Existing documents in the field of piston machines vibration rationing, in particular standards VDI 2056, ISO 2372, ISO 10816-6, the draft standard ISO 10816-8, as well as commercial standards, do not provide diagnostics and a safe, fault free compressors operation. Moreover, the draft standard ISO 10816-8 is not intended to be used in monitoring systems, since it does not guarantee the compressors safe operation as well. In 2011 in Russia the industry standard STO 03-007-11 has been adopted; it allows to carry out a vibration analysis monitoring of the piston compressors crucial components and ensures the compressors safe operation.
The standard applies to stationary piston compressors, operating on explosive and hazardous gases and sets the vibration standards for assessing their condition during operation and acceptance tests after mounting and repair.
The vibration parameters rates, specified in STO 03-007-11, are of advisory nature for all the machines which are not enumerated in the machinery list, supplied in the standard appendix.
These rates can be adjusted according to resolutions of the enterprise responsible technical services as bringing the diagnosed equipment to the required reliability activities, guaranteeing safety and fault-free operation of the hazardous facilities. The standard specifies the vibration parameters rates and prescribes their use for the arrangement of vibration monitoring, vibration analysis, condition monitoring and operational risks for stationary piston compressor units.
This document determines the frequencies ranges of measurement for each vibration parameter and proposes to measure not only the mean square values of acceleration, velocity, displacement, but their amplitudes, as well. The vibration rates are given for the five compressors constructive groups with unit capacities from 0,02 to 2 MW. The paper considers the standard STO 03-007-11 main issues.
Kostyukov V.N., Naumenko A.P. Rationing of piston machines vibration // X International Conference Condition Monitoring and Machinery Failure Prevention Technologies - СМ/MFPT 2013
The studies have shown that existing diagnostic techniques for the pneumatic system within an electric train have low reliability, completeness and diagnostic depth.
To identify the diagnostic features that characterize different types of faults and the degree of their development, a large number of test data for each type of fault needs to be collected. In practice to do this work within a reasonable period of time is not possible. This raises the problem of modeling dynamic processes in the pneumatic system of the electric multiple unit with different types of faults.
As follows from the analysis of possible methods it was decided to model gas-dynamic processes in the pneumatic system of the electric multiple units using the combined method, i.e. some parts of the pneumatic system would be described analytically, the other parts – algorithmically. Modeling the system as a whole will be done by numerical method of finite differences.
The resulting model accurately describes the gas-dynamic processes in the pneumatic system of the electric multiple unit. After being improved with regard to pipelines it can be applied for modeling various types of faults in the pneumatic system.
Kostyukov V.N., Schelkanov A.V. Model of Electric Train Pneumatic System // Engineering Support of Railway Rolling Stock Maintenance and Dynamics Improvement: proceedings of the 2nd All-Russian Scientific and Technical Conference with International Participation. - Omsk: Omsk State Transport University, 2013. - pp. 67-75
The wheel-motor unit is the most important section of an electric train, which fault-free operation affects the safety of railway transport.
The aim of this work is to increase the reliability of wheel-motor unit diagnostics.
To ensure the most reliable diagnostics the test hardware should:
Make a clear health diagnostics of the tested assemblies;
Eliminate an opportunity for the diagnostic operator to make decision on the wheel-motor unit health on his own;
Provide automatic acceleration of the drive motor maintaining the predetermined speed;
Provide automatic consistently-set adjustable rotation of the wheel pair in forward and reverse directions;
Simultaneously measure vibration in all tested assemblies;
Detect vibration signals from the selected tested assemblies.
The COMPACS®-EXPRESS vibroacoustic monitoring system meet most of the requirements. The system is designed to monitor health of wheel-motor units of railway rolling stock. The system measures the vibration parameters, generates expert reports and displays them on the monitor, as well as provides automatic acceleration of the drive motor maintaining the predetermined speed of the wheel pair. Test results are generated in the form of reports on technical condition for each wheel-motor unit and the railcar as a whole.
Zaytsev A.V. Improvement in Techniques of EMU-Train Wheel-Motor Unit Diagnostics // Engineering Support of Railway Rolling Stock Maintenance and Dynamics Improvement: proceedings of the 2nd All-Russian Scientific and Technical Conference with International Participation. - Omsk: Omsk State Transport University, 2013. - p.60-67
It is known that the lack of fact-based equipment quality control during production and service, as well as the lack of in-service observation over the real health degradations do not allow us timely take cost-effective and technically efficient measures to maintain a high level of equipment reliability.
The problem of diagnostics reliability and guaranteed delivery of the diagnostics data to the executives and managers of different responsibility levels is solved by automatic condition monitoring and creation of automated control systems.
DYNAMICS SPC expertise in monitoring and diagnostics of critical equipment at various industries and railway transport made possible to create innovative health control technology for rolling stock on the basis of real-time monitoring that is Automated Control System for Safe-Money-Saving Real-Time Maintenance of equipment (ACS).
The purpose of introducing ACS into railway transport is to increase the safety and smooth functioning of the transport through the effective health monitoring of rolling stock and infrastructure facilities on the basis of continuous automatic real-time monitoring.
Kostyukov V.N., Kostyukov Al.V., Kazarin D.V., Schelkanov A.V. Resource-Saving Operation and Maintenance of Motor-Driven Rolling Stock // Eurasia Vesti. - 2013. - August. - p.20.
DYNAMICS Scientific & Production Center (DYNAMICS SPC) was founded in June 11 in 1991 by Vladimir Kostyukov in Omsk.
The crucial moment for the company was a successful implementation of the first computer monitoring system for pump units developed by the DYNAMICS SPC specialists for the 36/1-3 deasphalting unit and AVT-10 atmospheric and vacuum crude unit of Omsk refinery.
Over 2 years there were more than 6 systems on the refinery. The systems were protecting about 138 machines of the 6 most important plants from the breakdowns. Also, there was the diagnostic network Compacs-Net® used for issuing voice announcements for the specialists.
In 1994 the preventing shutdowns and condition computer monitoring system COMPACS® was approved by Ministry of Fuel and Power and State Committee for Industrial and Mining Safety Supervision of Russian Federation.
Today more than 500 systems are implemented in Russia and other countries in 12 industry branches: petrochemical, oil-refining, mining, metallurgic, railway transport and community facilities, etc.
Kostyukov V.N. DYNAMICS Scientific & Production Center // Success as a lifestyle. - 2013 - September. - P.38-39
The article represents a brief biography of V. N. Kostyukov who is a member of Russian Engineering Academy and International Academy of Social Science, The Russian Government laureate and professor.
V.N. Kostykov has developed the concept of machinery and production facilities condition monitoring based on the stated and justified scientific provision. The provision claims that the observation may be conducted by measurement of diagnostic signals (vibration parameters) and their changes speed.
During 40 years fundamental experimental and theoretical researches were made. The researches were touching the relation between the vibration acoustic signals and fault inception and development, machinery condition degradation within the serial and pilot production and real operation at the production facilities.
The basic techniques of monitoring were created; synthesis principles and basis of adaptive diagnostic and monitoring systems design were developed. The diagnostic and monitoring systems are invariant to the production facilities construction and configuration.
The brand-new system class was developed: real-time automatic control systems for resource-saving operation of production facilities and its implementation technology were developed and approved by the Department of Energy and Federal Service for Ecological, Technological and Atomic Supervision and also was recommended for large-scale implementation.
Kostyukov V.N. The goal is to provide reliability of machinery operation // Business Glory of Russia: interbranch anthology 2013. – No.3 (41). - P.60-61 (http://www.slaviza.ru/944-cel-obespechenie-nadezhnosti-raboty-oborudovaniya.html)
The proprietary development of DYNAMICS SPC is machinery computer monitoring system utilizing pollutant-free, resource-saving and safety operation technology. The specialists of DYNAMICS SPC translated into reality 40-years of experience in creation and implementation of vibration analysis systems, embodying the latest scientific and technological discoveries into the unique product.
The monitoring system provides automated data processing of sensor readings, elimination of ineffective manual data collection and analysis, display of the diagnostic results in understandable form. The continuous measurements and analysis of sensor readings allow determining deviations from the normal values on early stages of failure appearance, predicting any sensor behavior and prompting personnel on failure repair and conducting condition-based decommissioning for repair only in case of full use of machinery operation resource and with preservation of reparability.
The unique automated patented expert system for vibration-acoustic machinery diagnostic in real-time exists only in the COMPACS® systems and is one-of-a-kind.
Kostyukov V.N. Rapid response system // Omsk Business Journal. - 2013. - P.7-9
There is a quite huge area of compressor equipment use where its operation safety is a primary and dominant factor. Such equipment is created for hazardous production facilities of petrochemical industries. Receiving not only reliable but timely diagnostics is highly significant for the equipment. The diagnostics provides accident-free operation with maximal operation life of replaceable assemblies and details. In order to achieve this, it is essential to diagnose the equipment within shorter period of time than failure development period. For the petrochemical and gas industries such diagnostic period may amount to several minutes, hours, days, weeks or even months.
Safety and reliable production facilities operation is one of the major problems which can be solved by providing observability for production facilities. The condition of the equipment significantly affects techno-economic performances of the production and technology-related incidents.
Observability of production facilities condition is carried out through monitoring, which is a supervision of production facilities.
Kostyukov V.N., Naumenko A.P. Condition monitoring and diagnostics of compressor equipment in real-time // Modern concepts of choice and maintenance of compressor equipment at refineries and petrochemical industries: seminar proceedings. - Moscow: “Research and development Center of Board of Master Mechanics”, Ltd., 2013. - P.122-139
Current level of industrial development requires special attention to environmental safety of machinery operation and processes especially at explosive and fire-hazardous productions. DYNAMICS SPC offers brand-new level of environmentally friendly and resource-saving machinery operation and processes based on computer condition monitoring in real-time.
The implementation of automated control system for safe and resource-saving machinery operation provides accidents elimination, turnaround increase, machinery and facilities processes repair and operation in real-time. DYNAMICS SPC products are certified by Federal Agency on Technical Regulating and Metrology and Russian Technical Supervisory Authority, and approved for usage in potentially hazardous productions.
Monitoring system allows to process data provided by sensors automatically, to eliminate effectless manual labor of data collection specialists, to analyze data and reporting diagnostic results in understandable form. The system conducts continuous measurements and analysis of sensors readings, which makes possible to reveal abnormals on the early stages of failure nucleation and to predict machinery behavior. The instructions for failure elimination and taking the machinery out of service for repair due to actual machinery condition with full usage of its residual life and sustaining its reparability are given to the specialists automatically and in advance.
Kostyukov V.N. We make future safe! // Regions of Russia. - 2013. - №8. - p.48 (http://www.gosrf.ru/mag/rr88/index.html p.50-51)
The basis of reliable and resource-saving machinery operation of potentially hazardous productions is real-time condition monitoring of facilities. This is proved by a long-term experience of using monitoring systems on “Lukoil” refineries. The reciprocating compressors (RC) condition is determined by the number of parameters (absolute and relative vibration of assemblies and RC details; temperature of the assemblies, oil and compressed gas; gas pressure in decreasing space, in suction and discharge manifolds).
Any monitoring system is based on the following efficiency criteria:
Providing safety measures for reciprocating compressors maintenance;
Timely system response to fast-evolving and potentially hazardous defects and failures of assemblies and details;
Minimum costs for the system are determined by the system’s architecture and number of measuring channels.
The results of many years of the research reveal that absolute vibration parameters change due to degradation of assemblies and details structural parameters. The distance between interacting and coupled details determining the machinery condition increases as a result of degradation. Therefore, the absolute vibration monitoring is a common technique for accident prevention and diagnostics of reciprocating compressors.
Kostyukov V.N., Naumenko A.P., Fedorinov I.A., Zolotarev V.N. The experience in operation of real-time condition monitoring of reciprocating compressors // Compressors and pneumatics . - 2013. - №5 (July). - P.4-8