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
The condition of regulatory base in the field of vibration reliability is considered. It is noted that the concept of absolute vibration of a shaft for the practicing specialists in vibration adjustment, repair and operation is new. So when performing operational norms on vibration the residual imbalance can exceed several times admissible at factory balancing. The examples proving the specified contradictions are given. Recommendations about improvement of system of standards are made.
Kumenko A.I., Kostyukov A.V., Boychenko S.N., Suminov I.A., Selifanov I.V. Providing vibration reliability of turbine units of TPPs and NPPs. Condition and updating the regulatory base. // Nadezhnost i bezopasnost energetici, 2016. - №2(33). - p. 21-25
The article dwells upon the task of calculating statistical features of plane bearings used in modern power units. The traditional approach used in guidebooks for bearing feature calculation is based on an isothermic model of lubrication layer flow. The current work considers heat and changes of all lubrication properties caused by temperature.
There are examples of statistical feature calculation in order to determine a base segmental Kingsbury bearing with six plates, including the results of the bearing capacity calculation, losses due to friction and heated lubrication and considering change of properties due to heating and uneven temperature distribution
Kuzminykh N.Yu., Kumenko A.I., Kostyukov V.N. Modeling statistical features of plane bearings for major power turbine units. // Nadezhnost i bezopasnost energetici, 2016. - No. 1(32). - p. 24-29
Improvement of fault diagnosis reliability and depth is based on the application of fault criteria system, which is formed by combining the various parameters of diagnostic signals.
Therefore, the extension of the scope of signal diagnostic parameters and fault symptoms is important for diagnosis. The paper discusses the possibility of applying probabilistic characteristics both numerical and functional to estimate the parameters of vibration processes that characterize the defects and faults of the various mechanisms. Studies of vibration parameters when changing the condition of rolling bearings within various units and mechanisms showed that the probability density of the instantane-ous values oftbe vibroacoustic signal, and in particular, the acceleration also changes its parameters wben the bearing condition changing. Similar results were obtained when analyzing the probabilistic characteristics of the instantaneous values of vibroacoustic signals received from different assamblies of reciprocating compressors. We found that the change in the condition of such reciprocating compressor parts as discharge and suction valve, details of piston-cylinder units, slide-crank and cranking mechanisms, the crank-shaft bearings, the probability curves of the instantaneous vallies of the vibration signal significantly change. The latter fact is clearly visible when analyzing the parameters of the approximated distribution functions and probability density. For the first time in vibroacoustic diagnostics it was proposed to use such probabilistic characteristic of random processes as a characteristic function to analyze the properties of distribution function curve and probability curve.
The studies have shown that the area under tbe curve of the modulus of the characteristic function of the instantaneous value of vibroacoustic signals of different components and mechanisms may be used as a diagnostic parameter. Formation of the diagnostic features vector based on the parameter has allowed to propose a new diagnostic feature of fault invariant to machine design and the limit values ot vibroacollstic signal. Based on revealed regularity there have been developed a method and techniques of vibroacoustic diagnosis of various units of machines and mechanisms, as well as the vibroacollstic signal processing algorithm. Application of the deveIoped diagnosis method and diagnostic characteristics based on the characteristic function of vibroacoustic signal alows to increase the depth and the reliability of diagnosis whiIe simplifying diagnosis algorithms.
V. N. Kostyukov, А. Р. Nаumenkо, S. N. Boychenko (DYNAMICS Scientific & Ргоduсtion Center, Ltd., Omsk, Russia); 1. S. Kudr'yavtseva (Omsk State Тесhniсаl University, Omsk, Russia) Formation of diagnostic feature vector based on characteristic function of vibroacoustic signal // Нефтепереработка и нефтехимия. - 2016. - № 8. - 51-56
The article describes an experience of implementing a test bench with a control system for pump diagnostics COMPACS-RPG at a pump unit acceptance test shop of OAO Volgogradneftemash in 2011.
Using the data stored in the automated control systems COMPACS for safe resource-saving operation and maintenance allowed to build a system for automatic diagnostics and control over the pump unit testing and running at their standard and limiting operational conditions.
V.N.Kostyukov, A.V. Kostyukov, S.N. Boychenko, A.V. Lazarev, А.А. Pavlov, A.G. Shestov Innovative solution for pump units development and manufacturing // Neftepererabotka&Neftechimiya. - 2016. - № 8. - 51-56
The significance of resource-machinery operation based on stationary monitoring system, automatic diagnostics and its usage results are under consideration as illustrated by COMPACS systems of SIBUR units.
The article dwells upon the importance of timely control of asynchronous motor condition and the need to develop new methods of condition diagnostic of their main assemblies. Currently available test benches for electric motors usually control vibration, temperature, rpm and current consumption of an asynchronous electric motor(AEM). That ensures high accuracy of AEM mechanic assemblies’ condition assessment, but condition of AEM insulation in that case can be observed only indirectly.
A perspective new method of AEM stator winding insulation defect diagnostics is a partial discharges control method. A partial discharge is an electric discharge paralleling a part of insulation between different-potential electrodes. Partial discharges (PD) occur in insulation defects, inclusions, uneven parts, gaps between the insulation layers. Such spots with dielectric properties different from the main insulation’s properties cause redistribution of electric field which leads to occurrence of insulation parts with high strength of electric field. Multiple PD during machinery operation may have a negative influence on the insulation state and (if the PD are intensive enough) cause a defect growth , sometimes, to a dielectric breakdown, which may result in machinery breakage or accident.
A.V. Kostyukov, S.N. Boychenko, A.V. Schchelkanov, Е.А. Burda (ООО «NPC DYNAMIKA»), S.А. Averyanov, V.I. Maiorov (OOO MRP Gazpromneft Omsk Refinery). Experience in application of The COMPACS-RPE bench system with an integrated partial discharges sub-system in repair production of OOO MRP Gazpromneft Omsk Refinery // Chimicheskaya Technika. -2016. - No 7. - p. 4-6, Cover page