THE COMPACS SYSTEM®
REAL-TIME VIBRATION DIAGNOSTICS
OF MACHINERY WITH PROBABILITY CLOSE TO 1
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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.
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Comprehensive diagnostics of EMU-trains in depot

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The adopted system of maintenance and repair, relied on the resources of skilled labour force and a substantial reserve of equipment reliability for a long time, in the late twentieth century became ineffective. Numerous manual controls and diagnostics devices, existing in the technological arsenal of depot, due to low reliability of the obtained results, due to the implementation of ineffective ways of control by elements, low automation of the process of diagnosis, did not provide a way of equipment condition monitoring in the necessary volume and quality. As a result, the intensity of faults and failures of rolling stock has increased dramatically.

To change the situation revolutionary became possible only by using the automatic diagnostic systems for different types of rolling stock equipment.

The DYNAMICS SPC accumulated experience in condition monitoring and diagnostics of hazardous production facilities of various industry and transport branches has allowed to make a list of requirements and create the unique software-hardware complex – the COMPACS®-EXPRESS-TR3.

The comprehensive system for train unit diagnostics is an innovative research and designed for detailed, complex condition assessment of the main train subsystems with interactive operation at pre-repair and after-repair testing. Among the train subsystems, to be diagnosed with the system there are the control circuits, electro-pneumatic brake circuits, power circuit, heating circuit and auxiliary machinery circuits, including their electrical insulation, pneumatic system, wheel-motor units and the current collectors. As the statistics shows the subsystems’ data and the machinery included in them are most strongly influenced by the "human factor" during the repair and by external factors during operation. According to the statistics, not less than 85% of all damages and almost 80% of the cost for the maintenance and repair of rolling stock is depending on this equipment.

An effective principle of each unit diagnostics with maximum involvement of EMU-units standard equipment in the testing process is implemented and successfully approved by the system. As a consequence, it provides the autonomy and automation of the diagnostic process.

During the tests performed in the automatic emulation of various operational modes of the electric train machinery, the system determines the quantitative characteristics of the parameters and processes used as informative diagnostic features: vibration, signal spectra, voltage, current, resistance, pressure, force, time intervals, number of impulses and displays them on the monitor screen. In accordance with the programmed algorithm, a built-in automatic expert system displays purposeful instructions to the personnel for their further action in the form of text expert messages and provides a high-quality display of diagnostic signs based on the multi-colored icons, the color of which corresponds to the particular danger level of the machinery condition.

With the help of the present innovative research, for the first time for depots it became possible to:

  • reliably and efficiently detect failures and hidden defects of machinery, which decrease performance index and lead to the increase in power consumption of the train in general;
  • discover parts and machines which impair operational condition of electric machines and high-voltage switching devices;
  • use full resource of assemblies and machines with saving of their maintainability, consequently reducing the necessity in groundless repairs;
  • provide purposeful work of the maintenance staff aimed at elimination of the present defects and their root-causes;
  • reduce the labor intensity of the train control and set-up;
  • almost completely eliminate the faults in operation and unplanned repairs, due to reduction of the main cause – unsatisfactory quality of the repairs in depots.

The implementation of the innovative systems for the comprehensive condition diagnostics of the train units in such amount is carried out for the first time in Russia and surpasses the global level. It has a high economic and social impact, and is a powerful tool for increase of safety and uninterruptedness of railway transport operation. It creates prerequisites for fast reconstruction of the repair system on safe resource-saving basis.

 

Kostyukov V.N., Kostyukov Al.V., Kazarin D.V. Comprehensive diagnostics of EMU-trains in depot // Eurasia News (Evrazia Vesti), Sept. 2012, p.30

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Tags: COMPACS-EXPRESS-TR3 diagnostics expert system electric multiple unit reliability railway Date: 26.05.2015
Views: 1465
 

Condition-based maintenance of machinery by ACS SMSRTM COMPACS

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Due to wide application of computer technology allowing the large data arrays processing and the automation of PM planning with regard to the information received on diagnostics, maintenance, repair of equipment, data about actual failures of equipment, the new products such as CMMS (computerized maintenance management software) and EAM (Enterprise Asset Management) have come on the market. These products aim at planning the diagnostics maintenance and repair work of equipment, warehouse stock of spare parts, etc., by using the information about equipment range and configuration, periodicity of the reglamented PM, and the parameters of ambient conditions. However, the major difficulty in using these systems is the manual input of information in situation of the equipment ambient and operating conditions instability.

The actual cost of such total management substantially exceeds the calculated value and creates an illusion of efficiency. In this case, the equipment passportization, which is done by commissioning consultants and the company’s specialists, is possible; however, keeping such data base up-to-date at an enterprise that has tens of thousands units of various equipment is impossible. This is proven by the numerous articles, published in the press, and by customers’ feedback. The implementation of the PM method on such software products is possible only in small enterprises with simple configuration of process equipment. These software makes data input to the system labour-consuming and subjective that becomes the reason for the situation when more than 70% of the companies consider the results of the products’ implementation as unsuccessful, because this approach to PM does not solve their major problems: the unpredictability of equipment faults, low level of reliability of the process, and considerable losses due to shutdowns while its working condition is being restored, high maintenance and repair costs due to inefficient use of the equipment’s existing resources, high administrative costs of data input and processing.

In order to provide efficient asset management to the Customers, DYNAMICS SPC offers absolutely new unique solution Compacs Asset Management™ (САМ™), which is based on objective, relevant and timely information about the equipment condition provided by the monitoring systems COMPACS®, integrated into the single diagnostic network of the enterprise Compacs-Net®. All the above mentioned systems form the automated control system of safe resource-saving equipment operation SMSRTM™ COMPACS®.

 

Kostyukov V.N., Kostyukov A.V. Condition-based maintenance of machinery by ACS SMSRTM COMPACS // Industrial Automation ("Avtomatizatsiya v promishlennosty"). - 2012. - №9. - pp.12-17

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Tags: Compacs-Net COMPACS ACS SMSRTM™ САМ™ Date: 12.05.2015
Views: 1483
 

Classification of vibration parameters trends for RTCM

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The paper presents broad-scale research held by means of the COMPACS® systems of automated diagnostics and real-time condition monitoring that have been implemented on considerable amount of machinery equipment at a number of enterprises in the Russian Federation.

As a result of this research, a knowledge base of vibration parameter trends has been compiled. It reveals regularities between the type of vibration parameter measurement and the degradation of unit condition. The mathematical model of a vibration parameter trend has been confirmed experimentally, and it states an exponential growth of the vibration parameter trend at the stage of extremely gross wear.

In addition, the statistical properties of the vibration parameter trends have been researched. It has been established that generally the values of vibration parameters and their growth rates are subject to the Weibull-Gnedenko distribution.

The paper presents the developed classification of vibration parameter trends and other diagnostic features that can be measured by the Real-time condition monitoring (RTCM) systems.

Trends that have low, middle and high-speed growth rates have been discovered as well as the trends of monotonous, exponential, alternate and multimodal character. The trends that are characterized by high and low dispersion have been sorted out. Each trend type reflects different defects developing in equipment and degree of danger of these defects.

This data allowed us to calculate the norms of vibration parameters and their growth rate for centrifugal pumps and compressors. The obtained results are the base of some Russian State Standards relating to condition monitoring of equipment at hazardous industries.

 

Kostyukov V.N., Kostyukov A.V. Classification of vibration parameters trends for RTCM // The Eighth International Conference on Condition Monitoring and Machinery Failure Prevention Technologies (CM-2011/MFPT-2011)

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Tags: COMPACS condition monitoring diagnostics vibration analysis vibration parameter trend Date: 05.05.2015
Views: 1428
 

Standards in the field of condition monitoring and diagnostics of hazardous production facilities

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Low observability of hidden destruction processes of production facilities condition caused by wear and wrong actions taken by the maintenance personnel is a fundamental reason of hazardous production facilities operational problems. The analysis of reliability of technological units of modern refinery and petrochemical complexes shows that more than ¾ of failures are machinery unit failures, high concentration of which often appears as a reason of accidents and production faults which cause unit downtime and reduce coefficients of technical use and readiness.

In order to fix this problem it is necessary to provide observability and assessment of unit condition during the manufacture and acceptance at the consumer plants, during repair in special departments of enterprises, during the assembly of units and their operation. The observability of failure development requires constant diagnostics with an automatic delivery of objective results independently from the will of executive personnel to the personnel responsible for the machinery operation. The condition diagnostic and monitoring system should reveal the failures and provide supervision for their development and timely warn the personnel about the necessity of machinery decommissioning for repair or its emergency shutdown.

The article reviews the current state standards of the Russian Federation, and the standards of the professional public organizations developed by the authors. These standards define the basic requirements for condition monitoring of the equipment at hazardous production facilities which can underlie the transition to risk monitoring of hazardous production facilities.

 

Kostyukov V.N., Naumenko A.P., Kostyukov An.V., Boychenko S.N., Kostyukov Al.V. Standards in the field of condition monitoring and diagnostics of hazardous production facilities // Safety of industry labor. - 2012. - № 7. - pp. 30-36

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Tags: condition monitoring diagnostics standard accidents prevention Date: 24.04.2015
Views: 1357
 

From monitoring systems to safe resource-saving operation of machinery. Results of implementation for 20 years

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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

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Tags: COMPACS condition monitoring diagnostics resource-saving accidents prevention Date: 10.04.2015
Views: 1428
 

Modern methods and means of on-line monitoring of parameters and real-time health monitoring of piston machines

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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)

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Tags: condition monitoring diagnostics piston compressor vibration analysis Date: 20.03.2015
Views: 1374
 

Condition monitoring and diagnostics of rolling bearings of high-voltage electric motors during their operation

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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

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Tags: vibration analysis rolling bearings electric motor diagnostics Date: 06.02.2015
Views: 1355
 

Condition monitoring and diagnostics of rolling bearings of high-voltage electric motors during their operation

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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

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Tags: vibration analysis rolling bearings electric motor diagnostics Date: 06.02.2015
Views: 57
 

Analysis of malfunctions of wheel-motor units of motor-driven rolling stock for the purpose of their diagnostics

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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

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Tags: diagnostics wheel motor unit vibration analysis rolling stock MDRS Date: 23.01.2015
Views: 1460
 

Choice of reciprocating compressors units for real time health monitoring

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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

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Tags: diagnostics piston compressor vibration analysis Date: 16.01.2015
Views: 1413
 
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