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
The paper presents the method of adaptive standardless vibration analysis of equipment on the basis of the analysis of vibroacoustic signals associated with unobserved errors of machines and units, which arise during the manufacturing process and in operation. Part of these errors is not presented adequately in ratio and interval scales.
We derived a canonical equation of links between diagnostic features of the signal and structural parameters of the machine condition, which represents the bisector of the first angle of information plane. The results of simulation for normal distribution are presented as well.
Kostyukov V.N. Adaptive method of vibroacoustic diagnostics // Actual problems of electronic instrument engineering: Proceedings of V International Conference. - Novosibirsk, 2000. - V.6 - p. 142-147
The COMPACS® system for computer monitoring carries out vibration monitoring and analysis of centrifugal compressors by means of the sensors of absolute and relative vibration installed on the outside (on the housing of each compressor bearing) and inside (above the rotor shaft) in orthogonally related directions in order to measure and control radial displacements and axial shift of the shaft.
The sensors of temperature, rotational speed and current consumption are used additionally. It enables diagnosing of technical condition and mode of operation of the compressors. Continuous vibration analysis and monitoring of technical condition of the units have positive results.
Every unit may become "good" in case of timely repair and estimation of its quality according to the unit condition by means of the COMPACS® system for vibration monitoring (both stationary and personal - COMPACS®-Micro), which enables to collect vibrations from all points of the compressor unit and transmit them to COMPACS-NET® diagnostic network of engineering supervision or to the Internet in order to analyze and control safe resource-saving operation.
Kostyukov V.N., Starikov V.A., Tarasov E.V. Monitoring and diagnostics of centrifugal compressors // Proceedings of VI International Symposium 'Consumers and manufacturers of compressors and compressor equipment'. - St. Petersburg, 2000. - p. 174-177
The report deals with the problems of vibration analysis of machine equipment on the basis of the analysis of vibration parameter trends. Main modern methods of machine vibration analysis are based on the evaluation of vibration parameters and on the analysis of vibration signal spectra.
Harmonic analysis of the spectrum usually requires knowledge of an exact construction of a machine; and existing methods of vibration analysis and prediction of technical condition do not take into consideration harmful effect of the human factor. Reliability of evaluation of machine equipment condition can be increased considerably by the use of the laws of processes of destruction and operability loss.
The processes of pump-and-compressor unit degradation were researched at a number of Russian refineries by means of the COMPACS® stationary systems for vibration monitoring. The researches concerned showed that rates of operability loss differ at various machine assemblies.
Kostyukov A.V. Evaluation of machinery performability by vibration parameter trends // DYNAMICS OF MACHINE AGGREGATES: Proceedings of the 5th International Conference. - Gabcikovo (Slovak Republic), 2000. - p. 101-104
In order to ensure failure tolerance of a process system it is necessary to monitor the equipment degradation, diagnose and control the equipment condition by giving the personnel notifications concerning urgent immediate actions.
Reliability and service life of the units depend heavily on their vibration; and vibration, in turn, is determined by the errors in manufacture, assemblage, repair and mounting at the unit as well as by operational defects caused by wear, mistakes of maintenance personnel and faults of operating conditions of the unit. That determines the necessity of vibration analysis of equipment condition at all stages of its life-cycle: for evaluation of workmanship, repair and mounting at the unit, for evaluation of technical condition in operation due to wear, mistakes of maintenance personnel and violation of operating conditions of the unit.
During vibration analysis of even one process unit diagnostic information should be collected, processed, presented and transmitted to the personnel in appropriate form during short interval of time (5-10 minutes) determined on the one hand by the maximum speed of malfunction development, and on the other hand – by the necessity of timely detection of mistakes or negligence of maintenance personnel and violation of operating practices which causes the unit failure. Considerable information scope requires the use of only stationary systems for continuous vibration monitoring.
Kostyukov V.N. Vibration analysis and monitoring of the units of plants with uninterrupted cycle // DYNAMICS OF MACHINE AGGREGATES: Proceedings of the 5th International Conference. - Gabcikovo (Slovak Republic), 2000. - p. 95-100
The main types of vibration signals used in the systems for equipment vibration analysis are the signals of vibration acceleration, vibration velocity, and vibration displacement. The parameters of these signals (RMS value, peak value) are in common use in different diagnostic and vibration-survey systems for equipment condition control.
In order to receive the required signal it is allowed to use appropriate sensor as an end device: piezoaccelerometer – for vibration acceleration parameter, inductive sensor of vibration velocity - for vibration velocity, displacement sensor – for vibration displacement.
But most devices and systems for vibration measurement use vibroaccelerometer as an end device, and the integration operations are used for acquisition of the signal of vibration velocity and vibration displacement.
Boychenko S.N. Algorithms for spectral integration of vibroacoustic signals for equipment vibration analysis // DYNAMICS OF MACHINE AGGREGATES: Proceedings of the 5th International Conference. - Gabcikovo (Slovak Republic), 2000. - p. 34-37
Russian refineries are used groups of ten thousand pumping units, basically centrifugal pumps, both Russian and foreign production. It’s power ranges from tens kilowatts to tens megawatts.
Technological settings of primary oil processing, catalytic cracking, catalytic reforming and others contains a different number of units, which ranges from groups of ten to hundred units depending on powers of settings. Specialists never raised doubts the necessity an anti-accident protection a powerful compressor and other unique machines, but not a pumps, which high concentration in modern technological settings however offen was reason of damages and other production troubles.
Really, if we take probability of pump trouble-free operation in day equal 0.99, then for the group of machines, containing 100 units, refusal probability close to 1, and the technological system herewith practically disabled. For reaching stability of a technological system to different perturbations, including failures of motor pumps, it is necessary to provide overseeing with the exterior on it exterior and interior factors describing its availability index of product, and control by its state by means of opportune acceptance of engineering and organizational measures.
Kostjukov V. N., Boychenko S.N., Kostjukov A.V. Vibration monitoring of pumps in Russian refineries // Mimosa Meeting 17, Scottsdale, Arizona, April 12-16, 1999
The introduction of ecologically clean resourse-keeping technology is the main demand of modern production especially in dangerous branches of industry such as oil-gas-refining, oil-chemical etc.
It's impossible to imagine oil-chemical production without reliable accident-free work of technological equipment. By means of computer vibration monitoring COMPACS® system we provide fundamentally new level of safe processes and machine maintenance based on the latest information technologies, saving large financial and personnel resourses.
Kostjukov V. N. Safe Maintenance of The Equipment is The Technology of The XXI Century - Russian Experience // Mimosa Meeting 17, Scottsdale, Arizona, April 12-16, 1999