The article is concerned with the experience of creation of automated control systems for ecologically conscious and safe resource-saving operation of machinery of the plants with uninterrupted cycle (Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment - ACS SRSM™ - COMPACS®) on the basis of stationary systems for monitoring.
The created ACS systems enable elimination of harmful effect of human errors on the operation of technological systems, use of equipment during the whole operating life provided retention of its maintainability and production safety. In addition, ACS systems realize the strategy for minimal cost diagnostics and the technology of search and liquidating fundamental causes of equipment failures.
Kostyukov V.N. Automated systems for diagnostics and monitoring of resource-saving operation of equipment of oil-and-gas industry // CITOGIC. - 2000. - Volume 10. - Book 3. - M.: 2000. - p.22-35
Vibroacoustic analysis is put to use in order to increase reliability and objectivity of condition monitoring of all bearings and reduction gear of wheel motor units of ER-2 electric multiple unit.
The COMPACS®-EXPRESS system ensures evaluation of current technical condition and prediction of future technical condition of the elements of wheel motor unit by the results of measurement of vibration parameters, determines quantitative characteristics of physical quantities used as diagnostic features, displays them on the screen as a special board which shows quantitative and qualitative characteristics of the feature.
At the same time built-in expert system displays on the screen text and graphical information on a technical condition of wheel motor unit according to the test results. A printing device records this information, and the test results are automatically archived in the form of test reports.
Implementation of the COMPACS®-EXPRESS system for vibration analysis enables to improve the quality of repair and reliability of electric stock.
Kostyukov V.N., Avilov V.D., Kharlamov V.V., Naumenko A.P. The COMPACS system of vibration analysis for evaluation of technical condition of rolling stock units // New technologies - to railway transport: human resource development, organization of transportation process, operation of technologies: collected articles with international participation (in 4 parts). - Omsk: OSTU, 2000. - Part 3 - p. 245-247
The article presents the mechanism of unit vibration trends, which represent the mixture of gradual and discontinuous processes, and the mechanism of spreading of vibration spectrum in case of the unit degradation.
We proposed and tested the method of recursive synthesis of orthogonal diagnostic features that is invariant to the unit type. This method based on the blocks of spectral matrix realizes the concept of "collective recognition". In addition, we developed and tested deterministic models of unit performability and method of approximation of multimodal intensity of wear by Veibull-Gnedenko mixture of distributions.
The results obtained form the basis of the strategy for minimal cost diagnostics and enable significant reduction of costs and shortening of the period of implementation of the systems for condition monitoring of hazardous production facilities.
Kostyukov V.N. Synthesis of invariant diagnostic features and models of the unit condition for the purpose of diagnostics // Omsk Research Bulletin. - Omsk: 2000. - Issue 12. - p. 77-81
Vibroacoustic signal matrix reflecting the structure of diagnosed machine has been synthesized in the article. The matrix rows contain the spectrum components in different frequency bands, the matrix columns contain the components relating to certain classes of condition and types of defects of various kinematic couples, and residual 'noise' that reflect the principle of information completeness.
We considered spectral matrix conversions for the synthesis of diagnostic features, proposed the method and system for automatic recognition, which are invariant to machine construction, proposed an adaptive algorithm for recognition in conditions of a priori uncertainty, which enables recursive improvement of the machine construction by the parameters of its vibration.
The aspect, which is realized after considering the results of the synthesis of a spectral matrix of vibration signal, enters into invariance principle that is one of the bases of the strategy of minimum cost. The use of invariance principle in vibration analysis and diagnostic systems enables significant reduction of the implementation period.
Kostyukov V.N. Synthesis of a spectral matrix of machine vibration and its recognition for the purpose of diagnostics // Omsk Research Bulletin. - Omsk: 2000. - Issue 12. - p. 71-77
The paper presents the model of quasi-periodic vibroacoustic signal intended for diagnostics of batch-type objects.
In addition, we synthesized generic diagnostic features describing technical condition of batch-type objects, which are invariant to its construction. It enables to shorten the period of experimental and survey work as well as the time required for gathering of the signal statistics in different conditions of the objects during the implementation of diagnostic systems.
Kostyukov V.N. Generic diagnostic model of vibroacoustic signal of batch-type objects // Omsk Research Bulletin. - Omsk, 1999. - Issue 6. - p. 37-41
Ensuring accident-free operation of pump-and-compressor equipment (PCE) is inseparably linked with condition control.
The COMPACS® stationary and portable systems enable condition monitoring and diagnostics of a wide range of PCE (including reciprocating compressors) by vibroacoustic, temperature and other diagnostic parameters.
Сontinuous condition monitoring of the machinery forms the basis of the technology for safe operation of machine equipment that is intended to the elimination of sudden failures of the units, which cause accidents with important consequences. Condition monitoring is carried out by analyzing diagnostic features of the condition and automated detection of causes of the unit malfunctions with timely failure warning to the maintenance personnel in the form of voice and visual messages.
Boychenko S.N., Kostyukov Al.V., Naumenko A.P. Automation of the diagnostics of pump-and-compressor equipment // Consumers and manufacturers of compressors and compressor equipment: Proceedings of the Fourth International Symposium. - St. Petersburg, 1998. - p. 225-232
Machinery failures make up the major part of failures of units of oil-refining and petrochemical complexes. Machinery failures often cause accidents and manufacturing defects.
In order to mend matters it is necessary to ensure observability and evaluation of technical condition of the units during the manufacturing process, during acceptance at consuming plants, during repair at repair departments of refineries, during the mounting of assemblies at the unit, and during operation at process units.
Increase of petrochemical complex (PCC) reliability without replacement of equipment and reconstruction is realized by implementation of monitoring tools at all stages of life cycle of PCC units, i.e. by different systems for vibration analysis and vibration monitoring - stationary, personal and stand (on input diagnostics of the bearings, diagnostics and balancing of pump spindles, etc.), their integration into a single diagnostic network ACS SRSM™ (Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment), which enables automatic preparation and circulation of diagnostic information between the systems and submission of the information at all levels from operator and mechanic to the shop heads.
Kostyukov V.N., Boychenko S.N., Kostyukov Al.V. Russian experience of automatic diagnostics and monitoring of pump-and-compressor equipment on the basis of the COMPACS systems // Safe operation of compressor and pumping equipment. - Odessa, 2001. - p. 154-170
The necessity of accident-prevention protection of powerful compressors and other unique equipment has never raised doubts of the experts, but not the protection of pumping units. High concentration of pump units at petrochemical process units often causes accidents and other production defects.
In case we take the probability of trouble-free operation of a pump unit per day equal to 0.99, the probability of failure for machine fleet containing 100 units will be near 1. In this case the process system is almost nonserviceable.
Increase of operating reliability and maintainability of the units, technical and environmental safety, corporate culture and procedures discipline represents a powerful source of prevention of accidents and personnel traumatizing, and saving of considerable means required for the reconstruction of Russian enterprises. It is achieved by the implementation of ecologically conscious resource-saving technology of operation of oil and gas equipment on the basis of the COMPACS® complex of methodological means and firmware for computer vibration monitoring, vibration analysis and prediction of technical condition of pump-and-compressor equipment.
Malov E.A., Shatalov A.A., Bronfin I.B., Dolgopyatov V.N., Kostyukov V.N., Boychenko S.N., Meling A.Y. Efficiency of implementation of the COMPACS stationary systems for vibration analysis at Omsk Refinery // Industrial safety. - M.: 1997. - № 1. - p. 9-14
Vibration-survey transducers (VST) are designed for transformation of mechanical oscillations, impulse and impact mechanical effects to a proportional electrical signal.
Among various classes of VST (electromagnetic, inductive, capacitive, etc.) piezoelectric vibration transducers have widespread application. Detecting element of concerned transducers is piezoelectric ceramics comprised in the form of plate, disk, and ring with working surfaces covered by the electrodes generally made of silver, platinum, and nickel alloys.
The article presents the requirements for VST for industrial application, their technical characteristics and terms of delivery.
Kostyukov V.N., Donskov V.I., Ivanov A.A., Zagorodniy V.S. Vibration-survey transducers for industrial application // Foreign radio electronics. - M., 1996. - № 9. - p. 65-67
Long experience of Scientific Design and Technological Department (SDTD) PIEZOPRIBOR in the field of development and construction of piezoelectric vibration sensors (vibration accelerometers) was used to create a number of vibration analysis units for engineering, space-rocket hardware, nuclear power stations, and oil refining industry.
One of the last works ofDYNAMICS Scientific & Production Center (SPC) is creation of the COMPACS® system of automatic vibration analysis and computer monitoring for accident prevention and condition control of refining and petrochemical equipment.
Vibration accelerometers of types AB-ZPFR and AB-320FR developed by SDTD PIEZOPRIBOR in partnership with DYNAMICS SPC are of service in this system. Concerned vibration accelerometers have a number of unique characteristics. They are continuously upgraded according to the customer requirements and thus ensure reliable measurement of machinery vibration condition. The system operates according to the principle of conversion of physical parameters (vibration, temperature, pressure, current, etc.) of the equipment under control into an electrical signal by means of the sensors.
Kostyukov V.N., Donskov V.I., Tishina T.G. COMPACS system of computer monitoring for accident prevention and condition control // Foreign radio electronics. - M.: 1996. - № 9, p. 68-69