The features of Real-time condition monitoring of machinery and the differences from On-line and Off-line condition monitoring are considered. Taking into account a human factor, the monitoring system model has been reviewed. This model shows that observability of the units state and the entire production complex equipment can be provided by measuring the diagnostic signals (vibration parameters) and rate of their change, which show accurately within scale the generalized units errors and rates of their growth, as well as residual life and its reducing, and the whole complex safety.
Determinate partial ageing functions and their rates, defined by the generalized errors, structural parameters and rates of their growth are offered to be used as variables of the unit’s state. Regularities for petrochemical complex units operation based on a sporadic character of control actions, which are the framework of the monitoring system generalized model, are identified taking into account the human factor.
Technical state of the production complex and correspondingly the risk of its operability loss are offered to be evaluated according to a minimum residual operability and a maximum rate of its loss, observed by the diagnostic and monitoring systems among the units group composing the complex. The required operational speed of the diagnostic and monitoring systems (DMS) is offered to estimate the maximum rate of the petrochemical complex residual operability loss according to the observability criteria of the monitoring theory Conclusions:
Monitoring allows to transfer the equipment and production complexes failures from a “sudden” to a “gradual” category;
Necessity of the failures reduction by ten times and corresponding increase of the equipment run-to-failure requires decrease of the monitoring mistakes to minimum (zero);
Decrease of a statical error and the implementation period reducing up to some months requires development of diagnostic methods and standard techniques invariant to the equipment type diagnostic features formation;
Decrease of a dynamic error requires a significant excess of the monitoring pace over pace of failures development at the production complexes, thus excluding a manual labor by means of automation of all monitoring processes: from parameters measurement and automation of a diagnostic output of information on the equipment state up to its unhampered and timely delivery and presentation to all levels of the production complex control.
Kostyukov V.N, Kostyukov A.V. Real-time monitoring of machinery malfunctions // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.83.
Current Russian and International standards in the field of standardizing parameters for piston machines vibration including piston compressors are reviewed. It is shown that the current standards do not meet the requirements for the piston compressors safe operation at hazardous production facilities. The article describes the Russian Federation National Standard "Condition monitoring and diagnostics of machines. Hazardous equipment monitoring. Vibration generated by rotodynamic pump and compressor units".
Kostyukov V.N, Naumenko A.P. Standardization in vibration monitoring of piston compressors // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.82-83.
Operation experience and results of the COMPACS® stationary system for machinery health monitoring and automatic diagnostics are given. The system manufactured by DYNAMICS SPC is intended to prevent sudden failures and breakdowns of the CDU-VDU equipment, shifting them from the sudden to the observed category. The system warns the staff about changes in the equipment technical state, giving recommendations to take urgent actions in order to lead the equipment into "acceptable" technical state.
Description of the system operation in real conditions is given, and analysis of the dynamic equipment operation is carried out. Reasons of the equipment failures are described, and recommendations for improving technical and economic parameters of the equipment operation and maintenance cycle optimization are offered.
Kostyukov An.V., Kostyukov Al.V., Tarasov E.V., Putintsev S.L., Chatkin A.P. Operation of equipment for primary oil processing under control of the COMPACS stationary system for health monitoring and automatic diagnostics // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.81.
The efficiency of malfunction detection for machinery protected by diagnostic and condition monitoring systems is strongly dependent from quality of their tuning, full and objective examination during post-production acceptance tests. However, the task of minimizing the influence of human factor on design quality check-up and tuning process can be successfully solved by automatic test benches.
A test bench provides automation of the most laborsome tasks, such as:
Diagnostic feature calibration in measuring channels;
Metrological check-up for measuring channels;
Expert system check-up, including defect signal formation and registering of the expert system messages;
Automatic formation and printing of a test report, as well as database storage of the results.
Tarasov E.V., Kazarin D.V., Zaytsev A.V., Pavlenkov D.V., Kostuykov V.N. Automatic test bench for machinery diagnostic and condition monitoring systems // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.80-81.
The research is based on the data obtained by an on-board monitoring system COMPACS®-EXPRESS-3 and aimed mostly at increasing reliability of machinery diagnostics of rolling stock units (in electric trains) by finding codependences in changes of vibration diagnostic features during condition degradation process from analyzing statistic properties of their distribution.
At the same time, the results obtained during the course of work are invariant to the diagnostic subject and can apply to machinery in hazardous production facilities in FEC.
The completed research allowed to establish the criteria according to which the cases of defect development were found using trends of vibration diagnostic features.
Tsurpal A.E., Kazarin D.V., Dederer Ya.V., Kostuykov V.N. The research of vibration activity of machinery units by vibration parameter trends // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.78-79.
The paper is aimed at researching the influence of rotation frequency and condition of rolling bearings on the level of vibration spectrum components which corresponds to the frequencies of rolling element bearing defects exposure.
The research is based on a theory of experimental planning using an experimental stand to assign frequency and record vibration signals. Different types of bearings have been subjected to the experiment: regular rolling bearings as well as rolling bearings with artificiality created defects and bearings with defects obtained during long-term operation.
The obtained results show the direct dependence between the level of spectrum components corresponding to the frequencies of rolling bearing defect exposure and rotation frequency. It should be noted, that such sensitive dependence is directly connected with condition of the rolling bearing under analysis
These results laid a foundation for creating mathematical models of rolling bearings vibration used in automatic expert systems for rolling bearing diagnostics.
Basakin V.V., Kazarin D.V., Zaytsev A.V., Teterin A.O., Kudryavtseva I.S. The research of rotation frequency influence and technical state condition upon the level of vibration spectrum components of rolling bearings // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.79-80.
Ensuring the safe operation of machine units such as pumps, compressors and other production equipment has always been one of the most relevant tasks in the industry. Failures of the mentioned machinery can often lead to malfunctions and accidents, causing losses and damaging the environment. For example, the analysis of statistics on oil refining and petrochemical industries shows that failures of machine units account for more than 70% of the total number of equipment failures in these industries.
The wide application of electric motors, including electric motors with a working voltage of 380 V, as part of machine units, necessitates the development and use of new methods for monitoring their technical condition, which allow detecting emerging defects at early stages and preventing their further development.
To assess the insulation condition of electrical machine windings, methods for controlling the parameters of partial discharges occurring in the insulation of windings are being increasingly used, which is caused by the improvement of technical and instrumental diagnostics, which allow to register and analyze such discharges.
Kostyukov V.N., Burda E.A. Study of the applicability of the partial discharge measurement method for diagnostics of insulation condition of stators of asynchronous electric motors with an operating voltage of 380 V // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2014. – p.228-233.
The main diagnostic task is to recognize condition of machines and units, classify them as faultless or faulty ones. The task is closely connected to false alarm or defect skipping risks.
When a method for axle equipment of wheel-motor units diagnostics is utilized there is always a chance of defect skipping or false alarm.
In rolling stock operation conditions, skipping a defect may lead to unit’s destruction, which cause not only an expensive unscheduled repair, train schedule failure, but also a technogenic hazard and transport accident.
False alarm may lead to additional repairs for units which does not require maintenance, and, consequently, make their condition even worse and decreasing rolling stock’s operating availability rates.
The paper is aimed at increasing diagnostic reliability with minimum expenses for testing procedures.
Kostyukov V.N., Zaytsev A.V., Teterin A.O. Increasing diagnostic reliability of axle equipment of wheel-motor units in electric trains // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2014. – p.183-190.
The paper is aimed at finding dependency between the RMS value of vibration parameters of rolling bearings in different conditions and the axial load.
he research is carried out by means of an experimental unit based on the COMPACS®-RPP system using drive 1602 which allows to set axial and radial load values and measure vibration radially.
The subject of research is an operable bearing, bearings with seeded defects of inner and outer race, and a bearing with rolling elements defect which occurred due to long-term service.
From the analysis of the obtained results one can make a conclusion on a rolling bearing condition having a considerable impact on RMS values’ dependency on an axial load.
The operable bearing and bearings with seeded defects of inner and outer race are lacking or have non-considerable amount of such dependency. That may testify that such seeded defects have no considerable impact on dependency between bearing vibration and an axial load.
Bearings with rolling element defects which occurred due to long-term service have RMS value considerably dependent on the applied axial load. The most sensitive to changes in axial load are RMS values of vibration displacement and vibration acceleration.
Kostyukov V.N., Boychenko S.N., Basakin V.V., Teterin A.O., Kudryavtseva I.S. Research on dependency of bearing vibration parameters on axial load // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2014. – p.123-127.