THE COMPACS SYSTEM®
REAL-TIME VIBRATION DIAGNOSTICS
OF MACHINERY WITH PROBABILITY CLOSE TO 1
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Certification
In 2001 the quality management system of DYNAMICS SPC was put through facultative certification. In 2018 it was recertified for compliance with standards ISO 9001:2015. Its results confirmed a high level of goods and services quality management.
In 2001 the quality management system of DYNAMICS SPC was put through facultative certification. In 2018 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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Real-time condition monitoring – innovative technology of maintenance and repair production

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The prime means of machinery operability support is preventive maintenance. The intervals between maintenance/repairs as well as their size and contents depend on the statistical data. That method does not consider special features of the particular assembly, its actual operation conditions, such as stochastic loads on the machines, or operation procedure, etc. A machinery maintenance system based on such approach has several disadvantages.

Switching from preventive maintenance to condition-based maintenance allows considerably (in a few times) increase run-to-failure period and decrease operational costs. The real-time condition monitoring of machines and their parts ensures an objective assessment of condition during operation. The second component of the innovative technology for maintenance, repair, run-to-failure growth and reduction of cost required for a demanded condition support is detection of faulty parts of the machine before repair and an accurate assessment of their condition after the repair.

 

Kostyukov V.N., Naumenko A.P., Kostyukov Al.V., Boychenko S.N. Real-time condition monitoring – innovative technology of maintenance and repair production // Territoriya NDT (NDT Territory). - 2014. - №1. - p.66-69.

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Tags: condition monitoring diagnostics vibration analysis machinery Date: 10.01.2017
Views: 1003
 

Reliability increase of piston machines equipped with condition diagnostic and monitoring system (DMS)

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Vibration analysis provides a comprehensive assessment of a piston machine’s condition by outer vibration of its casing, and makes an effective instrument for investigating dynamic processes’ quality during assembling, production, defects detection and their critical growth during operation. The highest efficiency rate can be reached by ensuring the condition monitoring of not only a piston machine, but all conjugated mechanisms and attached assemblies.

Internal combustion motors are the most important types of piston machines for which vibration-acoustic diagnostics allows to provide safe accident-free operation with the longest possible operating life.

A DMS is a system (or machine) which product is current information on the condition of the machinery and possible danger, with required commentary (prognosis of residual operating life, prompting on the nearest urgent actions to be made, etc.) and a set risk level.

 

Kostyukov V.N. Reliability increase of piston machines equipped with condition diagnostic and monitoring system (DMS) // Machine manufacturing. Encyclopedia. - Moscow: Mashinostroenie. Dvigateli vnutrennego sgoraniya. - 2013. - Vol. IV-14. – Annex, par.4. - p.775-781

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Tags: condition monitoring diagnostics piston machine vibration analysis machinery Date: 16.12.2016
Views: 1011
 

Vibration analysis of motors

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Internal combustion motors are multifactor source of powerful vibration-acoustic signals. The motor’s vibrations are caused by unevenly rotating masses – inertia of reciprocating masses, centrifugal inertia and its moments, gas dynamic processes – power of gas pressure, inlet/outlet gas flow, fuel injection, and, also, impact and friction between elements and details of assemblies and mechanisms.

 

Kostyukov V.N., Naumenko A.P. Vibration analysis of motors // Machine manufacturing. Encyclopedia. - Moscow: Mashinostroenie. Dvigateli vnutrennego sgoraniya. - 2013. - Vol. IV-14. - Par. 6.2.5. - p.679-682

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Tags: condition monitoring diagnostics vibroacoustic signal vibration analysis machinery motors Date: 09.12.2016
Views: 1029
 

Advantages of real-time condition monitoring

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The paper consideres continuous condition monitroing and real-time automatic diagnostics of pump units at refinery and petrochemical facilities.

Using recommendations issued by the COMPACS® condition monitroing system with an automatic expert system, the maintenance personnel can ensure safe resource-saving operation of machinery of hazadours production facilities at refineries and petrochemical companies, search and correct errors in technology process, control operation procedure of machinery according to its condition.

 

Kostyukov V.N., Kostyukov An.V., Tarasov E.V. Advantages of real-time condition monitoring // Neftepererabotka i neftehimiya (Oil-refining and petrochemistry). - 2013. - №11. - p.44-51

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Tags: condition monitoring diagnostics expert system resource-saving machinery hazadours production facilities Date: 06.12.2016
Views: 1028
 

Self-diagnostics of piezoelectric transducers

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Self-diagnostics of a system for diagnostics and monitoring (hereinafter - SDM) of hazardous production facilities ensures minimal cost of such system’s operation, metrological reliability and availability factor [1-7]. Modern SDM comprising software-hardware complexes having combination of self-diagnostic methods which decreases their reliability. The paper considers a hardware method of a SDM’s vibration measuring channel end-to-end self-diagnostics from the sensor’s sensing element to the display.

The suggested method is based on producing a test signal to the sensor circuit and its further analysis by software-hardware means [2, 5], was utilized, particularly, in development of SDM for petrochemical units.

The paper considers an approach to reliability increase of a condition monitroing system  with a piezo-sensor by means of condition control for measuring-transducing channel using self-diagnostics. The paper considers selection of the most efficient parameters for self-diagnostic circuit. The results of the practical experience are presented.

References:

  1. Donskov, V., Ivanov, A., Zavgorodniy, V., Kostyukov, V.,  “Vibration transducers for industrial application”, Foreign radioelectronics, No. 9, pp 65-67, 1996.
  2. 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.
  3. Kostyukov, V., Bojchenko, S., Kostyukov, A.,“Automated control systems for safe resource-saving operation of equipment at refining and petrochemical plants (ACS SRSTM –COMPACS®)”, Moscow, Mashinostroenie, ISBN: 5-217-02971-4, 163 p, 1999.
  4. Kostyukov, V., “Monitoring of Industrial Safety”, Moscow, Mashinostroenie, ISBN: 5-217-03151-4, 212 p, 2002.
  5. Kostyukov, V., Certificate for useful model No. 1537 “The system for machines diagnostics on their body vibration”, International classification of inventions - G01M15/00, Russian Federation, application of 15/03/1994, published on 16/01/1996, bulletin No. 1, 2 p.
  6. Computer Aided Maintenance, Rules for selection and use of systems, Maintenance Management, No. 4, pp 15-19, 1997.
  7. Computer Aided Maintenance, Champion the maintenance cause internally, Lack of formal strategy and performance, Look after your assets, Maintenance Management, No. 5, pp 23-27, 1997.

 

Kostyukov V.N., Kostyukov Al.V. Self-diagnostics of piezoelectric transducers // The 11th International Symposium on Measurement Technology and Intelligent Instruments (ISMTII 2013)

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Tags: condition monitoring diagnostics vibration sensor machinery Date: 22.11.2016
Views: 1055
 

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: 1014
 

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: 1011
 

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: 1106
 

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: 1055
 

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: 1024
 
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