Safe operation of complicated productions including hundreds and thousands of units of energy equipment is only possible with the information on its technical condition and available power being submitted to the company administration.
Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) represent a new class of production control systems that inseparably link all stages of diagnosing.
ACS SRSM™ realize a safe resource-saving technology (Safe Maintenance™ - SM™ - technology) for equipment condition control, which enables real-time condition monitoring of equipment and controllability of its quality at all stages of life cycle, stability, safety and efficiency of production process.
Kostyukov V.N., Naumenko A.P., Sinicyn A.A. Monitoring system of energy equipment // The problems of vibration, vibration adjustment, vibration monitoring and diagnostics: Collected reports, theses. - 2005. - pp. 110-114
The paper presents the results of theoretical and experimental investigations intended to justification of choice of the complex of diagnostic signals and features for evaluation and prediction of technical condition of rotor machines and units.
In the practice of vibration analysis and vibration control sometimes the signals of vibration acceleration and vibration displacement are not put to use because they are considered to be closely coupled with vibration velocity signal. In the course of repeated observation of vibration parameter trends accumulated by the systems for vibration analysis and vibration monitoring at a number of Russian plants more than once we evidenced the cases when only parameters of vibration acceleration and/or vibration displacement responded to the development of various defects of rotor assemblies.
These cases denote considerable narrowing of the range of diagnosed malfunctions with the use of parameters of only vibration velocity signal. Thus, the problem of independence degree of the signals of vibration acceleration, vibration velocity and vibration displacement arises.
Kostyukov A.V. Forming a vector of independent diagnostic features of technical condition of rotor assemblies // Collected articles on propulsion engineering dedicated to 175th anniversary of MSTU n.a. N.E. Bauman. - M.: MSTU n.a. N.E. Bauman, 2005. - pp. 26-30
Improving the quality and reliability of aviation equipment is impossible without correct information on its technical condition at all stages of equipment life cycle. Information on present, past and future technical condition of a product is obtained by the methods of technical diagnosis, genesis and prediction.
Regularities of machinery performance loss revealed during long industrial researches of thousands of machines and units in the field enabled to formulate a number of principles of the synthesis of continuous monitoring systems and Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™).
Realization of these and other principles enabled creation of new methods of diagnostics and prediction of the machinery service life without dismantling, which are invariant to equipment construction and form of connection between diagnostic features and structural parameters of technical condition applied in the COMPACS® systems and software.
Kostyukov V.N., Molteninov A.V. Diagnostics of technical condition of fuel pumps of gas turbine engines // Aircraft engines of XXI century: Collected theses of the II International Scientific and Technical Conference. - Volume III. - M.: Central Institute of Aviation Motors. - 2005. - pp. 69-73
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