We examined the principle of a spectral matrix which is based on the method of vibroacoustic diagnostics of batch-type equipment using synchronous comb filtering.
Modern computer aids enable realization of this method in the frequency domain, which increases precision of selection of multiple frequency components, and improves operation speed by ensuring the potentiality of work at the samples with limited length.
On the basis of the algorithms of a spectral matrix we developed the COMPACS® expert system that enables reasonably quick, complete and reliable diagnostics of technical condition without equipment dismantling.
Boychenko S.N. Spectral matrix of vibration in automatic diagnostics of batch-type equipment // Education through science: International Symposium. - M.: MSTU n.a. N.E. Bauman, 2005. - p. 63
Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) enable automatic acquisition and use of reliable diagnostic information on the equipment condition in real-time mode. Such information represents a complex of diagnoses of condition of structures, machines, units and mechanisms that are collected on closely adjacent intervals of time so that the equipment condition varies insignificantly.
Nowadays about ten kinds of nondestructive testing (such as vibration, acoustic emission, thermal, electrical, etc.) are integrated in ACS SRSM™ COMPACS®.
Thus, the system enables continuous monitoring of production complex by the set of different methods of nondestructive testing on the basis of integrated hardware and software platform (COMPACS® distributed system for vibration analysis and computer monitoring), which enables diagnosing of condition of machine and columned-capacitive equipment, pipelines and tanks, furnaces and other equipment of petrochemical complex.
Kostyukov V.N., Kostyukov A.V. ACS SRSM™ COMPACS - the most important tool for equipping of refinery services that ensures safe and reliable operation of equipment // Proceedings of industry conference of chief mechanics of refineries and petrochemical plants. - 2005. - p. 218-221
It was theoretically proved and practically confirmed that vibration parameter trends develop according to an exponential model on the areas of catastrophic wear of equipment. The practice of vibration analysis showed that different defects develop at different time intervals.
Consequently, the stage of catastrophic wear of different units takes different periods of time. Thus, the duration of exponential growth of vibration parameter trend is determined by the type of defect or malfunction associated with wear at a time (i.e., the type of wear process).
From the above reasoning it is possible to carry out vibration analysis of the equipment condition by determination of the rates of growth at different time intervals (at different areas of the trend), which correspond to different defects and stages of their development. Excess of the rate of growth at a certain area indicates hazardous development of corresponding defect or malfunction.
Kostyukov Al.V. Prediction of the equipment condition by the rates of change of vibration parameters // International Symposium "Education through science". Proceedings of the section "Internal Combustion Engines". - 2005. - p. 48-49
The report presents the concept of resource-saving safety of gas-processing enterprises, which enables elimination of production failures caused by the equipment diagnosed, reduction of cost of repairs and spare parts, equipment operation in accordance with the actual technical condition, justified replacement of the equipment, control of the personnel actions, significant increase of the safety and degree of technical readiness of production on the basis of the systems for automatic vibration analysis and condition monitoring of equipment in real-time mode.
Kostyukov V.N., Geraskin V.I., Berdnikov V.M., Kiyashko V.P., Boychenko S.N., Naumenko A.P. Automatic condition monitoring of LLC Astrakhangazprom machinery on the basis of ACS SMSPM™ COMPACS // 14 International Business Meeting "Diagnostics 2004". - 2004. - p. 1-4
The purpose of monitoring system implementation is visualization of the equipment condition for early prevention of accidents and maximization of run-to-failure period of the equipment.
Only the availability of the systems, which automatically evaluate the equipment condition, enables complete elimination of a human factor from the process of diagnostics and control of execution of the regulations. Therefore, such systems enable to solve the problem of timely and targeted maintenance and repair on the stipulation that the unit capacity does not reduce.
The COMPACS® monitoring system meets the requirements and enables diagnostics and prediction of basic malfunctions. The system notifies the personnel about urgent immediate actions intended to control the equipment condition; it enables to control execution of diagnostic regulations of the systems and the personnel actions, to develop the plans of targeted repairs in real-time mode, to release from repair equipment with the maximum potential life.
Kostyukov A.V. Monitoring systems // Proceedings of industry conference of chief mechanics of refineries and petrochemical plants. - Kirishi, 2004. - p. 177-180
Improving the quality and reliability of aviation equipment is impossible without correct information on its technical condition at all stages of life cycle: in developing in design office, at the manufacturing stage and in operation. Information on present, past and future technical condition of a product is obtained by the methods of technical diagnosis, genesis and prediction.
The quality of these methods is characterized by PD probability of acquisition of correct information on the product condition at a time. Vibration monitoring of condition integrates these methods into a single continuous process by the elimination of passing through the time intervals with unobserved changes of the condition.
Reliability of the results of monitoring (PM) is determined not only by the reliability of vibration analysis (PD), but also by the frequency of vibration control (TK) that should be considerably smaller than duration of malfunction development (TN) because it determines the probability of detection (PT) of a critical malfunction.
Kostyukov V.N. Condition monitoring of aircraft units // Collection of reports of scientific and technical conference "Sensors and detectors for aviation equipment "DDAT-2003". - Penza, 2003. - p. 87-95
The COMPACS® system for automatic vibration analysis is the firmware complex providing new technology for safe operation and maintenance of mechanical equipment. The COMPACS® system falls into the category of the systems for measurement and diagnostics; it is intended to solve the problems of vibration monitoring of process equipment condition.
The hardware of the COMPACS® systems for automatic vibration analysis is constructed with the most advanced components; the characteristics of the COMPACS® systems constantly improve. In addition, the systems have a flexible structure at the expense of microprocessor control. All modern systems have a backbone network of the links between modules and diagnostic controller by control and signal lines; also they correspond to all fundamental principles of construction of the COMPACS® measurement and diagnostic systems.
The hardware structure of the COMPACS® system for vibration monitoring includes:
distributed system of end devices which control major parameters of the equipment;
distributed system of portable modules which enable initial conversion of the signals from the sensors and their translation to a diagnostic controller as well as control over the integrity of the sensors and communication lines;
vibration analysis station that control portable modules and ensure data collection and processing.
Starikov V.A. COMPACS system hardware // Collection of reports of scientific and technical conference "Sensors and detectors for aviation equipment "DDAT-2003". - Penza, 2003. - p. 18-21
The necessity of creation of an expert system (ES) for automatic vibration analysis and prediction of technical condition of electric drives is conditional on a high speed of the degradation processes and a large number of the units in petrochemical industry.
ES use enables to copy and spread the knowledge, and thus makes a unique experience of several highly skilled professionals available for a number of specialists. The COMPACS® ES enables reasonably quick, complete and reliable vibration analysis of technical condition of an electric motor without dismantling since it detects the following malfunctions:
unfastening of a motor to a base;
dog leg and unbalance of revolving parts;
inadmissible oscillations of a base;
inadmissible temperature of machine units;
frequency content and amplitudes of current of drive electric motors.
Kostyukov V.N., Boychenko S.N. Use of spectral matrix algorithms for vibroacoustic analysis of electric drives of centrifugal pumps of petrochemical production // Proceedings of 8th All-Russian Scientific and Technical Conference "Modern development trends of construction of collector and other electromechanical energy converters". - Omsk, 2003 .- p. 239-243
The article presents the results of research of orthogonality of the signals of vibration acceleration, vibration velocity and vibration displacement in the course of the defect development by means of numerical simulation of defects and correlation analysis.
Orthogonality of diagnostic features is an important condition that significantly simplifies the process of vibration analysis of the equipment condition. The more independent characteristics form a vector of diagnostic features, the easier to relate it to the vector of the equipment condition.
The dependence of the equipment condition is simplifying if all diagnostic features of a vector are orthogonal.
Kostyukov A.V., Kostyukov V.N. Experimental unit for research of vibroacoustic processes in electromechanical units on the basis of Agilent VEE software suite // Proceedings of 8th All-Russian Scientific and Technical Conference "Modern development trends of construction of collector and other electromechanical energy converters". - Omsk, 2003. - p. 226-239