The research is aimed at solving an urgent task of evaluating impact of personnel mistakes on performance of real-time diagnostic and monitoring systems for hazardous production facilities and determining the best ways of evaluating the monitoring system’s class taking into consideration the human factor.
Kostyukov V.N., Naumenko A.P. On dependency between personnel qualification and failures skipped by monitoring system // Technique and technology of the petrochemical and oil and gas production: Proceedings of the 7th international scientific and technical conference (Omsk, April 24-28, 2017). - Omsk: Publishing House of OmSTU, 2017. - p.172-173
When operating machinery on continuous technological manufactures one of the key issues is the timely detection and trouble-free decommissioning of units with a high degree of degradation of parts and components to their destruction and jamming. At the refining industries wide application centrifugal pumps equipped with rolling bearings. Rolling bearings are a key node, providing supporting and working functions of the dynamic equipment. At the same time, rolling bearings in the construction of a centrifugal pump unit is the most vulnerable host. Topical is the timely detection of incipient defects and ensuring monitoring of degradation of units and parts of the centrifugal pump unit during operation. The vibration of a centrifugal pump unit reflects the degradation processes occurring during the operation of the equipment. Thus the tracking vibration we can carry out an assessment of the technical condition of the equipment. The destruction of a centrifugal pump unit does not occur instantaneously and occupies defined time intervals. These time intervals can take corrective action and prevent the development of an emergency situation. On some pumping units degradation process is the stage and accordingly, there are jumplike character vibration changes. The analysis stepwise process of degradation and algorithms have been developed to ensure a warning of staff in advance of a failure of the unit. Applying the approach for the control of the degradation stage of technical condition monitoring and automatic diagnosis system has improved the operational safety of oil refineries.
Kostyukov V.N., Tarasov E.V. Diagnostics of technical condition of rolling bearings operation // Proceedings of International Scientific-Technical Conference "Dvigatel-2017" celebrating 110 years of Piston Motors Specialist Program in Bauman Moscow State Technical University / Moscow, - 2017. - p.19-20
Modernization of a characteristic criterion system for machinery and mechanisms’ failures is an urgent task of technical diagnostics. The paper is aimed at discovering special features of the evaluation of normal values of diagnostic signal parameters corresponding to different types of the condition of the diagnosed object. The classic approach is based on the following principle: a nonfaulty condition characterizes a diagnostic sign which value is lower in nonfaulty condition than in faulty one. A non-classic case – worsening of the condition features a lower value of the diagnostic sign. In both cases a task on accurate determination of the diagnostic sign’s value at known values of probability of failure skipping and false alarm. The paper considers methods of the accurate calculation of the diagnostic sign’s value for various cases of the probability distribution.
The results of the research show that statistical decision-making methods could be successfully applied for determination of limiting (threshold) values of diagnostic signs both for classic and non-classic cases of the probability density function, by setting particular conditions of optimal choice of a diagnostic sign’s value and an accurate calculation of the probability of failure skipping and false alarm.
Kostyukov V.N., Naumenko A.P. Features for Evaluation of Diagnostic Signs // Proceedings of International Scientific-Technical Conference "Dvigatel-2017" celebrating 110 years of Piston Motors Specialist Program in Bauman Moscow State Technical University / Moscow, - 2017. - p.18-19
The paper dwells upon the precision of vibration parameter-based diagnostics of asynchronous motors with continuous monitoring systems. For diagnostics of asynchronous motors, it is important to separate mechanical and electrical components of a signal using its long selection ensuring necessary resolution capability. In that case, a combined monitoring algorithm is used to separate the mechanical and electrical components of a signal, although the monitoring period remains minimal. Using the empirically acquired data we found out the suggested combined algorithm separates mechanical and electrical components and ensures minimal monitoring period.
Kostyukov Al.V., Boychenko S.N., Dudkin A.V. Increasing precision of asynchronous motor diagnostics in real-time monitoring systems // THE YOUNG RUSSIA: BREAKTHROUGH TECHNOLOGIES – INTO PRODUCTION. - No 1, - 2017. - p.249-254
To determine machinery condition methods of vibration diagnostics are widely used today. Those methods are utilized in personal, bench and stationary systems and adapted for various causes, including diagnostics of asynchronous motors by the vibration parameters of their bearing units.
Asynchronous motors can have specific defects of the electromagnetic system. Such defects are detected by the vibration diagnostic methods, but it’s quite difficult to localize and classify them. That might be connected with the fact that vibration signals may reflect processes undergoing on the stator windings, iron core and rotary conduction system.
The partial discharge method increases precision of the diagnostics since various defects of the electromagnetic system have different values of partial discharge parameters. For instance, one can determine a stator winding phase in which the defect is developing. A combination of vibration diagnostics and partial discharge methods helps to detect defects of asynchronous motor electromagnetic system using various physical effects simultaneously to increase the precision of diagnostics.
Kostyukov Al.V., Boychenko S.N., Schelkanov A.V., Burda E.A Combining methods of vibration diagnostics and partial discharges for asynchronous motor diagnostics // THE YOUNG RUSSIA: BREAKTHROUGH TECHNOLOGIES – INTO PRODUCTION. - No 1, - 2017. - p.28-32
The paper describes a study of vibration parameters distribution laws for in-operation vibration in rotary units. To evaluate the reliability of rotary units’ diagnostics it is important to know the nature of the distribution of diagnostic signs characterizing the equipment operation. The chi-squared test is used to check whether the empiric distribution belongs with the theoretical one. The experimental data helped to determine that an empiric distribution of diagnostic signs in rotary equipment is best to be described with a logarithmically normal distribution law.
Kostyukov V.N. Zaytsev A.V., Teterin A.V., Basakin V.V. Studying vibration parameters distribution laws for in-operation vibration in rotary units // THE YOUNG RUSSIA: BREAKTHROUGH TECHNOLOGIES – INTO PRODUCTION. - No 1, - 2017. - p.33-36 (http://elibrary.ru/title_about.asp?id=41264)
The paper dwells upon an urgent problem of specialist training in various industries considering specific training programs for colleges and universities and demands of actual productions. Based on the specialist training program analysis, experience of the NDT personnel pre-certification training and college/university student training, communication with personnel of the existing production facilities, it was concluded that not only college training programs, but personnel training systems should be changed in order to comply with existing order at the modern enterprises of various industries.
Kostyukov V.N., Kosyih A.V., Naumenko A.P. On training scientific and engineering personnel and certification of NDT and technical diagnostic specialists // Kontrol. Diagnostika. - 2017. - p. 38-44
The paper dwells upon problems of modeling vibration-acoustic (VA) signals of machines and mechanisms. Its main objective is creating approaches to developing a phenomenological model of VA signal structure during the occurrence of defects and malfunctions. Partial models of VA signal structures of certain malfunctions of piston machines are suggested.
Kostyukov V.N., Naumenko A.P. Generalized model of vibration-acoustic signal structure and formation mechanism // Proceedings of the XXI Russian NDT and Diagnostics Conference. - Moscow: "Spektr" Publishing House, 2017. - p.187-196
The paper dwells upon methodical issues of using shaft sensors for balancing and monitoring of imbalance in super-critical rotors. On the example of shafting with four rotary-table bearings, there are various results of different types of and finding distributed imbalance of a super-critical rotor with five discs.
The suggested method allows giving a constant estimation of residual imbalance state in modern systems of monitoring and technical diagnostics.
Kumenko A.I., Kuzminyih N.Yu., Timin A.V. Monitoring distributed imbalance of experimental rotor using shaft sensor // Proceedings of the XXI Russian NDT and Diagnostics Conference. - Moscow: "Spektr" Publishing House, 2017. - p. 186-187
The paper dwells upon the methodology of using shaft sensors in systems for vibration control, monitoring and automatic diagnostics of power units’ condition. It suggests the ways of improving the regulatory environment in monitoring and diagnostic systems for turbine units.
Apart from traditional vibration-parameter-based criteria stated by GOST R 55263-2012 and GOST R 55265.2-2012, we suggest additional criteria for reliability of rotors and turbine units supported by sleeve-type bearings. First of all, those are criteria for static and dynamic responses, as well as criteria for a shaft floating. For static responses we suggest, on the first stage, a maximum permissible deviation of 40% from the rotor’s weight. For dynamic responses, we suggest standards for dynamic loads due to residual imbalance. For sub-critical rotors, the dynamic load must not exceed 5 % from the rotor’s weight, supported by the bearings. For super-critical rotors - 2 % maximum.
We suggest methods for their rating by the results of measuring static and dynamic displacements of the rotors’ necks. The paper gives examples of modeling static and dynamic forces in a power turbine unit’s bearings. Also, there are examples of modeling static and dynamic forces in turbine units’ bearings.
Those criteria of rotary units’ operation status imply using a full system of shaft sensors measuring displacement from both sides of the bearing as per GOST R 55263-2012, unlike ISO 13373-3: 2015, since for an introduction of the said criteria one needs to know quite precisely the position of shaft neck in the bearing bore.
The formulated criteria can be used for machinery status assessment in modern automatic diagnostic systems.
Kumenko A.I., Kuzminyih N.Yu., Timin A.V. Reliability criteria and condition monitoring of power turbine units using static and dynamic powers in shafting supports // Proceedings of the XXI Russian NDT and Diagnostics Conference. - Moscow: "Spektr" Publishing House, 2017. - p. 181-186