The most important result of Soviet era of vibration monitoring development is a prove of considerable impact that errors in assembling and operation of machine have on its residual life, and also possibility of predicting the residual life span by the vibration diagnostics results.
For production and transport industries the fundamental reasons of high costs and losses are determined by subtle occurrence and development of faults, as well as poor observability of actual processes of machinery deterioration during its whole lifespan.
Stability can be achieved by means of observability and controllability, when all monitoring processes are coupled together and monitoring time does not exceed the shortest interval of machinery fault development.
The shortest monitoring period can be achieved by the in-built automatic expert system revealing all main problems to the personnel operating the machine and forwarding this information through the automatic diagnostic network to the managers and production heads.
Kostyukov V.N. Innovative technology for machinery “health” monitoring for accidents prevention and condition-based operation of machinery – Russian technological break-through // Modern approaches towards selection of equipment and materials during project development, building and operation of production facilities of refinery and petrochemical companies: proceedings of the Council of Chief Mechanics meeting
Ensuring the safe operation of machine units such as pumps, compressors and other production equipment has always been one of the most relevant tasks in the industry. Failures of the mentioned machinery can often lead to malfunctions and accidents, causing losses and damaging the environment. For example, the analysis of statistics on oil refining and petrochemical industries shows that failures of machine units account for more than 70% of the total number of equipment failures in these industries.
The wide application of electric motors, including electric motors with a working voltage of 380 V, as part of machine units, necessitates the development and use of new methods for monitoring their technical condition, which allow detecting emerging defects at early stages and preventing their further development.
To assess the insulation condition of electrical machine windings, methods for controlling the parameters of partial discharges occurring in the insulation of windings are being increasingly used, which is caused by the improvement of technical and instrumental diagnostics, which allow to register and analyze such discharges.
Kostyukov V.N., Burda E.A. Study of the applicability of the partial discharge measurement method for diagnostics of insulation condition of stators of asynchronous electric motors with an operating voltage of 380 V // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2014. – p.228-233.
The main diagnostic task is to recognize condition of machines and units, classify them as faultless or faulty ones. The task is closely connected to false alarm or defect skipping risks.
When a method for axle equipment of wheel-motor units diagnostics is utilized there is always a chance of defect skipping or false alarm.
In rolling stock operation conditions, skipping a defect may lead to unit’s destruction, which cause not only an expensive unscheduled repair, train schedule failure, but also a technogenic hazard and transport accident.
False alarm may lead to additional repairs for units which does not require maintenance, and, consequently, make their condition even worse and decreasing rolling stock’s operating availability rates.
The paper is aimed at increasing diagnostic reliability with minimum expenses for testing procedures.
Kostyukov V.N., Zaytsev A.V., Teterin A.O. Increasing diagnostic reliability of axle equipment of wheel-motor units in electric trains // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2014. – p.183-190.
The paper is aimed at finding dependency between the RMS value of vibration parameters of rolling bearings in different conditions and the axial load.
he research is carried out by means of an experimental unit based on the COMPACS®-RPP system using drive 1602 which allows to set axial and radial load values and measure vibration radially.
The subject of research is an operable bearing, bearings with seeded defects of inner and outer race, and a bearing with rolling elements defect which occurred due to long-term service.
From the analysis of the obtained results one can make a conclusion on a rolling bearing condition having a considerable impact on RMS values’ dependency on an axial load.
The operable bearing and bearings with seeded defects of inner and outer race are lacking or have non-considerable amount of such dependency. That may testify that such seeded defects have no considerable impact on dependency between bearing vibration and an axial load.
Bearings with rolling element defects which occurred due to long-term service have RMS value considerably dependent on the applied axial load. The most sensitive to changes in axial load are RMS values of vibration displacement and vibration acceleration.
Kostyukov V.N., Boychenko S.N., Basakin V.V., Teterin A.O., Kudryavtseva I.S. Research on dependency of bearing vibration parameters on axial load // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2014. – p.123-127.
Rolling bearings are the most common and important elements applied in modern engineering. For rotary mechanical equipment – rolling bearings are node points limiting machinery operational resource in general.
The most effective method, which allows to detect both – nucleating and developed defects of rolling bearings, are vibration-acoustic method of NDT.
To make a valid assessment of rolling bearings condition – it is required to know how various factors are influencing vibration level.
The paper is aimed at studying a dependency between the RMS value of vibration parameters of rolling bearings in different conditions and the radial load.
Kostyukov V.N., Boychenko S.N., Basakin V.V., Teterin A.O., Kudryavtseva I.S. Research on dependency of bearing vibration parameters on radial load // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2014. – p.118-123.
One of the main components of safe accident-free operation of industrial facilities is its high-quality production and maintenance. Throughout the years a concept of increasing quality of production and repair by means of objective condition assessment of assemblies and machines is commonly used.
The concept is implemented on the basis of automated control system for safe resource-saving operation and repair of machinery – COMPACS®. The bench variant of the system operates successfully at dozens of repair productions of Russia and CIS.
One of the latest development of DYNAMICS SPC among the bench systems is a pump units diagnostic and testing control system COMPACS®-RPG. The system is implemented at Volgogradneftemash, JSC – the biggest Russian producer of pump units.
The system is intended for collaborative work with new diagnostic and test bench (DTB) for pump units produced by Volgogradneftemash, JSC in order to carry out hydraulic, quality assurance and periodic tests of pump units with full assessment of their quality after assembly.
Through the COMPACS-RPG system, specialists of DYNAMICS SPC solved the task of providing an automatic operation of the bench with real-time calculation of all required characteristics and test protocol printing.
The paper dwells upon the usage of the modern systems for diagnostics and comprehensive condition monitoring (DMS) for fuel and power industry machinery, which make an integral part of the reliability control system for comprehensive production facilities providing safe resource-saving operation.
The paper considers the basic principles and the most important properties and characteristics of such systems, as well as their classification by 13 main features, describes methods for DMS types determination. The paper shows the examples of system type calculation for various software and hardware, the systems’ application domains for implementation at power facilities according to the risk of fault skipping. The paper classifies the machinery by the risk matrix considering probability of a fault occurrence and its economic, ecological and technogenic consequences.
The paper suggests more detailed classification criteria for facilities targeted by technical regulation (FTR), hazardous production facilities (HPF) and critically important facilities (CIF). As an example of the first class DMS - the stationary condition monitoring system COMPACS® is described. The system comprises all general principles of the first-class DMS building according to GOST R 53564.
Kostyukov V.N., Boychenko S.N., Naumenko A.P., Kostyukov An.V., Kostyukov Al.V. Monitoring risks of fuel and power industry machinery // [Electronic source]//New on Russian electric power industry. 2014. №3, p. 30-44. - URL: http://energo-press.info/журнал-новое-в-российской-электроэне/архив-новое-в-российской-электроэнер/
Technology for real-time diagnostics and monitoring of piston machines is based on collection and processing of data which are to provide detection of defects and malfunctions of piston machines with specified detalization and accuracy, as well as their danger rates.
The technology implementation comprises usage of vibration-acoustic signal structure models in case of occurrence of defects and failures of assemblies and details of piston machines, combination of diagnostic features of failures and signal parameters in case of failure occurrence, ways of vibration-acoustic signal processing and evaluation system for the vibration-acoustic signal parameters.
One of the practical ways of the technology implementation and solutions of piston machines diagnostic and monitoring tasks is introduction of the given solutions which form a database connecting diagnostic features of failures and condition of piston machines’ details into functioning algorithms of the diagnostic and monitoring system COMPACS®.
The presented methodology of monitoring and diagnostics based on measuring the parameters of secondary processes (vibration-acoustic oscillations) allows to implement the algorithms of the real-time expert system for decision-making with automatic detection (diagnosing in time with diagnostic signals’ change) of more than 20 malfunctions of assemblies, such as piston compressors of hazardous production facilities, their danger rates and issuing prescriptions to the personnel for the required maintenance actions.
Naumenko A.P. Basic principles of technology for real-time diagnostics and monitoring of piston machines // XX Russian scientific conference on NDT and technical diagnostics: proceedings – Moscow: Spectr Editorial, 2014. – p.358-362.
The paper dwells upon the experience of operating condition monitoring systems for hazardous production facilities of power, mining, metallurgy and transport industries.
The paper shows the difference between the machinery parameter monitoring systems and condition monitoring systems. Parameter monitoring systems measure parameters of physical processes, however, without determining the causes of their change. Condition monitoring systems not only determine the change of physical parameters, but also the causes of their changes.
Those systems use algorithms of a real-time automatic decision-making expert system with an automatic machinery malfunction diagnosing, automatically show the personnel which actions should be made in order to eliminate the malfunctions.
Sometimes such systems in Russia are called “vibration monitoring systems”. The term “real-time” when referring to condition monitoring means that the speed of determining parameter measuring, condition evaluation, and depiction of the diagnostic results have to be adjusted to the speed of the machine’s degradation and exceed it by a few times in order to eliminate outliners and increase reliability of the diagnosis, along with creation of time reserve for making a management decision and carrying out all necessary actions.
Technical and economic efficiency indicators for the monitoring systems application are given in the paper.
Kostyukov V.N. Vibration monitoring of production and transport facilities // XX Russian scientific conference on NDT and technical diagnostics: proceedings – Moscow: Spectr Editorial, 2014. – p.357-358.
EMU-train depots widely use the COMPACS®-EXPRESS vibration acoustic diagnostics systems, designed for condition evaluation of WMU of motor-driven rolling stock during scheduled maintenance and repair works.
The diagnostics is aimed at increasing reliability and resource of technical systems. The main diagnostic task is to evaluate the condition of units and assemblies and classify it as good or faulty. That is closely connected with the risk of false alarm or defect skipping. The present work is devoted to reliability increase of rotary units’ condition diagnostics with simultaneous decrease of complexity of its usage.
An analysis of geometrical parameters of a bearing assembly resulted in dependency of vibration level from rotation frequency and defect’s size. According to the dependency, the vibration signal amplitude rate is proportional to the bearing rotation frequency and the defect’s size. Using the COMPACS®-EXPRESS systems the dependency proved valid. A diagnostic error connected with false alarm or defect skipping probability can be eliminated by using an ambiguity area limited by the highest and the lowest critical values.
The paper considers the developed approach to reduce the diagnostic error by using an ambiguity area and conducting an additional independent testing. Thus, using an ambiguity area in condition evaluation together with two independent tests, increasing complexity of its usage not more than by 2, substantially increases the reliability of rotary units condition diagnostics.
Kostyukov Al.V., Kazarin D.V., Zaytsev A.V. Reliability increase of rotary units’ vibration analysis // XX Russian scientific conference on NDT and technical diagnostics: proceedings – Moscow: Spectr Editorial, 2014. – p.355-357.