Improvement of fault diagnosis reliability and depth is based on the application of fault criteria system, which is formed by combining the various parameters of diagnostic signals.
Therefore, the extension of the scope of signal diagnostic parameters and fault symptoms is important for diagnosis. The paper discusses the possibility of applying probabilistic characteristics both numerical and functional to estimate the parameters of vibration processes that characterize the defects and faults of the various mechanisms. Studies of vibration parameters when changing the condition of rolling bearings within various units and mechanisms showed that the probability density of the instantane-ous values oftbe vibroacoustic signal, and in particular, the acceleration also changes its parameters wben the bearing condition changing. Similar results were obtained when analyzing the probabilistic characteristics of the instantaneous values of vibroacoustic signals received from different assamblies of reciprocating compressors. We found that the change in the condition of such reciprocating compressor parts as discharge and suction valve, details of piston-cylinder units, slide-crank and cranking mechanisms, the crank-shaft bearings, the probability curves of the instantaneous vallies of the vibration signal significantly change. The latter fact is clearly visible when analyzing the parameters of the approximated distribution functions and probability density. For the first time in vibroacoustic diagnostics it was proposed to use such probabilistic characteristic of random processes as a characteristic function to analyze the properties of distribution function curve and probability curve.
The studies have shown that the area under tbe curve of the modulus of the characteristic function of the instantaneous value of vibroacoustic signals of different components and mechanisms may be used as a diagnostic parameter. Formation of the diagnostic features vector based on the parameter has allowed to propose a new diagnostic feature of fault invariant to machine design and the limit values ot vibroacollstic signal. Based on revealed regularity there have been developed a method and techniques of vibroacoustic diagnosis of various units of machines and mechanisms, as well as the vibroacollstic signal processing algorithm. Application of the deveIoped diagnosis method and diagnostic characteristics based on the characteristic function of vibroacoustic signal alows to increase the depth and the reliability of diagnosis whiIe simplifying diagnosis algorithms.
V. N. Kostyukov, А. Р. Nаumenkо, S. N. Boychenko (DYNAMICS Scientific & Ргоduсtion Center, Ltd., Omsk, Russia); 1. S. Kudr'yavtseva (Omsk State Тесhniсаl University, Omsk, Russia) Formation of diagnostic feature vector based on characteristic function of vibroacoustic signal // Нефтепереработка и нефтехимия. - 2016. - № 8. - 51-56
The article describes an experience of implementing a test bench with a control system for pump diagnostics COMPACS-RPG at a pump unit acceptance test shop of OAO Volgogradneftemash in 2011.
Using the data stored in the automated control systems COMPACS for safe resource-saving operation and maintenance allowed to build a system for automatic diagnostics and control over the pump unit testing and running at their standard and limiting operational conditions.
V.N.Kostyukov, A.V. Kostyukov, S.N. Boychenko, A.V. Lazarev, А.А. Pavlov, A.G. Shestov Innovative solution for pump units development and manufacturing // Neftepererabotka&Neftechimiya. - 2016. - № 8. - 51-56
The significance of resource-machinery operation based on stationary monitoring system, automatic diagnostics and its usage results are under consideration as illustrated by COMPACS systems of SIBUR units.
The article dwells upon the importance of timely control of asynchronous motor condition and the need to develop new methods of condition diagnostic of their main assemblies. Currently available test benches for electric motors usually control vibration, temperature, rpm and current consumption of an asynchronous electric motor(AEM). That ensures high accuracy of AEM mechanic assemblies’ condition assessment, but condition of AEM insulation in that case can be observed only indirectly.
A perspective new method of AEM stator winding insulation defect diagnostics is a partial discharges control method. A partial discharge is an electric discharge paralleling a part of insulation between different-potential electrodes. Partial discharges (PD) occur in insulation defects, inclusions, uneven parts, gaps between the insulation layers. Such spots with dielectric properties different from the main insulation’s properties cause redistribution of electric field which leads to occurrence of insulation parts with high strength of electric field. Multiple PD during machinery operation may have a negative influence on the insulation state and (if the PD are intensive enough) cause a defect growth , sometimes, to a dielectric breakdown, which may result in machinery breakage or accident.
A.V. Kostyukov, S.N. Boychenko, A.V. Schchelkanov, Е.А. Burda (ООО «NPC DYNAMIKA»), S.А. Averyanov, V.I. Maiorov (OOO MRP Gazpromneft Omsk Refinery). Experience in application of The COMPACS-RPE bench system with an integrated partial discharges sub-system in repair production of OOO MRP Gazpromneft Omsk Refinery // Chimicheskaya Technika. -2016. - No 7. - p. 4-6, Cover page
The paper presents the logical-linguistic model that provides sufficient depth and completeness of diagnostics in compliance with all the checks and standards required by the instruction. Diagnostic signs were determined considering each required check to build the model. The results of the diagnostic model development have been applied and successfully tested on various electric train sets.
A.V. Schelkanov Development of Logical-linguistic Model of Pneumatic Electric Train System for Diagnostic Purposes // Izvestia Transsiba. - 2016. - No 5. - p.48-54
A hypothesis on homogeneity of groups of the similar electric train mechanical nodes was put forward to improve the reliability of the recognition of the technical condition of the mechanical parts of the rail rolling stock and the calculation of the critical parameter values. The parameters of the node vibration generated when the train moves were collected; a new technique was developed and the statistical analysis of the measured vibration parameters of the same-type nodes was conducted within the hypothesis testing experiment.
V. N. Kostyukov, A. V. Kostyukov, D. V. Kazarin, V. V. Basakin Uniformity Evaluation of Vibration Parameters of Similar Electric Train Nodes // Izvestia Transsiba. - 2016. - No 5. - p.30-35
The paper describes the formation of SPC DYNAMICS. The company’s history dates back to 1989. In that year Vladimir Kostyukov, the founder of the company, was invited to Omsknefteorgsintez to address the problem of trouble-free equipment operation through the creation of permanently-installed systems for vibration health monitoring of pumps and compressors. The successful implementation of the first permanently-installed computer monitoring systems was the beginning of SPC DYNAMICS.
A.V. Kostyukov NPC DYNAMICA – Russian Innovations // Chimicheskaya Technika. -2016. - No 5. - p. 4-6, Cover page
Increasing scale and complexity of hazardous production facilities in petroleum refineries make it paramount to enhance the industrial safety and mitigate machinery related risks. That is why the strategy of operational efficiency improvement based on risk management has taken a special place among the strategic priorities of KazMunayGas - downstream operations. Even today the company is implementing a number of large-scale risk management projects. The projects involve the introduction of machinery health monitoring systems in the subsidiaries, since early failure detection, monitoring of failure development and timely corrective actions constitute a major safety task. The systems monitor equipment while in operation and maximize the design lifetime of the equipment. The paper presents the experience of the Pavlodar Oil Chemistry Refinery on transition to the Safe Resource-saving Operation and Maintenance of Machinery based on the real-time health monitoring systems.
The paper presents a possible approach to the assessment of the probability of omission the equipment failure, which is controlled by the monitoring system, considering the influence of a human factor as a managing part of a monitoring system on monitoring results. The aim of this paper is a selection and assessment of those components of the human factors that affect the likelihood of failure in modern monitoring systems.
V.N. Kostyukov, A.P. Naumenko Human Factor Influence on the Assessment of the Monitoring System Failure Probability // NDT World. - vol.19. - #1, pp. 72-77