The COMPACS® system
Real-time vibration diagnostics
of machinery with probability close to 1
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In 2001 the quality management system of SPC Dynamics was put through facultative certification. In 2016 it was recertified for compliance with standards ISO 9001:2008. Its results confirmed a high level of goods and services quality management. In 2001 the quality management system of SPC Dynamics was put through facultative certification. In 2016 it was recertified for compliance with standard GOST ISO 9001-2011. Its results confirmed a high level of goods and services quality management.
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Risk management

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Anthropogenic accidents and emergencies for 70-80 years have been accompanying technological development. To neutralize such threat the production industries require an effective risk management, creation and implementation of safety mindset, technology and equipment.

Sudden emergency shutdown of hazardous production facilities may not only cause considerable economic losses due to shutdown and operability restoration, but also a risk of ecological and anthropogenic accidents and emergencies. In order to avoid the emergencies, a reliable and timely diagnosis is required, so it could provide accident-free operation with maximum resource utilization of replaceable parts and assemblies.

Main production facilities, as a rule comprise machines (pumps, compressors, air-blowers, etc.) and static equipment (columns, tanks, pipelines, etc.). Today, for the condition diagnostics of such facilities the automatic diagnostics and monitoring system COMPACS® is commonly used.

The results of its implementation practice confirm the invariability and uniformity of application of the developed methods and systems for diagnostics of rolling and plane bearings, valves, gas-hydrodynamic and electro-magnetic units, gears, crank-type, crosshead and other mechanisms, centrifugal, gear-wheel pumps, electric motors, piston and centrifugal compressors, and other machines, air-coolers.

 

Kostyukov V.N. Risk management // Government supervision (Gosudarstvennyiy nadzor) - 2013 - №4 (12). - p.44

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Tags: COMPACS condition monitoring diagnostics nondestructive testing accidents prevention technical condition Date: 15.11.2016
Views: 493
 

Analysis of vibrational activity of traction electric motors in electric trains for diagnostic purposes

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There is a common opinion that it is difficult, and sometimes even impossible to ensure objective diagnostics of rolling stock’s rotor machinery condition in operation, due to great amount of interferences, such as high level of noise accompanying weel-railtrack interaction.

However, even in order to reach the dynamic error rating 1% (for the most important machinery the acceptable error rate is 0.1 %) it is required to carry out diagnostics at least every two hours, which can be achieved by using on-board condition monitoring systems of rolling stock assemblies.

The paper is aimed at providing an assessment of vibration parameter rates in operating traction motors.

 

Kostyukov V.N., Kostyukov Al.V., Kazarin D.V., Tsurpal A.E., Basakin V.V., Zaytsev A.V. Analysis of vibrational activity of traction electric motors in electric trains for diagnostic purposes // Improving the efficiency of collector electromechanical energy converters operation: Proceeding of IX international scientific conference – Omsk, Omsk State Transport University, 2013 – p. 214-221.

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Tags: condition monitoring diagnostics nondestructive testing rolling stock technical condition traction motor EMU-train electric train Date: 08.11.2016
Views: 458
 

Multifunctional sensors based on piezoceramics

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It is nowadays quite common to use sensors, based on piezoceramics, due to their increased reliability and temperature stability [2, 5]. Piezoelectric sensors are used to measure force, pressure, acceleration, humidity, temperature and consumption. Thus, for example, force sensors use a direct piezoelectric effect, which changes a charge amount on the opposite planes of a crystal under the influence of compression or stretching. The temperature measurement by dint of the piezoelectric crystal is usually based on anisotropy -
selecting an appropriate alignment of a piezoelement cut with respect to crystallographic axes, one can change its thermofrequency response (TFR), which is generally a non-linear function of temperature.

In addition, it is known about the temperature influence on properties of piezoceramic vibration transducers [1, 2], as well as about restrictions on the maximum allowable temperature, which does not cause irreversible changes in piezoceramic materials (PCM) characteristics [3, 4]. For most PCM the maximum allowable temperature ranges in 0.5-0.8 of the Curie point temperature; for example, for PZT-19 this is 150°C-200°C. In most cases, the diagnosed equipment temperature packs up this temperature range.
Moreover, it is not required to measure the temperature up to a degree, it is necessary to determine elevation of certain threshold values, that indicates development of the equipment destruction process.

Systems for equipment technical condition monitoring contain dozens or even hundreds of vibration and temperature sensors. Development of multifunctional sensors, which allow to measure a number of parameters, is an important task of instrument making. The paper is devoted to developing a method for determining temperature using a piezoceramic vibration transducer. The paper presents the development and testing results for a combined vibration/temperature piezoelectric sensor. Temperature measurement inaccuracy in
the entire vibration measurement range does not exceed ±1º C in the temperature range from -40º C to 100º C.

References:

  1. Kostyukov, V., Morozov, S., Certificate of authorship No. 1740994 “Device for machines diagnostics”, International classification of inventions - G01M15/00, USSR, application of 01/09/1983, published on 15/06/1992, bulletin No. 22, 4 p.
  2. Donskov, V., Ivanov, A., Zavgorodniy V., Kostyukov, V., “Vibration transmitter for industrial application”, Foreign radioelectronics, No. 9, pp 65-67, 1996.
  3. Bogush, M., “Piezoelectric sensors for extreme operating conditions”, Rostov on Don, Publishing house of the North Caucasus Research Centre of High School, 346 p, 2006.
  4. Yanchich, V., “Piezoelectric sensors of vibrational and shock acceleration”, Tutorial, Rostov on Don, Publishing house of the Southern Federal University, 77 p, 2008.
  5. Yanchich, V., “Piezoelectric transducers (accelerometers)”, Rostov on Don, Publishing house of the Southern Federal University, 304 p, 2010.

 

Kostyukov V.N., Kostyukov Al.V., Boyarnikov A.V. Multifunctional sensors based on piezoceramics // The 11th International Symposium on Measurement Technology and Intelligent Instruments (ISMTII 2013). - P. 263-264

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Tags: condition monitoring diagnostics vibration sensor machinery Date: 01.11.2016
Views: 522
 

The diagnostics of electric train transverters using parameters of three-phase alternating current spectrum

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Researches and a technical analysis of damages, faults and unscheduled repair of electric trains have revealed that in an auxiliary circuit of the direct current electric train the part which is the most vulnerable to sudden failures is an auxiliary transverter.

To carry out an efficient diagnostics of the transverter by a three-phase alternating current spectrum, one needs to analyze the three-phase alternating current spectrum when the transverter is operating with a minimal load. That allows to eliminate the impact of current consumers – such as electric machines – on AC-signal waveform in transverter’s generator. In that case, almost all generated power is spending on feeding the exciting winding and control circuits.

In order to obtain the experimental data, the signals of three-phase alternating currents of transverters were registered during the commissioning of transverters which have been operating from one to two years, including those which were in a pre-accident condition.

 

Kostyukov V.N., Kostyukov Al.V., Kazarin D.V., Tsurpal A.E. The diagnostics of electric train transverters using parameters of three-phase alternating current spectrum // Improving the efficiency of collector electromechanical energy converters operation: Proceeding of IX international scientific conference – Omsk, Omsk State Transport University, 2013 – p. 207-214.

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Tags: condition monitoring diagnostics nondestructive testing technical condition EMU-train electric train Date: 25.10.2016
Views: 483
 

Research on partial discharge parameters in asynchronous motor stator winding insulation

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Timely detection of defects in electric machinery insulation on an early stage of their development in order to prevent accidents requires application of modern methods of diagnostics and monitoring.

Today, methods for electric machinery diagnostics based on control of partial discharges occurring in electric machinery insulation, such as methods for control of partial discharge parameters in asynchronous motor stator winding insulation, are becoming widely spread.

To make a condition assessment of an electric motor insulation one need to know acceptable (critical) values of partial discharge parameters. Their determination requires accumulation and analysis of statistical data on partial discharge parameters for single-type motors having similar technical condition. If the same-name partial discharge parameters of such electric motors will be having close values that will allow to determine the critical values of the partial discharge parameters for various types of electric motors.

In order to determine a possibility of finding the criteria for partial discharge parameters assessment, an experimental system on the basis of a software-hardware platform for electric motors diagnostics COMPACS®-RPE was developed by DYNAMICS SPC. The system allows to carry out the diagnostics of electric motors by the results of measurements of such parameters as: vibration, current, temperature, and revolutions per minute of the electric motor.  In order to change partial discharge parameters the COMPACS®-RPE system was upgraded with a MDR sub-system for partial discharges.

 

Kostyukov V.N., Kostyukov Al.V., Burda E.A. Research on partial discharge parameters in asynchronous motor stator winding insulation // Improving the efficiency of collector electromechanical energy converters operation: Proceeding of IX international scientific conference – Omsk, Omsk State Transport University, 2013 – p. 201-207.

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Tags: condition monitoring diagnostics nondestructive testing electric motor diagnostics technical condition machinery Date: 18.10.2016
Views: 533
 

Technical condition evaluation of the electric multiple unit pneutronic system equipment

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The paper considers the actual problem - technical condition evaluation of control circuits, power circuits equipment, equipment auxiliary circuits and air brake network, which due
to the numerous electrical and mechanical connections constitute a complicated pneutronic system of an electric multiple unit. According to the operational data, 60 % of all electric multiple units malfunctions fall on this system.

Diagnostic methods, main diagnosed parameters and malfunctions diagnostic features have been provided. The structure, composition and an operation concept of the complex, providing the condition assessment of the electric multiple unit pneutronic system in the depot environment, have been represented as well.

The examples of the equipment diagnostics, received in real conditions of the complex application, have been provided.

 

Kostyukov V.N., Kostyukov A.V., Kazarin D.V., Shchelkanov A.V. Technical condition evaluation of the electric multiple unit pneutronic system equipment // X International Conference Condition Monitoring and Machinery Failure Prevention Technologies - СМ/MFPT 2013

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Tags: condition monitoring diagnostics nondestructive testing vibration analysis technical condition EMU-train Date: 11.10.2016
Views: 531
 

Technical condition evaluation of the electric multiple unit pneutronic system equipment

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The paper considers the actual problem - technical condition evaluation of control circuits, power circuits equipment, equipment auxiliary circuits and air brake network, which due
to the numerous electrical and mechanical connections constitute a complicated pneutronic system of an electric multiple unit. According to the operational data, 60 % of all electric multiple units malfunctions fall on this system.

Diagnostic methods, main diagnosed parameters and malfunctions diagnostic features have been provided. The structure, composition and an operation concept of the complex, providing the condition assessment of the electric multiple unit pneutronic system in the depot environment, have been represented as well.

The examples of the equipment diagnostics, received in real conditions of the complex application, have been provided.

 

Kostyukov V.N., Kostyukov A.V., Kazarin D.V., Shchelkanov A.V. Technical condition evaluation of the electric multiple unit pneutronic system equipment // X International Conference Condition Monitoring and Machinery Failure Prevention Technologies - СМ/MFPT 2013

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Tags: condition monitoring diagnostics nondestructive testing vibration analysis technical condition EMU-train Date: 11.10.2016
Views: 0
 

Innovative technology of eco-friendly safe resource-saving operation of hazardous production facilities

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Development of a technosphere caused to the humanity both – benefits and serious hazards: accidents, man-made disasters, which are align with technological advancement. The situation is worsening due to the growth of plants capacity and development of full-scale production, since it becomes quite difficult – to chase the development of degradation processes in hundreds and thousands machines operating in various technical states. In the late 80th of the last century the situation became so bad, that the largest and the most advanced industrial enterprises started to look for new approaches towards provision of safe resource-saving operation of hazardous production facilities (HPF).

More than 25 years ago, the standard-bearing petrochemical company Omsknefteorgsintez, which is currently known as Gazpromneft-Omsk Refinery, JSC placed its bets on Omsk scientific developments by giving the scientists of one of research institutes a chance to create a unique software-hardware complex which provides the maintenance personnel and management with objective data on technical condition of the most important machinery units in real time.

Pilot operation of the first systems has shown that they are highly efficient and absolutely necessary for any large-scale refinery production. That became a driver to continuation of the research and development of the system. A world-wide novelty of the suggested solutions together with a wise technical policy of Omsk Refinery has allowed to establish DYNAMICS Scientific & Production Center in 1991.

Scientists and engineers of the DYNAMICS SPC have created a unique product – the computer monitoring system for accident prevention and condition control - COMPACS®, which has a leading position in the world not only by its technical features, but also by the scale of its implementation. Today, more than 500 automatic control systems for safe resource-saving operation and maintenance - COMPACS® are implemented on dozens of enterprises of 12 industry brunches, including transport, proving monitoring of more than 17 000 machines and units of more than 1700 types.

 

Kostyukov V.N., Kostyukov An.V. Innovative technology of eco-friendly safe resource-saving operation of hazardous production facilities // Neft i gaz Sibiri. - 2013. - №4 (October). – p.11.

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Tags: condition monitoring diagnostics nondestructive testing vibration analysis technical condition hazardous production facilities Date: 04.10.2016
Views: 472
 

Innovative technology of eco-friendly safe resource-saving operation of hazardous production facilities

Print

Development of a technosphere caused to the humanity both – benefits and serious hazards: accidents, man-made disasters, which are align with technological advancement. The situation is worsening due to the growth of plants capacity and development of full-scale production, since it becomes quite difficult – to chase the development of degradation processes in hundreds and thousands machines operating in various technical states. In the late 80th of the last century the situation became so bad, that the largest and the most advanced industrial enterprises started to look for new approaches towards provision of safe resource-saving operation of hazardous production facilities (HPF).

More than 25 years ago, the standard-bearing petrochemical company Omsknefteorgsintez, which is currently known as Gazpromneft-Omsk Refinery, JSC placed its bets on Omsk scientific developments by giving the scientists of one of research institutes a chance to create a unique software-hardware complex which provides the maintenance personnel and management with objective data on technical condition of the most important machinery units in real time.

Pilot operation of the first systems has shown that they are highly efficient and absolutely necessary for any large-scale refinery production. That became a driver to continuation of the research and development of the system. A world-wide novelty of the suggested solutions together with a wise technical policy of Omsk Refinery has allowed to establish DYNAMICS Scientific & Production Center in 1991.

Scientists and engineers of the DYNAMICS SPC have created a unique product – the computer monitoring system for accident prevention and condition control - COMPACS®, which has a leading position in the world not only by its technical features, but also by the scale of its implementation. Today, more than 500 automatic control systems for safe resource-saving operation and maintenance - COMPACS® are implemented on dozens of enterprises of 12 industry brunches, including transport, proving monitoring of more than 17 000 machines and units of more than 1700 types.

 

Kostyukov V.N., Kostyukov An.V. Innovative technology of eco-friendly safe resource-saving operation of hazardous production facilities // Neft i gaz Sibiri. - 2013. - №4 (October). – p.11.

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Tags: condition monitoring diagnostics nondestructive testing vibration analysis technical condition hazardous production facilities Date: 04.10.2016
Views: 0
 

Operational Safety Monitoring for Thermal Station Facilities

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Absence of computer monitoring with automatic failure diagnostics of supplementary machinery of thermal stations has a bad impact on its operation. The main task of supplementary machinery (grinders; fans; smoke-exhausters; coolers; feed, condensate, circulatory and line pumps) is to support the operation of turbine-generator units. It is a common case, when many of the supplementary units are operating without any equipment reserve, and their sudden failure leads to a decrease of quantity and quality of power output, and in some cases – to the whole power unit shutdown.

The systems for condition monitoring and automatic diagnostics COMPACS® provide full-time condition monitoring of supplementary machines and prompting of personnel’s decisions on ensuring the machinery operational safety. For such purpose the units consisting of a drive motor, transmission and actuator are equipped with vibration sensors and the feeder bays of the electric substation – with current sensors

Application of the computer monitoring system for condition monitoring and accident prevention COMPACS® allows to ensure accident-free operation of supplementary machines of a thermal station by means of early detection of developing malfunctions and their constant monitoring in real time.

 

Kostyukov V.N., Tarasov E.V., Putintsev S.L. Operational Safety Monitoring for Thermal Station Facilities // Problems of vibration, vibration alignment, vibration monitoring and diagnostics of power stations: proceedings of the VIII International Scientific Conference - Moscow, JSC "VTI", 2013. – p. 218-225

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Tags: condition monitoring diagnostics vibration analysis technical condition Date: 30.09.2016
Views: 467
 
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