The burst out economic crisis, mainly caused by non-objective assessment of real processes undergoing in global economy, points out the urgency of development and implementation of systems for economic condition monitoring in all economic braches. The development of such system allows to carry out an objective assessment of real processes undergoing at enterprises and timely inform concerned parties (management, consumers, shareholders, suppliers) about their current efficiency. In case of condition worsening it points out the main factors having harmful influence on the economy. Consequently, the task of provision of guaranteed production safety level and getting the planned results with minimum expenses is very urgent for Refinery and Petrochemical companies.
Efficiency of Refineries and Petrochemical companies mostly determined by value of material and human resource expenses for the machinery repair and losses due to accidents and downtime. Machinery wear rates are significantly determined by the adequacy of production and maintenance personnel work.
On the modern stage of effective management of machinery condition monitoring, we developed a new product - Compacs Asset Management (САМ™), which works on the bases of the COMPACS® system data and allows to make reports on the machinery operation for any time period, calculate efficiency index of technological complex machinery operation management in real time (САМ™ Index), and to make the process of decommissioning for repair automatic by means of the COMPACS® system data integration into the TORO-module of the enterprise management system (ERP, ЕАМ).
Kostyukov V.N., Kostyukov A.V. From monitoring systems to safe resource-saving operation of machinery. Results of implementation for 20 years // Council of Chief Mechanics. - 2012. - p.67-74
The paper is devoted to the current development and prospect development of modern methods and means of condition monitoring and diagnostics of reciprocating compressors in hazardous industries. The analysis of well-known monitoring systems enables determination of points for installing sensors in compressors and their assemblies including the controlled assemblies. The principles of condition control presented in monitoring systems have been studied. Technology of condition monitoring systems was examined.
The most systems receive diagnostic signals by means of stationary systems called on-line monitoring systems, in which equipment condition is estimated at the moment of signal receipt according to the measured parameter value without analyzing the causes of its change. In addition, the lack of automatic expert systems of diagnostics and lengthy diagnostic period exceeding the time of defect development testify that the examined on-line monitoring systems are parameter monitoring systems.
Methodology, implementation technology and principles of construction of real-time condition monitoring systems have been analyzed. The methodology of real-time condition monitoring and diagnosing is based on measurement of parameters of indirect processes (vibroacoustic oscillation) that requires installation of 5 sensors or less in a cylinder. The measurement of direct structure and thermodynamic parameters is provided as well.
The condition monitoring system is based on algorithms of real-time decision-making expert system with automatic detection (i.e. diagnostics during measurement of diagnostic signals) of more than 23 malfunctions of compressor assemblies and a hazard degree. The system also provides personnel with the instructions on compensatory control. Scientifically grounded diagnostic period enables reduction of static and dynamic errors by 5% that enables condition monitoring of the most significant equipment and overall production complex.
Naumenko A.P. Modern methods and means of on-line monitoring of parameters and real-time health monitoring of piston machines // The Eighth International Conference on Condition Monitoring and Machinery Failure Prevention Technologies (CM-2011/MFPT-2011)
During the operation of high-voltage motors at hazardous industries, it has been proved that, bearings do not work out the operating time assigned by the manufacturer. The report covers issues on the condition monitoring and diagnostics of the defects in rolling bearings of a high-voltage motors during theirs operation, defines the causes of a premature emergence and development of the defects as well the measures worked out for ensuring safe and prolonged operation of the rolling bearings of high-voltage motors.
The collection and analysis of vibration parameters of electric motors during their operation is performed by means of the real-time condition monitoring system. A spectral matrix of defects frequencies has been developed on the basis of the analysis of rolling bearings vibration source. The spectral analysis of vibration parameters showed the presence of frequency components that reveal defects of the bearings. As a result of vibration analysis, a number of defects in the rolling bearings have been revealed and proved during the motor repair and inspection of its bearings for likely defects.
The condition monitoring and diagnostics of the rolling bearings during the operation of the electric motors have allowed:
timely decommissioning of the motor with the damaged bearings as well as prevention of accidents which may have occurred with the unit that dispenses fire explosive products;
detection of the principal cause of frequent failures of the rolling bearings, which is application of the bearings in inappropriate working conditions and non-fulfillment of auxiliary measures recommended by manufacturers of bearings to prolong lifetime of the equipment;
submitting of recommendations on use of the bearings in the motor.
Kostyukov V.N., Tarasov E.V. Condition monitoring and diagnostics of rolling bearings of high-voltage electric motors during their operation // Condition Monitoring and Diagnostic Engineering Management (COMADEM-2011), pp. 824-833
During the operation of high-voltage motors at hazardous industries, it has been proved that, bearings do not work out the operating time assigned by the manufacturer. The report covers issues on the condition monitoring and diagnostics of the defects in rolling bearings of a high-voltage motors during theirs operation, defines the causes of a premature emergence and development of the defects as well the measures worked out for ensuring safe and prolonged operation of the rolling bearings of high-voltage motors.
The collection and analysis of vibration parameters of electric motors during their operation is performed by means of the real-time condition monitoring system. A spectral matrix of defects frequencies has been developed on the basis of the analysis of rolling bearings vibration source. The spectral analysis of vibration parameters showed the presence of frequency components that reveal defects of the bearings. As a result of vibration analysis, a number of defects in the rolling bearings have been revealed and proved during the motor repair and inspection of its bearings for likely defects.
The condition monitoring and diagnostics of the rolling bearings during the operation of the electric motors have allowed:
timely decommissioning of the motor with the damaged bearings as well as prevention of accidents which may have occurred with the unit that dispenses fire explosive products;
detection of the principal cause of frequent failures of the rolling bearings, which is application of the bearings in inappropriate working conditions and non-fulfillment of auxiliary measures recommended by manufacturers of bearings to prolong lifetime of the equipment;
submitting of recommendations on use of the bearings in the motor.
Kostyukov V.N., Tarasov E.V. Condition monitoring and diagnostics of rolling bearings of high-voltage electric motors during their operation // Condition Monitoring and Diagnostic Engineering Management (COMADEM-2011), pp. 824-833
One of the most important assemblies of electric rolling stock is a wheel-motor unit. Its faultless operation determines abilities of transport to fulfill their main functions.
One of the main requirements to the wheel-motor units is a set operational resource. Operation of rolling and sliding friction systems, such as ball- and roller-bearing assemblies, traction gears, commutator-and-brush device and other devices, which are the elements limiting the train resource in general, and depend on the vibration condition, quality of manufacture, repair and assembly.
It is reasonable to carry out the diagnostics of these facilities both during operation and maintenance with the required diagnostic depth.
Typical for these malfunctions is high level of noise, vibration, impact sound. By the deviations and higher levels of these parameters with the help of vibration analysis means it is possible to trace the defect development up to the moment when the usage of defected element is inexpedient or impossible in terms of operation.
Vibration analysis is based on the analysis of vibration process features changes, presupposing that the vibration signal of the operation unit contains all the information on the interactions of its details.
Basakin V.V. Analysis of malfunctions of wheel-motor units of motor-driven rolling stock for the purpose of their diagnostics // Nauka, obrazovanie, biznes (Science, education, business). - 2012. - pp. 136-140
The main purpose of condition monitoring systems (health monitoring systems) of piston compressors is maintenance of their safe and accident-free operation. The majority of modern piston compressor monitoring systems use direct measurement of structural parameters and thermodynamic process parameters. The quantity of structural parameters that can be measured by means of the sensors installed into assemblies does not guarantee sufficient control of technical condition of compressor assemblies and parts.
Measurement of compressor's thermodynamic parameters is an effective method of compressor's condition control in case the compressor squeezes technologically stable gases. Otherwise thermodynamic parameters mostly characterize technological working conditions of a compressor and not its technical condition.
The most effective monitoring covers condition of assemblies and details that are subject to frequent repairs. It should be noted that such assemblies and details determine safe exploitation of a compressor.
In order to reduce the cost of monitoring system's purchase and maintenance it is reasonable to measure the parameters of indirect processes, for example, vibration. Vibration sensors are easy to operate because they are mounted directly on a case of a compressor and its assemblies.
The paper presents data about repairs and faults of piston compressors at different oil-refining plants. On the basis of statistical data processing the most vulnerable assemblies and frequent faults are detected. In addition repair cost of a compressor is estimated. On the basis of the data obtained through processing the location of sensors to diagnose compressor assemblies and to detect defects by vibration parameters was detected.
The paper contains a block diagram of monitoring system of piston compressors based on a real-time condition monitoring system COMPACS® that has been functioning at oil-refining plants. Trends and parameters of vibration acoustic signals indicating emergence and development of compressor defects and malfunctions were analyzed. Emergence and development of defects and malfunctions in a compressor were illustrated by the analysis of trends and parameters of vibration acoustic signals. The analysis of data of COMPACS® monitoring system confirms high efficiency of compressor health monitoring systems that use vibratory (vibration acoustic) signals analysis.
Kostyukov V. N., Naumenko A.P. Choice of reciprocating compressors units for real time health monitoring // Condition Monitoring and Diagnostic Engineering Management (COMADEM-2011), pp. 824-833
Low objectiveness of condition assessment and lack of observability of hidden processes of condition degradation of potentially dangerous and critically important units, caused by the wear and inadequate actions of maintenance and repair personnel. These are the fundamental reasons of operational problems of the units.
Operational losses can be minimized by timely and purposeful maintenance on the basis of real-time condition monitoring results and usage of full resource of the units, eliminating unscheduled (emergency) shutdowns and repairs providing high level of safety and technical readiness.
The existing regulatory framework of international standards determines only the general approaches to the monitoring problem solving by measuring of parameters of different processes, including vibration measurement.
Joint usage of various methods of diagnostics and non-destructive testing for condition control of potentially dangerous and critically important units, on one hand, is a complicated and actual task, since it is necessary to develop a complex of diagnostic features based on various parameters of physical processes. On the other hand, various types of units demand specific decisions on choosing of the diagnostic methods and parameters.
The solution of this problem can be made on the basis of fundamental research works, adequate approbation of the decisions and the developed systems operation in real conditions of potentially dangerous and critically important units functioning.
Many years of DYNAMICS SPC experience in design, implementation and operation of real-time monitoring systems for dangerous production facilities without shutdown, demounting and decommissioning at Russian enterprises and abroad allowed to develop not only methodological bases and brand-new technological decisions and means of real-time condition monitoring, but, also, regulative-and-methodical documents, which determine the classification and main technical requirements to monitoring systems, operational norms of vibration for several types of machines and mechanisms, and principles of dangerous production facilities monitoring.
Kostyukov V. N., Naumenko A.P. Experience of monitoring systems design and operation // Monitoring – Nauka i bezopasnost’ (Monitoring - Science and Safety). - 2012. - pp.108-119
In the basis of diagnostics and monitoring of piston machines lies collection and processing of the data providing detection of defects and malfunctions of piston machines with a set depth of specification and reliability, as well as the danger rates.
Diagnostics and monitoring technology realization is based on the structure models of vibro-acoustic signals occurring if case of failure nucleation in assemblies and details of piston machines, combination of their diagnostic features (DF) of malfunctions and signal parameters (DPF) if case of failure nucleation, standard values of DF and DPF, vibro-acoustic signal transduction and vibro-acoustic signal parameter assessment.
One practical method of the technology realization and diagnostic and piston machines monitoring problems solution is implementation of the mentioned above methodological decisions which determine the knowledge base connecting DPF and condition of assemblies and details of piston machines into the algorithms of the COMPACS® diagnostic and monitoring system functioning.
The article deals with the principles of formation of the technology for diagnosing by vibroacoustic signal parameters and condition monitoring of piston machines. The methodology of diagnostic signal processing and the operating diagram of the system for technical diagnosing are considered. Particular attention has been paid to the structure and principle of operation of decision-making expert system.
Kostyukov V.N., Naumenko A.P. Basic principles of diagnostics and monitoring of piston machines // Bulletin of the Siberian office of Academy of Military Sciences. - 2011. - pp. 198-201
With the help of automatic systems for real-time diagnostics and monitoring COMPACS®, which cover a huge amount of machinery equipment on the dozens of Russian enterprises, wide-ranging researches were carried out. As the result, the database in the form of vibration parameter trends was created in order to discover connection patterns between the vibration parameter changes nature and condition degradation of units of different types.
There is an experimentally proved mathematic model of the vibration parameter trend, which confirms the exponential increase of the trend in a catastrophic wear state. The statistical features of vibration parameter trends are examined. It is ascertained that the values of vibration parameters and their growth rates with high reliability are subjected to the Weibull-Gnedenko law.
Classification of the vibration parameter trend and other diagnostic features measured by the real-time monitoring systems is conducted. It revealed the trends with slow, medium and fast growth rates, trends with monotonous, exponential, alternating and multimodal features. There are also trends characterized by high and low dispersion.
All the types of trends reflect different types of the developing faults and their danger level. This data allowed to evaluate the standards of vibration parameter s and their growth rates in the centrifugal pump-and-compressor units. The received results are the basis of several Russian Federal standards, concerning condition monitoring of hazardous production facilities.
Kostyukov V.N., Kostyukov A.V. Vibration parameter trend classification for the aims of real-time condition monitoring // Testing. Diagnostics. - 2011. - № 12. - pp.26-33
In order to provide stable, uninterruptible process of power production, one needs the constant condition control of the electric stations equipment. However, mainly, the general electric mechanisms - turbines – are equipped with the operational control and blocking systems. At the same time for the ensuring of a turbine operation it is necessary to use a few dozens of auxiliary equipment such as: different grinders, blowing fans, smoke-exhausters, feed, condensate, circulating, net pumps, coolers. Though, many auxiliary units are operated with no reserve and their sudden failure leads to the reduction of the amount of produced energy right up to full shutdown of the turbine.
Sudden failures are determined by the lack of constant automatic condition monitoring and diagnostics of auxiliary equipment. Usually, the vibration-diagnosing staff, which controls the equipment of thermoelectric power station by means of portable instruments, counts 2-3 members, and the number of the power station units is about several hundreds. In connection with that, the interval of the "manual" diagnostics of units exceeds the failure nucleation period, which leads to the sudden (from the operational personnel point of view) failure and faults of main units operation.
Equipping the auxiliary units of the power stations with systems of automatic diagnostics and condition monitoring COMPACS® is a real way to provide safe and reliable operation of electric stations.
The COMPACS® system ensures reliable diagnostics of the bearing defects, lubrication defects, technological process violations (cavitation, hydro-blows, etc.), defects of shaft centering and rotating parts balancing, poor fastening of pumps and electric motors, electro-magnetic defects, face seal failures more than 70% of which are caused by the high vibration rates of pumps and electric motors.
Kostyukov V.N., Tarasov E.V. Condition Monitoring and Automatic Diagnostics of the auxiliary equipment of the typical electric stations // Problems of vibration, vibration adjustment, vibration monitoring and diagnostics of the equipment of power plants. - 2011. - pp. 24-28
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