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
Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS® solve the following problems: vibration analysis and prediction of major malfunctions of equipment with early detection, full use of resources and retention of maintainability; monitoring of execution of diagnostic instructions and personnel actions through network (Internet) engineering; elimination of design and installation mistakes; optimization of flow charts and configuration; keeping of the databases of diagnostics, works, equipment replacement and service life; reporting at all control levels of the enterprise.
The Compacs-Net® network for vibration analysis is of service in on-line monitoring of execution of instructions of automatic systems for vibration analysis. The central element of the CompacsNet® network for vibration analysis and the collector of diagnostic information is the server that periodically examines the COMPACS® stations connected to a diagnostic network and saves the findings as SQL-database.
Internet-based technologies integrate various systems for vibration analysis of equipment condition, which are located hundreds of kilometers apart, into single information complexes used in ACS SRSM™ COMPACS®, improve observability and controllability of equipment, and increase the systems efficiency by significant reduction of maintenance costs.
Kostyukov V.N., Boychenko S.N., Kostyukov Al.V. Internet technology in the COMPACS control systems for safe resource-saving operation of equipment // Oil Industry. Innovative Technologies in Oil and Gas Industry. - M.: 2005. - № 10. - p. 104-107
The problem of increase of anthropogenic safety and profitability is urgent for oil and gas industry in whole and especially for modern refineries with high concentration of power-intensive and potentially hazardous equipment.
One of the most promising ways to solve this problem is implementation of the technology for safe resource-saving operation of equipment on the basis of vibration analysis and real-time condition monitoring based on the new class of systems - Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS®.
Kostyukov V.N., Boychenko S.N., Bezzubov A.V., Mikerin O.B., Fedorinov I.A., Durosov V.M., Lvov O.S. The COMPACS saving system ensures safe resource-saving operation of equipment at OOO LUKOIL-Volgogradneftepererabotka // Automation and information technology. Special edition of 'Oil of Russia' journal. - M.: 2005. - № 4. - p. 101-105
The paper presents the results of long experience of vibration analysis and condition monitoring of reciprocating compressors.
On the basis of the collected data the principles and methodological support for data collection and analysis, which enable vibration analysis and condition monitoring of reciprocating compressors, have been developed in order to determine normative values of the measured parameters.
The paper also presents some results concerning the ways to measure the parameters, collect data, and diagnose the compressors, as well as data processing scheme and some normative values.
Kostyukov V.N., Naumenko A.P. Regulatory and methodological support of reciprocating compressor condition monitoring // Control. Diagnostics. - M.: 2005. - № 11. - p. 20-23