The provision of safe and trouble-free operation of machinery of hazardous production facilities, which significantly influences the technical and economic indexes of production and the occurrence of technogenic incidents, is inextricably connected with the control of machinery performance in real-time.
Today on the majority of enterprises the performance management of repair service as well as its subsidiaries is carried out in two ways. On the one hand, it is carried out by the checking the expenses compliance to the nomenclature and the costs of the approved budget items; on the other hand – by the calculation of the numbers of accidents and incidents caused by skipping of machinery failures and determining the situational losses of machinery or the shutdown.
However, the leading enterprises have already passed on to the observation of the interaction of the production system elements by the introduction of the real-time monitoring system COMPACS®. All this allows to influence the factors of the result achievement, which is, in fact, the essence of the management department of any organization. Through the monitoring of machinery condition it is possible to identify not only the quality of the main and auxiliary personnel, but also the amount of work performed. In this regard, in order to save the resources and reduce the expenses of manufacturing complex it is possible to remove the operating and repair personnel from the complex and transfer them to the separate organization departments. The objective and timely information about the status of the machinery service acts as a link integrating these departments into a common production system.
Kostyukov V.N., Kostyukov A.V., Gavrin S.V., Kozlov A.A., Yatsyuk N.V. The development of the machinery diagnostic systems // World of oil products. The Oil Companies’ Bulletin – 2012. – № 8. – pp. 43-46
The solution for the problems of safe operation of machinery of hazardous production facilities is provision of the condition observability of the facilities which have the largest impact on technical-and-economic performance of production and occurrence of technical accidents. The condition observability of production facilities can be reached by monitoring of their machines in order to determine its current state and predict the moment when the state turn extreme. The result of monitoring is a complex of diagnoses of monitored facilities included in production complex obtained in inseparably linked time periods during which state doesn’t change.
The machinery degradation process observability allows to eliminate emergency repairs and to carry out planned condition-based repair of machines, which ensures 100% elimination of accidents. Resource-saving means not only reduction of material expenditures, but, also, decreasing of labour force and money expenditures for operation, elimination of consequences of accidents and faults, as well as losses due to downtime of production facilities. Such a clear increase of time-between-repairs of technological units up to 2-5 years (which all companies demand from their plants) is impossible without introduction of a monitoring system – which is a basic element of safe resource-saving operation of refineries and petrochemical companies, providing observability of machinery and the most important static equipment of the main technological units on an integral diagnostic network of the enterprise.
The selection and validation of range of facilities which are to be monitored is carried out by analysis of the production technology scheme including the influence of the facilities on the operational process and technogenic accident probability by means of a special method. As a result, the categories of facility hazard are specified. The final result of the analysis is development of a program of equipping the enterprise with monitoring systems and transferring to condition-based machinery operation. The analysis of reliability of technological units at the modern refineries and petrochemical companies shows that more than three-fourths of all faults happen to machines which high concentration at the units often causes accidents and production troubles, as well as downtime of units and plants.
Kostyukov V.N., Naumenko A.P., Kostyukov Al.V., Kostyukov An.V., Boychenko S.N., Belyavsky O.G., Samkov S.F. The experience of introduction and operation of condition monitoring system for potentially hazardous production facilities // Chemical equipment. – 2012. – № 12. – pp. 24-28
The methodology of a diagnostic signal processing, a function chart of the monitoring system are considered in the article. The methodology of monitoring and diagnostics is based on measurement of indirect processes' parameters (vibroacoustic oscillations) therefore, no more than five sensors is established on the cylinder, measurement of direct structural and thermodynamic parameters is described as well.
The structure and principle of expert system's functioning of decision-making is given. Algorithm of automatic expert system includes the calculation diagnostic attributes values based on their normative values, formation sets of diagnostic attributes that correspond to individual classes to malfunction, issuing of expert system messages.
The scheme of a real-time condition monitoring system for piston compressors is presented in the article. The system has consistently-parallel structure of information-measuring equipment, which allows to measure the vibroacoustic signal for condition monitoring of reciprocating compressors and their operation modes. Besides, the system allows to measure parameters of other physical processes, for example, pressure in decreasing spaces (the indicator diagram) for monitoring and diagnostics, the inlet pressure and flowing pressure of each cylinder, inlet and delivery temperature of gas, valves temperature, position of a rod, leakage through compression packing and others.
Naumenko A.P., Kostyukov V.N. The Piston Compressor: The Methodology of the Real-Time Condition Monitoring // The 25th International Congress on Condition Monitoring and Diagnostic Engineering Management (COMADEM-2012)
As shown by the experience, substantial reliability improvement of refineries and petrochemical facilities without equipment replacement and reconstruction may be provided by introduction of the monitoring tools at the all stages of units’ lifecycle. The condition monitoring allows transferring most of the failures from “sudden” to “creeping failure” category due to early detection of errors and warning personnel about progressive damage which already exists but may not be dangerous yet, since it does not violate the Refinery units’ operability.
Relevant regulatory frameworks in the form of international standards are ascertained only common approaches in monitoring problem solving (ISO 13374) both by the vibration measuring (ISO 13373, 10816) and by the measuring of parameters of various processes (ISO 13379, 13380).
Sharing various methods of technical diagnostics and nondestructive testing for technical state assessment, on one hand, is a really difficult and urgent problem due to the need of selection of the complex diagnostic features. On the other hand, various facilities require selection of the specific diagnostics methods and features.
The solution of the problem can be found in basic researches carried out over the last 40 years, as well as relevant testing of the suggested solutions, and operation of the computer monitoring systems for accident prevention and condition control (COMPACS®) in real conditions of the productions.
Kostyukov V.N., Naumenko A.P., Boychenko S.N. Russian standards for technical state monitoring of hazardous production facilities // NDT days 2012, pp. 300-304
The report addresses the real-time condition monitoring of technical state and automatic vibration analysis of auxiliary equipment’s bearing supports, in particular, the control of the feed-pump operating modes of thermal power stations. The causes that lead to premature birth and development of defects in rolling bearings are identified and the development of activities ensuring safe and continuous operation of the auxiliary equipment of thermal power stations is carried out.
Collection and analysis of vibration parameters of pumping units during their operation are realized by means of real-time condition monitoring. Spectral analysis of vibration parameters of one of the pumps showed the presence of frequency components, which mark violations in the operating practices of the pump, the development of imbalance and, as a consequence, the development of defects in the bearings after a long-term operation of the unit.
Timely warning of the personnel on the operation of the unit with "UNACCEPTABLE" state and automatic warning about the required changes the operational process allows to recover the pump operational process in due time and prevent further development of defects.
Kostyukov V.N. 2002. Monitoring of Safety of Manufacture (Moscow: Mashinostroenie).
Kostyukov V.N., Bojchenko S.N. and Kostyukov A.V. 1999. Automated Control Systems of Safe Resource-Saving Operation of Oil Refining and Petrochemistry Equipment (ACS SMSRTM™ COMPACS®) (Moscow: Mashinostroenie).
GOST R 53565 2010. Condition Control and Equipment Diagnostics. Condition Monitoring of Hazardous Manufacture Equipment. Vibration of Centrifugal Pumping and Compressor Units ( Moscow: STANDARTINFORM).
Kostyukov V.N., Tarasov E.V. Condition Monitoring and Diagnostics of Rolling Bearings of High-voltage Electric Motors during Their Operation. The 24th Int. Cong. on Condition Monitoring and Diagnostics Engineering Management (Stavanger, Norway, 30 May - 1 June 2011) pp 900-904.
Kostyukov V.N., Tarasov E.V. Real-time condition monitoring of thermal power plants feed-pumps by rolling bearings supports vibration // The 25th International Congress on Condition Monitoring and Diagnostic Engineering Management (COMADEM-2012)
The regularity and safety of the suburban passenger transportations on the Russian Federation railway lines depends on reliable functioning of each unit as well as it is substantially up to operational efficiency of more than 7,5 thousand electric train sections. Today the reliability of an electric train can be maintained by the ongoing preventive maintenance system formed on the schedule-based preventive principle which provides the list and the volume of the required control and recovery operations.
The cycle of large-volume current repair works in depot includes: uninstalling and diassembling operations for revision, repair, assembly, testing, transit of equipment and components, as well as its installation back to the electric train, which are time- and labour-consuming works. On the last stages of the cycle the repaired, checked and operative equipment may be damaged. Also, there is no guarantee for operation of the equipment within the system of the electric train because of the functionality violations.
Lack of the appropriate means and methods for the objective control of repair quality, assembling and adjustment of demanding and the most complex electric train systems especially electrical circuits, make impossible to control the quality of the carried out works. As a result, number of running electric trains with hidden problems occuring after the repair reaches 30-40%. Additionally, they can have lost of new defects caused by the“human factor”. The length of debugging stage, successful acceptance tests as well as further no-failure operation of an electric train, in this case, directly depends on qualification and other subjective qualities of the debuggers.
On the basis of the complex systems of automatic diagnostics, it is possible to change that situation as follows: to carry out the debugging stage at the repair and maintenance department reducing its duration, to provide an objective assessment of repair quality as well as assembly and adjustment of the electric train systems and equipment, and, consequently, to increase the percent of faultless results of the first acceptance test. Such systems are based on the automatic expert failure-detecting system which excludes the subjective failures of the diagnostician and provides reliable quantitative and qualitative state assessment for the most complex and demanding electric trains' systems in accordance with the requirements of the major regulative documents.
Kostyukov V.N., Kostyukov A.V., Kazarin D.V., Basakin V.V. Diagnostics of electric multiple-unit train electrical circuits’ equipment during the debugging and acceptance testing // NDT days 2012, pp. 309-313
Traction electric motor (TEM) is the most important assembly of the electrical-driven rolling stock (EDRS). Out of a total number of EDRS failures only about 30% are TEM failures. If one of TEM fails, it causes higher loads for other motors and that shortens the motors' lifetime.
Today there are several problems in the TEM diagnostics:
lack of the modern diagnostic systems in the depot and maintenance depot;
lack of the system viewpoint: every system diagnoses certain parameters of TEM which are not in the common base of the specific TEM.
In the article the complex diagnostic method for traction electric motor is presented. The method will allow changing of the traction electric motor repair type from the operation-based repair into condition-based repair.
Melk V.V. Developing of a method for complex diagnostics of traction electric motors // Operational reliability of locomotive park and increase of efficiency of train haulage. - Omsk: OSTU, 2012. - pp. 417-421
The paper is devoted to the new method of vibration analysis by means of the system for Real-Time Condition Monitoring of machinery (RTCM). The speed of generation and delivery of diagnostic instructions to the personnel by the RTCM systems must exceed the rate of industrial equipment degradation.
The paper presents the research on the regularity in formation of mixture of noise and periodic components of vibrations (MNPCV) of a pump. A generalized static diagnostic model of vibration has been developed to provide diagnostics of the unit by the method of recurrent selection of components from MNPCV in time and frequency domain.
The research shows that MNPCV are generated by a random process of occurrence and development of malfunctions and defects in the pump. With regard to vibration analysis, the principle of information completeness (π-principle) has been formulated. It states that in order to improve the credibility it is necessary to combine selection and use of MNPCV blocks for vibration analysis, which together form complete statistical group.
The paper illustrates the efficiency of the proposed methods in the diagnostics of defects of tooth gear, bearing, especially in the heavily loaded antifriction bearing with the radial clearance.
Kostyukov V.N. Real-time condition monitoring of gear pumps by the recurrent selection of the noise and periodic components of vibration // The Ninth International Conference on Condition Monitoring and Machinery Failure Prevention Technologies (CM-2012/MFPT-2012)
The main task of the technical diagnostics is determination of an object state when the data is limited. Analysis of a state is usually done in operation when the data is hard to obtain. Often there is no way to make an unambiguous conclusion, so it may be necessary to use statistical methods.
State determination depends on the completeness of the information, and the more information about the object we have, the lower the risk of an error there is. In this way, searching the object information is a relevant question.
In addition to the statistical methods, a spectral analysis method is widespread in vibration analysis. It allows to give characteristics to a frequency content of a measured signal. Cepstral analysis and wavelet analysis are less common. Using of methods of the fractal analysis is recommended to improve reliability and accuracy of the state determination.
Kostyukov V.N., Boychenko S.N., Pavlenkov D.V. Assessment of possibility of using the fractal analysis for machinery diagnostics // Operational reliability of locomotive park and increase of efficiency of train haulage. - Omsk: OSTU, 2012. - pp. 143-149
One of the most important tasks in the increase of the maintenance quality is an improvement of the operating reliability for motor driven rolling stock (MDRS) when there are low maintenance expenses as well as a limited period of time for repair and maintenance.
In the current state the rolling stock is maintained by the schedule-based preventive repair. That’s the reason of the high consumption of resources, regardless of the real operating conditions of the unit in the MDRS. At the same time, the origin and development of defects lead to unscheduled repairs as well as additional expenditures.
The solution can be provided by the on-board condition monitoring system. It makes an assessment of the state of every unit and gives objective information about the expediency of a further operation in real time. The effectiveness of the system is in its continuous operation and making a diagnosis within a period, which is less than the period prior to a malfunction development to a critical (emergency) condition. This makes possible the gradual transition from the resource-demanding schedule-based preventive repair system to the condition-based maintenance.
Machinery of auxiliary circuits including the system of the auxiliary machines is the most important machines, which provide normal functioning of all electric train systems.
The necessity of this machinery real-time condition monitoring is caused by hard service conditions, in comparison with all-industrial machines. The following conditions could cause an early mechanical failure as well as unplanned repair: the contact mains voltage fluctuation, sudden temperature difference, the high humidity, and also vibration.
Tsurpal A.E. Selection of the parameters for diagnostics of electric train auxiliary circuits’ equipment // Operational reliability of locomotive park and increase of efficiency of train haulage. - Omsk: OSTU, 2012. - pp. 143-149