Real-time health monitoring of machinery malfunctions

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 health monitoring of machinery malfunctions // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.83.

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