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
The paper provides an analysis of standard documents - ISO standards and Russian GOST analogues, such as: ISO 13379- 2:2014 (GOST R ISO 13379- 2- 2016) Condition monitoring and diagnostics of machines - General guidelines on data interpretation and diagnostics technique. Part 2. Data-driven applications; ISO 13373-3:2015 (GOST R ISO 13373- 3- 2016) Condition Monitoring And Diagnostics Of Machines — Vibration Condition Monitoring — Part 3: Guidelines For Vibration Diagnosis; ISO 13373- 9:2015 (GOST R ISO 13373- 9- 2016) Condition monitoring and diagnostics of machines - Vibration condition monitoring - Part 9: Diagnostic techniques for electric motors.
Kumenko A.I., Kuzminyih N.Yu On additional requirements to vibration control and condition monitoring systems for turbine units of TPS and NPC // Proceedings of the XXI Russian NDT and Diagnostics Conference. - Moscow: "Spektr" Publishing House, 2017. - p. 174-180
For companies with an uninterrupted production cycle where the technology of operation is strictly set, the main problem of efficiency increasing is the reliability of equipment which is greatly influenced by the personnel operating various production processes in real time and often causing degradation of its condition. Combined with severe wear out of the main equipment featured at the majority of production and transport companies, the personnel’s negative impact on equipment condition leads to considerable losses due to accidents and downtime, as well as the high cost of repair.
Kostyukov V.N., Kostyukov A.V., Kostyukov Al.V., Boychenko S.N., Kazarin D.V. Automatic systems for health monitoring of production and transport industries providing high safety and efficiency // Proceedings of the XXI Russian NDT and Diagnostics Conference. - Moscow: "Spektr" Publishing House, 2017. - p. 167-174
A big share of machinery failures (40÷50 %) is caused by the destruction of rolling bearings. To prevent sudden failures of rolling bearings a vibration diagnostics system for in-operation monitoring of bearings must be installed.
Virtually all methods of condition diagnostics of rolling bearings are based on the analysis of vibration-acoustic signals in time or frequency area. To increase the accuracy of diagnostic results, there is an urgent task aimed at developing new methods.
The paper dwells upon the problems of practical use of vibration characteristic function (CF) parameters for evaluation of rolling bearings’ condition. It describes an experimental system, system of diagnostic signs based on CF parameters, methods for obtaining experimental data, results of the data processing.
Kostyukov V.N., Kostyukov Al.V., Boychenko S.N. Application of characteristic function of vibration for condition diagnostics of rolling bearings // Proceedings of the XXI Russian NDT and Diagnostics Conference. - Moscow: "Spektr" Publishing House, 2017. - p. 155-162
The most critical part of a rolling stock, operability of which directly influences reliability of train operation and safety of transportation is a wheel-motor unit. The most loaded, liable to significant static and dynamic loads elements are bearing units of wheel-motor units. The most significant component of an operation cycle is a diagnostic system’s application. The widest acceptance in railway industry got systems of vibration diagnostics of wheel-motor units measuring vibration parameters, comparing them to critical values and using the results to determine the units’ condition. Level of diagnostic’s reliability that systems provide today is not enough, since the number of wheel-motor units failures is still pretty high. Today there are a variety of diagnostic means that differ in type of measurement means, data processing method and diagnostic task solution.
Zaytsev A.V., Kostyukov V.N., Kazarin D.V. Perfection of methods and means for vibration diagnostics of wheel-motor units of rolling stock // Proceedings of the XXI Russian NDT and Diagnostics Conference. - Moscow: "Spektr" Publishing House, 2017. - p. 155-162
The paper is aimed at increasing the reliability of diagnostics by creating an adaptive method of condition evaluation for typical mechanical assemblies of railway rolling stock in movement.
The condition of mechanical units of railway rolling stock has a great impact on transportation safety.
Using onboard systems for diagnosing mechanical units of railway rolling stock allows diagnostics with a minimum interval, due to which the dynamic error rate is acceptable, not more than 0.1%.
Basakin V.V., Kostyukov V.N., Kostyukov Al. V., Kazarin D.V. New method for diagnosing bearing units of railway rolling stock in movement // Proceedings of the XXI Russian NDT and Diagnostics Conference. - Moscow: "Spektr" Publishing House, 2017. - p. 145-152
The paper presents an algorithm for detecting exponential growth areas of acoustic emission activity based on approximation of saved values of informative parameters (hereinafter referred to as the trend) during continuous monitoring with the acoustic emission (AE) method. Besides, based upon parameters of exponential approximation of trends, a new method is suggested for predicting a time when AE parameters reach their critical (threshold) values.
This paper aimed at developing an algorithm for detecting hazardous developing defects during continuous monitoring with an AE method. The most important tasks are theoretical research of informative AE parameters studied as parameters for detecting hazardous developing defects, description of the algorithm for detecting exponential growths area, as well as analytical derivation of a formula to predict the critical condition of the monitoring object. The suggested algorithm is utilized in a stationary system for diagnostics and monitoring COMPACS (hereinafter referred to as the System) installed at a revivifier operating as a part of a reactor-revivifier unit of cat cracking section.
Application of the suggested approach can be found in systems of continuous monitoring of production facilities used for various purposes.
Kostyukov Al.V., Boychenko S.N., Bogomolov D.E. Detecting and predicting hazardous developing defects during continuous monitoring with an acoustic emission method // Proceedings of the XXI Russian NDT and Diagnostics Conference. - Moscow: "Spektr" Publishing House, 2017. - p.33-38
Implementation of the first stationary systems for automatic monitoring and diagnostics of machinery health – COMPACS in the early nineties of the last century, for the first time an opportunity to watch changes of machinery health in real operational conditions under deterioration and restoration factors was realized. The results of such systems implementation helped to solve several urgent problems of operational reliability and machinery operating life. It was established that about one-third of all machines decommissioned for repair had no need for the repair at all. More than 40% of machines after repair had the same high vibration rates as before. That meant they had to be dismounted and decommissioned once again to remove all defects and carry out another repair.
Kostyukov Al.V., Tarasov E.V., Dvuhzhilov D.V., Averyanov S.A., Mayorov V.I. Practical application of the COMPACS bench systems at AO Omsk Refinery Machinery and Repair Plant // Himicheskaya tehnika. - 2017. -No1. - p.17-20
Implementation of the Technology of safe resource-saving operation of machinery deals with a problem of a variety of machines and devices used in common production facility which requires different methods of condition monitoring. The paper describes the experience of using a comprehensive condition monitoring system providing safe resource-saving operation by means of its software and hardware solutions.
Boychenko S.N., Sititsyn A.A Experiencing safe resource-saving operation provided by the COMPACS stationary system // Proceedings of the VI School-Seminar RISKOM. - Omsk. - Publishing house "Zolotoy tirazh" (ООО "Omskblankizdat"). - 2016. - p.158-169