-NET® diagnostic network of engineering supervision or to the Internet in order to analyze and control safe resource-saving operation.
Kostyukov V.N., Starikov V.A., Tarasov E.V. Monitoring and diagnostics of centrifugal compressors // Proceedings of VI International Symposium 'Consumers and manufacturers of compressors and compressor equipment'. - St. Petersburg, 2000. - p. 174-177
The article is concerned with the experience of creation of automated control systems for ecologically conscious and safe resource-saving operation of machinery of the plants with uninterrupted cycle (Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment - ACS SRSM™ - COMPACS®) on the basis of stationary systems for monitoring.
The created ACS systems enable elimination of harmful effect of human errors on the operation of technological systems, use of equipment during the whole operating life provided retention of its maintainability and production safety. In addition, ACS systems realize the strategy for minimal cost diagnostics and the technology of search and liquidating fundamental causes of equipment failures.
Kostyukov V.N. Automated systems for diagnostics and monitoring of resource-saving operation of equipment of oil-and-gas industry // CITOGIC. - 2000. - Volume 10. - Book 3. - M.: 2000. - p.22-35
The report deals with the problems of vibration analysis of machine equipment on the basis of the analysis of vibration parameter trends. Main modern methods of machine vibration analysis are based on the evaluation of vibration parameters and on the analysis of vibration signal spectra.
Harmonic analysis of the spectrum usually requires knowledge of an exact construction of a machine; and existing methods of vibration analysis and prediction of technical condition do not take into consideration harmful effect of the human factor. Reliability of evaluation of machine equipment condition can be increased considerably by the use of the laws of processes of destruction and operability loss.
The processes of pump-and-compressor unit degradation were researched at a number of Russian refineries by means of the COMPACS® stationary systems for vibration monitoring. The researches concerned showed that rates of operability loss differ at various machine assemblies.
Kostyukov A.V. Evaluation of machinery performability by vibration parameter trends // DYNAMICS OF MACHINE AGGREGATES: Proceedings of the 5th International Conference. - Gabcikovo (Slovak Republic), 2000. - p. 101-104
Vibroacoustic analysis is put to use in order to increase reliability and objectivity of condition monitoring of all bearings and reduction gear of wheel motor units of ER-2 electric multiple unit.
The COMPACS®-EXPRESS system ensures evaluation of current technical condition and prediction of future technical condition of the elements of wheel motor unit by the results of measurement of vibration parameters, determines quantitative characteristics of physical quantities used as diagnostic features, displays them on the screen as a special board which shows quantitative and qualitative characteristics of the feature.
At the same time built-in expert system displays on the screen text and graphical information on a technical condition of wheel motor unit according to the test results. A printing device records this information, and the test results are automatically archived in the form of test reports.
Implementation of the COMPACS®-EXPRESS system for vibration analysis enables to improve the quality of repair and reliability of electric stock.
Kostyukov V.N., Avilov V.D., Kharlamov V.V., Naumenko A.P. The COMPACS system of vibration analysis for evaluation of technical condition of rolling stock units // New technologies - to railway transport: human resource development, organization of transportation process, operation of technologies: collected articles with international participation (in 4 parts). - Omsk: OSTU, 2000. - Part 3 - p. 245-247
In order to ensure failure tolerance of a process system it is necessary to monitor the equipment degradation, diagnose and control the equipment condition by giving the personnel notifications concerning urgent immediate actions.
Reliability and service life of the units depend heavily on their vibration; and vibration, in turn, is determined by the errors in manufacture, assemblage, repair and mounting at the unit as well as by operational defects caused by wear, mistakes of maintenance personnel and faults of operating conditions of the unit. That determines the necessity of vibration analysis of equipment condition at all stages of its life-cycle: for evaluation of workmanship, repair and mounting at the unit, for evaluation of technical condition in operation due to wear, mistakes of maintenance personnel and violation of operating conditions of the unit.
During vibration analysis of even one process unit diagnostic information should be collected, processed, presented and transmitted to the personnel in appropriate form during short interval of time (5-10 minutes) determined on the one hand by the maximum speed of malfunction development, and on the other hand – by the necessity of timely detection of mistakes or negligence of maintenance personnel and violation of operating practices which causes the unit failure. Considerable information scope requires the use of only stationary systems for continuous vibration monitoring.
Kostyukov V.N. Vibration analysis and monitoring of the units of plants with uninterrupted cycle // DYNAMICS OF MACHINE AGGREGATES: Proceedings of the 5th International Conference. - Gabcikovo (Slovak Republic), 2000. - p. 95-100
The article presents the mechanism of unit vibration trends, which represent the mixture of gradual and discontinuous processes, and the mechanism of spreading of vibration spectrum in case of the unit degradation.
We proposed and tested the method of recursive synthesis of orthogonal diagnostic features that is invariant to the unit type. This method based on the blocks of spectral matrix realizes the concept of "collective recognition". In addition, we developed and tested deterministic models of unit performability and method of approximation of multimodal intensity of wear by Veibull-Gnedenko mixture of distributions.
The results obtained form the basis of the strategy for minimal cost diagnostics and enable significant reduction of costs and shortening of the period of implementation of the systems for condition monitoring of hazardous production facilities.
Kostyukov V.N. Synthesis of invariant diagnostic features and models of the unit condition for the purpose of diagnostics // Omsk Research Bulletin. - Omsk: 2000. - Issue 12. - p. 77-81
The main types of vibration signals used in the systems for equipment vibration analysis are the signals of vibration acceleration, vibration velocity, and vibration displacement. The parameters of these signals (RMS value, peak value) are in common use in different diagnostic and vibration-survey systems for equipment condition control.
In order to receive the required signal it is allowed to use appropriate sensor as an end device: piezoaccelerometer – for vibration acceleration parameter, inductive sensor of vibration velocity - for vibration velocity, displacement sensor – for vibration displacement.
But most devices and systems for vibration measurement use vibroaccelerometer as an end device, and the integration operations are used for acquisition of the signal of vibration velocity and vibration displacement.
Boychenko S.N. Algorithms for spectral integration of vibroacoustic signals for equipment vibration analysis // DYNAMICS OF MACHINE AGGREGATES: Proceedings of the 5th International Conference. - Gabcikovo (Slovak Republic), 2000. - p. 34-37
Vibroacoustic signal matrix reflecting the structure of diagnosed machine has been synthesized in the article. The matrix rows contain the spectrum components in different frequency bands, the matrix columns contain the components relating to certain classes of condition and types of defects of various kinematic couples, and residual 'noise' that reflect the principle of information completeness.
We considered spectral matrix conversions for the synthesis of diagnostic features, proposed the method and system for automatic recognition, which are invariant to machine construction, proposed an adaptive algorithm for recognition in conditions of a priori uncertainty, which enables recursive improvement of the machine construction by the parameters of its vibration.
The aspect, which is realized after considering the results of the synthesis of a spectral matrix of vibration signal, enters into invariance principle that is one of the bases of the strategy of minimum cost. The use of invariance principle in vibration analysis and diagnostic systems enables significant reduction of the implementation period.
Kostyukov V.N. Synthesis of a spectral matrix of machine vibration and its recognition for the purpose of diagnostics // Omsk Research Bulletin. - Omsk: 2000. - Issue 12. - p. 71-77