The article describes the examples of the COMPACS® vibration monitoring system application for accident prevention of Reftinskaya GRES equipment: air-blowers, hot-blast fans, smoke exhausters, booster pumps, etc.
Equipping supplementary machinery with the COMPACS® condition monitoring stationary system eliminates accidents and converts “sudden failures” into “gradual” and “observable” and “controllable” by providing expert messages shown on the display covering all problems in diagnosed machinery. Due to that, machinery is ensured to be decommissioned for repair once it utilizes its full resource (reaching “Actions required” or “Unacceptable” condition) with full reparability. Automatic diagnostics provides after-repair commissioning of the machinery with objectively evaluated condition and ensured high quality of repair in “Acceptable” condition.
Application of a condition monitoring system allows to determine the causes of failure nucleation and development, as well as to find the fundamental causes of failures and help personnel to take precise actions for ensuring long-time accident-free operation of machinery.
Diagnostics of cavitation mode plays an important part in safe unit centrifugal pump operation, as soon as cavitation presupposes massive destruction of rotor wheel surface and pipe-lines, and additional vibration loads on unit construction. Currently, the main method of pump unit cavitation mode monitoring is spectral component analysis of case vibration signal. However, spectrum analysis requires precise data on pump unit construction (number of blades on rotor wheel, bearing types). Lack of such data or its irrelevance to the real one will lead to errors in cavitation mode measurements. Consequently, still, one of the urgent problems is development of new cavitation diagnostics methods using algorithms invariant to construction type of the unit.
The article dwells upon cavitation diagnostics of pump units by means of modern non-linear dynamics trend - fractal theory in which Hearst index related to a vibration signal dimension is used as a diagnostic feature. The main advantage of this feature is its invariance to the signal level and, consequently an independence from power and size characteristics of the unit.
The results of Hearst index usage during processes of pump unit testing and operation are also given in the article. It is shown that sensitivity of the feature equals or, in some cases, exceeded sensitivity of a spectral method.
Consequently, Hearst index allows to increase reliability rates of results issued by expert system of centrifugal pump unit health diagnostic system.
Kostyukov V.N. Production safety monitoring. Moscow: Mashinostroyeniye. 2002. 224 p.
Kostyukov V.N., Boychenko S.N., Kostyukov A.V. Automated systems for control of safe money-saving operation of oil-refinery and petrochemical productions (SMSRTM COMPACS®) [edited by. Kostyukov V.N.]. Moscow: Mashinostroyeniye. 1999. 163 p.
Kostyukov V.N. Synthesis of invariant diagnostic features and models of unit condition for diagnostic purposes// Omsk scientific bulletin 2000. Issue 12. p. 77-81.
Mandelbrot B.B. Fractals and chaos. Mandelbrot's set and other miracles. Moscow – Izhevsk: Research Center "Regulyarnaya i haoticheskaya dinamika" 2009. 392 p.
Feder E. Fractals – Moscow: Mir, 1991. 254 p.
Kostyukov V.N., Boychenko S.N. Real-time diagnostics and monitoring of pump unit cavitation mode // Condition Monitoring and Machinery Failure Prevention Technologies (СМ/MFPT 2014)
The authors assess the existing system of operation and maintenance of railway rolling stock in Russia; identify its main disadvantages and challenges. They argue that it is crucial to organize reliable condition monitoring of the most critical equipment.
Following the description of the features of transverter of electric train, they suggest a method of its troubleshooting which is based on monitoring of parameters of spectrum of three-phase alternating current. The method refers to both operational and pre-accident conditions of devices. Adequacy of the procedure is tested and confirmed on the basis of data obtained during the operation of the experimental unit.
Kostyukov V.N., Tsurpal A.E. Troubleshooting of transverter of electric train under operation conditions // Mir transporta. - 2014. - №4. - pp.46-53
Urge to improve the railway transport operation reliability makes it a serious concern – to solve a problem of observation and control over the equipment’s condition at any stages of its operation life. It is not a secret, that lack of objective assessment of manufacturing and repair of equipment, as well as not enough observability over real processes of condition deterioration at the operational stage may interfere with ability to make efficient, economically and technologically justified measures on sustaining high reliability rates for the equipment.
Great number of various diagnostic and control means available to industrial and service companies does not guarantee high-quality assessment of equipment condition. There is one more problem – practical application of diagnostic and control results requires their availability for all management levels. The solution for such problems may comprise an automatic system for continious monitoring and diagnostics.
Sizov S.V., Aristov V.P., Kostyukov V.N., Kostyukov Al.V., Kazarin D.V. Automated control system for safe resource-saving operation and maintenance of rolling stock – COMPACS // Delovaya slava Rossii: Interindustrial almanac. - 2014. - №3 (46). - pp. 14-16 (http://www.slaviza.ru/1406-cistema-monitoringa-sostoyaniya-oborudovaniya-elektropoezdov.html)
It has been almost 25 years since DYNAMICS SPC took up fundamental and applied research and development works, production and wide-scale implementation of the COMPACS® automatic diagnostic and condition monitoring systems into refinery and petrochemical companies.
The presented basic approach towards provision of petrochemical safety based on automated control systems for safe resource-saving operation of machinery – COMPACS® allows full utilization of each refinery enterprise and the whole company in general, and adopting the technology of safe resource-saving operation of machinery in real time which provides maximum possible run life at minimum operational costs. A perfect example of utilization of such approach is Syzran Refinery, JSC.
Kostyukov A.V., Sinitsyn A.A., Tkachenko A.A. General approach towards safety of refinery and petrochemical companies // Business&Class. - 2014. - June-August. - pp. 26-29.
The paper is aimed at determining possibility to provide reliable condition assessment of rotary units of mechanical part of rolling stock during operation and with acceptable cost of single diagnostic act. To reach that goal one need to develop a list of experimental researches of vibration acoustic processes and to create an experimental device for signal measurement.
The paper presents the results of development of the experimental device used within the framework of an integrated program of research of vibroacoustic processes to obtain data on vibration of mechanical components of rolling stock working in real operating conditions. The device enables prolonged continuous stream recording of signals from transmitters, in particular, from vibration sensors in the band to 900 kHz.
Results of the analysis of data obtained using the experimental device have been used as a basis for train component diagnosis algorithms, implemented in onboard condition monitoring systems COMPACS®-EXPRESS-3, installed on modern rolling stock.
Kostyukov V.N., Zaytsev A.V., Tsurpal A.E. A device for experimental studies of vibration of rolling stock components during operation // Transport of the Urals. - 2014. - №2. - pp. 77-80
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
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/
Modern production facilities equipment operation and transport complex are unthinkable without the use of health monitoring systems. Currently, the production and transport facilities of the complex are distinguished by the degree of impact on the country’s security, economy and ecology: objects of technical regulation, hazardous production facilities, critical facilities, strategic facilities.
It is clear that various classes of systems should be used for these objects health monitoring. Principles of monitoring construction documented in the literature are reflected in the standards. Monitoring systems should provide information on the equipment (monitoring object) status in the required quantity and quality to provide observability of its technical state. Observation systems results should advance to take control actions, which provide the required stability margin processing facility, quality of its operation, create a necessary supply of technological, environmental and economic safety. These systems form the basis of automated control systems for the safe resource-saving operation of equipment in real time within the whole enterprise.
Risk decisions are determined by monitoring errors - static, dynamic, and those due to the influence of human factor. A significant effect of a static error detection on the magnitude of a dynamic error detection and of the failure omission risk due to the monitoring system has been shown. An equation of the static and dynamic errors relation, invariant to the nature of these processes and diagnostic features has been obtained.
There have been obtained numerical estimates of the dynamic error increase for linear and exponential trends of technical state degradation in the objects, invariant to their nature. Ways of improving the monitoring systems for malfunctions in objects of different responsibility depends on the basis of a modernized classification criterion.
Makhutov N. A., Technogenic safety: diagnostics and monitoring of potentially dangerous equipment and its operation risks// N. A. Makhutov, M. M. Gadenin, Digest: Federal
reference book, Vol. 26, Moscow, SP "Center of Strategic Partnership", 2012. – 496 p. pp. 307-314.
Kostyukov V. N., Monitoring of condition and operation risks of the equipment in real time as a basis of industrial safety// V. N. Kostyukov, N. A. Makhutov, A.V. Kostyukov. Digest: Federal reference book, Vol. 26, Moscow, SP "Center of Strategic Partnership", 2012. – 496 p. pp. 321-326.
Kostyukov V. N, Boychenko S. N, Kostyukov Al. V., Automated control systems for safe money-saving operation of equipment at refining and petrochemical plants (SMSRTM – COMPACS®), Moscow, Mashinostroenie, ISBN: 5-217-02971-4, 1999, 163 p.
Kostyukov A.V., Kostyukov V. N., Improving the operational efficiency of enterprises, based on real-time monitoring, Moscow, Mashinostroenie, 2009, 192 p.
Kostyukov V. N., Naumenko A.P., Bases of vibroacoustic diagnostics and monitoring of machinery: tutorial. Recommended by EMO of higher education institutions of the Russian Federation for students of higher education institutions studying in the field 200100 – "Instrument making". Omsk, OmSTU, 2011, 360 p.
Kostyukov V. N., Condition monitoring of the equipment in real-time technology of safe maintenance of the XXI century, Тhe 5th International Conference on Condition Monitoring and Machinery Failure Prevention Technologies CM 2008/MFPT 2008/ 15-18 July, 2008, Edinburgh, Scotland, UK, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-31-4, 2008, pp 785-793.
Kostyukov V. N, Real-Time Condition Monitoring of Machinery, The 6th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies,
CM 2009/MFPT2009/ 23-25 June, 2009, Dublin, Ireland, BINDT & Coxmoor Publishing Co., 2009, pp. 1161-1170.
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Technologies, CM 2009/MFPT2009/ 23-25 June, 2009, Dublin, Ireland, BINDT & Coxmoor Publishing Co., 2009, pp. 1132-1135.
Kostyukov An. V., Increase of safety and operating efficiency of continuous production cycle enterprises based on real-time comprehensive condition monitoring of equipment, The 6th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2009/MFPT2009/ 23-25 June, 2009, Dublin, Ireland, BINDT & Coxmoor Publishing Co., 2009, pp. 1164-1179.
Kostyukov V. N., Real-time Condition Monitoring of Equipment, The 7th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies,
CM 2010/MFPT2010/ 22-24 June, 2010, Stratford-upon-Avon, England, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-33-8, 2010, Paper 236, 8 p.
Kostyukov V. N., Real-time Condition Monitoring of machinery by the recurrent selection of the noise and periodic components of vibration, The 8th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2011/MFPT2011/ 20-22 June, 2011, Cardiff, Wales, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2011, Paper 205, 13 p.
Kostyukov Al. V., Kostyukov V. N., Classification of vibration parameters trends for RTCM, The 8th International Conference on Condition Monitoring & Machinery Failure
Prevention Technologies, CM2011/MFPT2011/ 20-22 June, 2011, Cardiff, Wales, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2011, Paper 217, 10 p.
Naumenko A. P., Modern methods and means of on-line monitoring of parameters and realtime health monitoring of piston machines, The 8th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM2011/MFPT2011/ 20-22 June, 2011, Cardiff, Wales, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2011, Paper 209, 13 p.
Kostyukov V. N., Real-Time Condition Monitoring of gear pumps by the recurrent selection of the noise and periodic components of vibration, The 9th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2012/MFPT2012/ 12-14 June, 2012, London, England, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2012, Paper 259, 11 p.
Kostyukov V. N., Real-time Health Monitoring Systems of Machinery, The 10th International Conference on Condition Monitoring & Machinery Failure Prevention
Technologies, CM 2013/MFPT2013/ 18-20 June, 2013, Krakov, Poland, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-37-6, 2013, Paper 106, 10 p.
Kostyukov V. N., Naumenko A. P., Kostyukov An. V., Boychenko S. N., Kostyukov Al. V., Standards in the field of technical condition of hazardous facilities equipment, Industrial safety, Moscow, 2012, 7, pp. 30-36.
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Kostyukov V.N. Real-time health monitoring systems of machinery - risk assessment // Condition Monitoring and Machinery Failure Prevention Technologies (СМ/MFPT 2014)