In the last few years a common means for reliability control at refineries has become a risk management system which should provide optimization of maintenance and repair costs while increasing the turnaround interval of process plants. However, a large amount of data required for risk calculation, as well as significant problems connected with unevenness of the data, lack of standards for their collection, subjectiveness of manual data input, does not allow to consider the risk management systems to be complete enough for the increase of turnaround interval and providing required minimal risk level. The main parameter for risk assessment is the probability of equipment failure. Considering the possibilities and properties of the modern condition monitoring systems it becomes possible to propose real-time calculation of process plant failure probability and operation risk.
The paper considers a statistical approach to the assessment of equipment failure probability according to the data of permanently installed condition monitoring systems. It gives the results of research on statistical parameters of machinery operation time and failure probabilities.
Usage of condition monitoring systems for calculation and monitoring of machinery operation risk allows improving the efficiency of implementation of condition monitoring means and turnaround interval of process plants.
Kostyukov V.N., Kostyukov A.V., Boychenko S.N. Assessment of failure probability and operation risks of process plants according to data of condition monitoring systems // Proceedings of CM2016/MFPT2016
To visualize the physical processes that occur in the journal bearings of the shafting of power generating turbosets, a technique for preliminary calculation of a set of characteristics of the journal bearings in the domain of possible movements (DPM) of the rotor journals is proposed. The technique is based on interpolation of the oil film characteristics and is designed for use in real-time diagnostic system COMPACS®.
According to this technique, for each journal bearing, the domain of possible movement of the shaft journal is computed, then triangulation of the area is performed, and the corresponding mesh is constructed. At each node of the mesh, all characteristics of the journal bearing required by the diagnostic system are calculated.
Via shaft-position sensors, the system measures—in the online mode—the instantaneous location of the shaft journal in the bearing and determines the averaged static position of the journals (the pivoting vector). Afterwards, continuous interpolation in the triangulation domain is performed, which allows the real-time calculation of the static and dynamic forces that act on the rotor journal, the flow rate and the temperature of the lubricant, and power friction losses. Use of the proposed method on a running turboset enables diagnosing the technical condition of the shafting support system and promptly identifying the defects that determine the vibrational state and the overall reliability of the turboset. The authors report a number of examples of constructing the DPM and computing the basic static characteristics for elliptical journal bearings typical of large-scale power turbosets. To illustrate the interpolation method, the traditional approach to calculation of bearing properties is applied. This approach is based on a Reynolds two-dimensional isothermal equation that accounts for the mobility of the boundary of the oil film continuity.
Kumenko A.I., Kuzminyh N.Y.,Timin A.V. Calculation and Interpolation of the Characteristics of the Hydrodynamic Journal Bearings in the Domain of Possible Movements of the Rotor Journals // Thermal Engineering, 2016, Vol.63, No. 10, pp. 699-706
A perfection concept is proposed for automated control diagnostics systems used at power plants with application of shaft sensors. It is proposed a systematic approach to solve a number of practical problems related with safety and performance of power generating turbosets. Diagnostics of multi-rotor turboset technical condition are significantly improved due to "complete" set of shaft motion sensors, applied at both sides of each journal bearing. There have been given diagnostics signs of defects measured with shaft sensors and suggested some extra criteria of reliability of the shafting and supports.
To illustrate the method let us compute correcting alignments of fragment of shafting. Using simplified 2-rotor 4-support turboset, it is shown that: corrective alignments of supports, recommended by manufacturers of turboset and generator, may be not sufficient to compensate misalignments of supports, caused by thermal deformations of turboset support system. Those corrective misalignments should be computed individually for each turboset, using real thermal deformations and real clearances of journal bearings.
Kumenko A.I., Kuzminyh N.Y.,Timin A.V. Shaft sensor based on modeling diagnostic signs of power unit defects // Procedia Engineering. - 2016. - № 152. - P.531 – 539
The present work describes the structure and operational concept of the system for machinery condition monitoring using adaptive measurements. The work reveals the results of adaptive measurements procedure of the system illustrated by trends of centrifugal pump vibration signs. The work objective is to increase validity of machinery condition monitoring results through providing high spectral resolution. The spectral resolution is essential for separating defects in the vibration signal spectrum and retaining high speed of vibration measuring. This is required in order to eliminate the omission of defects with minimal expenses on hardware.
The purpose of this work is to develop the search technique of optimal operation procedures for rolling bearings during their condition diagnostics. From the perspective of completing the task for a condition assessment the operation procedure providing minimum diagnostic errors (machinery condition identification error) is considered optimal. The regularities obtained by the developed technique were tried and tested and taken as the basis of the diagnostic technique. Such technique is implemented in modern means, particularly in bench systems of rolling bearings diagnostic.
Kostyukov V.N., Kazarin D.V., Basakin V.V. Search technique of optimal operation procedures for rolling bearings for diagnostics purposes // Procedia Engineering. - 2016. - № 152. - P.516 – 520
The purpose of this article is to determine optimal conditions for rotor machinery operation in order to evaluate its condition using coherent function. The coherent function is an analogue of the correlation factor in frequency domain. The function reflects the linear relationship levels of harmonic components of parallel signals covered in the article. The conditions are considered optimal when the coherence function is expressed the most evidently. In other words, the coherent components are close to one.
Kumenko A.I., Boychenko S.N., Teterin A.O. Selection of coherent frequency components of vibroacoustic signals from assemblies of rotor machinery // Procedia Engineering. - 2016. - № 152. - P.511 – 515
The paper considers an analysis of vibration changes due to strength degradation of centrifugal pumps details while operating at refineries. The analysis revealed sudden changes of vibration in pump units operation. The paper offers a method of separating smooth changes from sudden ones, degradation process monitoring, and prompting personnel on scheduling the units decommissioning for repair and maintenance. Method of long-term diagnostics for the whole operation life of the pump unit is given.
The article presents the results of reciprocating compressors operation under the control of Vibration-Based Diagnostics monitoring systems, dwells upon the issues of usage of reciprocating compressors valves by various vendors and their influence on compressors’ vibroactivity. An adequate evaluation of vibroactivity of piston machines is provided by the Russian regulative database on vibration parameters.
Main differences of Russian and global methods of reciprocating compressors health evaluation, particularly, used frequency range, are presented in the article. It is shown that the approach laid in Russian standards on reciprocating compressors vibration regulations, ensures true-to-life assessment of reciprocating compressors assemblies and details condition. The examples given in the article confirm that the criteria of reciprocating compressors repair correctness assessment should be the machinery health, including its vibroactivity, not just mindless usage of new components purchased from the global brands. Practical examples of operation and monitoring of reciprocating compressors show that Russian developments and products, particularly, scientific-methodological and standards base of Vibration-Based Diagnostics monitoring, reciprocating compressors monitoring systems, reciprocating compressors valves are highly competitive with foreign ones, and sometimes even superior to them in parameters and characteristics, which is a positive factor under the conditions of current economic situation and import substitution policy.
Kostyukov V.N., Naumenko A.P. About the experience in operation of reciprocating compressors under control of the vibration monitoring system // Procedia Engineering. - 2016. - № 152. - P.497 – 504
The paper dwells upon the possibility of using adaptive algorithms based on fuzzy logic in vibration diagnostic systems. An urgent task of improving diagnostic systems by increasing diagnostic reliability with minimal costs for their testing is given in the paper. The authors prove fuzzy logic rules to be necessary for diagnostic tasks. There are functions of vibration acceleration values at various shaft rotation frequencies. An example of vibration diagnostic and monitoring system operation using fuzzy logic is given. The authors prove that using fuzzy logic-based algorithms allows moving forward to the next stage in vibration diagnostic system development.
Kostyukov V.N., Zaytsev А.V. Using adaptive algorithms based of fuzzy logic in vibration diagnostic systems // Procedia Engineering. - 2016. - № 152. - P.482 – 486
In the last ten years leading part in maintaining a proper reliability level of a rolling stock is played by technical diagnostics. A great number of means, complexes and systems evaluating rolling stock condition with a certain probability during scheduled maintenance and repairs in depot are developed and implemented today. However, it should be noted that in order to reach dynamic error of 1%(for critical equipment the acceptable error is 0.1%) it is required to perform diagnostics with 2-hour interval maximum, and that is possible only when using an on-board monitoring system detecting malfunction directly in movement.
Moiseev V.A., Kostyukov Al.V., Kazarin D.V., Tsurpal A.E. Experience of development and introduction of the on-board condition monitoring system for electric trains // Railway Transport. - 2016. – No. 8. - p.58-61