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
We developed resource-saving technology for production and repair of electric machines with the quality diagnostics at all stages: vibration analysis of the components quality, build quality of the units, quality of assembled machines and units in running and during acceptance test.
The technology is based on stand systems for vibration analysis of technical condition of rolling and plain bearings, dynamic balancing of rotors, build quality of bearing supports and rotary assemblies in own supports, comprehensive diagnostics of assembled machines and units.
This technology is realized on the basis of the COMPACS® stationary system – the system of computer monitoring for accidents prevention and condition control of machine equipment.
Kostyukov V.N., Karpov S.Y., Kovbasa N.I. Resource-saving technology for production and repair of electric machines on the basis of condition diagnostics // Proceedings of 8th All-Russian Scientific and Technical Conference "Modern development trends of construction of collector and other electromechanical energy converters". - Omsk, 2003 .- p. 214-219
The analysis of failure level of process equipment (furnaces, columns, machinery, etc.) shows that machine equipment failures make up about 70% of all failures. Thus, the automation of control over equipment operation on the basis of real-time vibration monitoring of the equipment condition is an actual problem.
Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™), which were developed by DYNAMICS Scientific & Production Center (SPC) for vibration analysis and control over safe resource-saving operation on the basis of real-time condition monitoring of equipment, solve the following problems:
vibration analysis and prediction of major malfunctions (> 95-98%) of equipment with early detection, full use of resources and retention of maintainability;
notification to the personnel of urgent immediate actions intended to control the equipment condition;
monitoring of execution of diagnostic instructions of the systems and the personnel actions through network (Internet) engineering;
development of the plans of targeted repairs in accordance with the actual technical condition of equipment;
elimination of design and installation mistakes;
optimization of flow charts and equipment configuration;
keeping the databases of diagnoses, works, replacements and service lives of equipment, reporting at all control levels of the enterprise.
Naumenko A.P., Boychenko S.N., Kostyukov Al.V. Condition monitoring of machine equipment is a solution to the problems of safe operation // Workshop meeting "Problems of safety, ecology and automation of shipment operations and storage of oil and oil products". - 2003. - p. 85-91
The report is concerned with the COMPACS® complex of methodical means and firmware providing new technology of resource-saving and safe operation of equipment. The systems implement vibroacoustic, thermal, acoustic emission, current and parametric (pressure, level, consumption, temperature) methods for diagnostics of machinery, vessels and equipment, which are protected by the patents for inventions, production prototypes and trademarks.
Built-in expert system carries out fully on-line automatic vibration analysis of the equipment malfunctions. This expert system is invariant to equipment construction and forms of connection between diagnostic features and structural parameters of the objects diagnosed.
At repair departments stationary systems for vibration analysis ensure output of 'nonvibrating' pumps and motors, which have the minimum dynamic loads and the maximum potential life, with 'one-time' assembling and commissioning.
COMPACS®-micro personal systems (automated working station of a diagnostician) ensure (off line) objective vibration monitoring of quasistatic equipment, transmit information to the stationary systems of vibration analysis for general announcing and reminding the personnel of condition of quasistatic equipment, realize the advantages of WINDOWS 95/98.
All these systems are integrated into a diagnostic network Compacs-Net®, they present diagnostic information according to the principle of MIMOSA standard ('look&feel') that considerably simplify training process.
Kostyukov V.N. Monitoring of safe operation of equipment // Proceedings of industry conference of chief mechanics of refineries and petrochemical plants. - Kirishi, 2002. - p. 269-270
The developed models and determined mechanisms of initiation and development of vibration and other processes accompanying operation of units of petrochemical complex enable their normalization in order to determine relative boundaries between different conditions of the units.
Experimentally proved fact underlying the methodology of normalization of machinery vibration parameters is that under normal operation of various units the values of vibration parameters are below certain values which can be used as the limits.
The developed methodological approaches and firmware of vibration monitoring of condition enable to liquidate fundamental causes of equipment failures (LiFCF technology), minimize the flow of requirements for maintenance, formulate and implement the strategy for minimal cost diagnostics of tens of thousands of bearings, several thousands of pumps, electric motors, couplings, reduction gears, dozens of compressors and air coolers of more than 350 types. Thus, methodological approaches and firmware concerned made a major contribution to the company profitability on the basis of resource-saving safety.
Kostyukov V.N. Normalization of vibration parameters in reciprocating compressor diagnostics // Proceedings of the Seventh International Symposium "Consumers and manufacturers of compressors and compressor equipment - 2001". - St. Petersburg, 2001. - p. 90-93
DYNAMICS Scientific & Production Center (SPC) proposes a COMPACS®-EXPRESS permanent station for vibration monitoring of wheel motor units (WMU) of electric multiple units and linehaul electric locomotives. The station is realized on the basis of the COMPACS® system which has a simple distributed architecture of fieldbus type and enables connection of analog and discrete signal sensors of all types - vibration transducers, thermocouples, etc.
A diagnostic controller installed at the shop, which does not require the systems for air conditioning and filtration, monitors, processes, and presents the results of diagnostics. Batch-produced system is certified by State Standard, included in State Register, and widely implemented in the country.
The station includes operator control panel and remote module with the sensors. The main task of the operator is to prepare WMU to tests and to place magnetic vibration sensors. All further actions are carried out at the operator control panel.
Avilov V.D., Kostyukov V.N., Borodulin A.G., Kovbasa N.I. Repair of locomotive units on the basis of the COMPACS resource-saving technology // Proceedings of IV Research and Practice Conference "Resource-saving Technologies in Railway Transport". - M., 2001 - p. IX-1-IX-2
Practical development and implementation of the technology for liquidating fundamental causes of equipment failures (LiFCF™) showed that less than 15% of the units consume more than half of all resources intended for equipment repair. More than 2/3 failures of face seals are caused by above-standard vibrations of the pumps and electric motors.
The implementation of the COMPACS® stationary systems for vibration analysis and equipment condition monitoring at process units of petrochemical complexes enabled elimination of major cause of failures – latent unobservable nature of their emergence or development. The systems enabled immediate elimination of severe accidents of pumping units associated with shafts breakage and bearings failure causing depressurization of face seals and further ignition. For instance, for 3 years of operation at JSC Tobolsk petrochemical combinat the COMPACS® systems prevented 122 failures of pumping units and accidents with ignition. It should be noted that in 1994-95, before implementation of the system, 5 such events took place.
The averaged estimation of cost efficiency of ensuring resource-saving safety by the implementation of stationary systems for continuous vibration monitoring of hazardous production facilities shows that the main sources of profitability increase are: decrease in number and duration of process unit downtimes, reduction of equipment losses, and reduction of costs of equipment repair and restoration, faster commissioning of process systems.
Kostyukov V.N., Kostyukov Al.V., Boychenko S.N. Russian experience of automatic diagnostics and monitoring of pump-and-compressor equipment on the basis of the COMPACS systems // Safe operation of compressor and pumping equipment. Proceedings of Scientific and Technical Seminar. - Odessa, 2001. - p. 154-170
The analysis of reliability of process units of modern refining and petrochemical complexes (PCC) shows that high concentration of machinery – pumping and compressor units, air coolers, smoke exhausters etc. with the unit capacity from tens of kW to several MW - often causes production defects and emergency situations.
Condition monitoring enables the unit personnel to predict most failures (formerly considered as sudden) by means of early detection and reporting about developing malfunction.
The implementation of the COMPACS® stationary systems for diagnostics and monitoring at PCC process units enables elimination of major cause of failures – latent unobservable nature of their emergence or development. Implemented systems enabled elimination of severe accidents of pumping units associated with shafts breakage and bearings failure causing depressurization of face seals and further ignition. Thus, it enables minimization of the time and cost of maintenance as well as realization of the strategy of minimum value diagnostics (SMVD™) that make a major contribution to the company profitability.
Kostyukov V.N. Control of equipment of petrochemical plants on the basis of the COMPACS automatic systems for diagnostics and monitoring // Proceedings of industry conference of chief mechanics of refineries and petrochemical plants of Russia and CIS. Equipment condition control and repair management system. - Kirishi, 2000. - p. 186-199