The efficiency of malfunction detection for machinery protected by diagnostic and condition monitoring systems is strongly dependent from quality of their tuning, full and objective examination during post-production acceptance tests. However, the task of minimizing the influence of human factor on design quality check-up and tuning process can be successfully solved by automatic test benches.
A test bench provides automation of the most laborsome tasks, such as:
Diagnostic feature calibration in measuring channels;
Metrological check-up for measuring channels;
Expert system check-up, including defect signal formation and registering of the expert system messages;
Automatic formation and printing of a test report, as well as database storage of the results.
Tarasov E.V., Kazarin D.V., Zaytsev A.V., Pavlenkov D.V., Kostuykov V.N. Automatic test bench for machinery diagnostic and condition monitoring systems // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.80-81.
The research is based on the data obtained by an on-board monitoring system COMPACS®-EXPRESS-3 and aimed mostly at increasing reliability of machinery diagnostics of rolling stock units (in electric trains) by finding codependences in changes of vibration diagnostic features during condition degradation process from analyzing statistic properties of their distribution.
At the same time, the results obtained during the course of work are invariant to the diagnostic subject and can apply to machinery in hazardous production facilities in FEC.
The completed research allowed to establish the criteria according to which the cases of defect development were found using trends of vibration diagnostic features.
Tsurpal A.E., Kazarin D.V., Dederer Ya.V., Kostuykov V.N. The research of vibration activity of machinery units by vibration parameter trends // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.78-79.
The paper is aimed at researching the influence of rotation frequency and condition of rolling bearings on the level of vibration spectrum components which corresponds to the frequencies of rolling element bearing defects exposure.
The research is based on a theory of experimental planning using an experimental stand to assign frequency and record vibration signals. Different types of bearings have been subjected to the experiment: regular rolling bearings as well as rolling bearings with artificiality created defects and bearings with defects obtained during long-term operation.
The obtained results show the direct dependence between the level of spectrum components corresponding to the frequencies of rolling bearing defect exposure and rotation frequency. It should be noted, that such sensitive dependence is directly connected with condition of the rolling bearing under analysis
These results laid a foundation for creating mathematical models of rolling bearings vibration used in automatic expert systems for rolling bearing diagnostics.
Basakin V.V., Kazarin D.V., Zaytsev A.V., Teterin A.O., Kudryavtseva I.S. The research of rotation frequency influence and technical state condition upon the level of vibration spectrum components of rolling bearings // 5th International Conference on Oil and Gas Engineering. – Omsk: INTECH Edit., 2015 – p.79-80.
The paper dwells upon the method of calculation of guideline values of diagnostic signs in terms of statistical decision-making theory. It gives an example of calculation of the probability of the defect skipping and false alarms, the risk of the failure skipping while selecting the size of the regulatory characteristic of different decision-making methods.
It is shown that it is reasonable to use a method of minimum number of false decisions if the costs of false alarms and defect skipping are comparable. If the defect skipping cost is considerably higher than the cost of the false alarm it is advisable to use method of Neumann-Pearson. Selection of threshold values of diagnostic signs according to their distribution functions for different states of a machine under diagnostics should be made when the probability rates are >0.93 and <0.95.
Kostyukov V.N., Naumenko A.P. Risk assessment of selection of guideline values of diagnostic signs // Condition Monitoring and Machinery Failure Prevention Technologies (СМ/MFPT 2015)
The paper dwells upon new approaches towards imbalance diagnostics for both – separate rotors and shaft rotors. The methods are based on comprehensive usage of sensors for absolute support displacement and relative/absolute shaft displacement.
There are a lot of tasks to be solved with such sensors’ application, but the main one is the diagnostics of imbalance and its spreading area. The present paper covers only that one task.
Along with minimizing the absolute radial vibrations of journals and supports, it is also suggested to minimize turning angles of journals and consequently decrease the residual rotor vibration. The method can be utilized witht the COMPACS® system and intended for morden systems of imbalance monitroing and diagnostics and its automatic detection.
Kumenko А.I. Balancing of flexible rotors and shafting systems based on the COMPACS systems with the use of shaft sensors // Neftegaz.ru. – 2015. – №3. – p. 58-61.
Safe resource-saving operation of the machinery of the industry and transport branches is a very urgent task. Real-time condition monitoring of the machinery provides observability and allows to implement safe resource-saving technology of the machinery maintenance and repair. This paper considers the experience in operation of systems for health monitoring of hazardous production facilities and the machinery of energy sector and rail transport in case of smooth or discontinuous changes in vibration diagnostic features that reflect the corresponding multi-stage processes of destruction machines generating multimodal trends vibration parameters.
The paper proves that real-time condition monitoring systems increase diagnostics productivity in million times in comparison to "manual" tools, and provide economical effect for a consumer due to:
Increase of technogenic safety and machinery run-to-failure in dozens and hundreds of times.
Increase of readiness coefficient and main production assets usage coefficient.
Kostyukov V.N., Tarasov E.V. Real time vibration-diagnostic condition monitoring of production and transport complex machinery // Condition Monitoring and Machinery Failure Prevention Technologies (СМ/MFPT 2015)
The paper dwells upon the results of implementation of the stationary system of condition monitoring and automatic vibration analysis COMPACS® for elimination of sudden failures of thermal power station units. A description of the system’s functions, capabilities and application advantages are presented in the paper. There are detailed examples of the operation of auxiliary equipment, mainly, rotating aggregates, under the system’s control.
Kostyukov V.N., Tarasov E.V., Putintsev S.L. Safety operation monitoring of thermal station facilities // New in Russian Power Industry (Novoe v rossiyskoy elektroenergetike). 2015. – #2. – p. 6-13.
PJSC Enel Russia has been cooperating with DYNAMICS SPC since 2009. Current situation at the power industry enterprises is that the control and emergency shutdown systems are equipped in operation only at the main power mechanisms – turbine units. At the same time, several dozens of auxiliary machines (mills, blowers, smoke exhausters, power, condensate, circulating, network pumps, cooling towers) are used to support the operation of one turbine. Also, there are a lot of auxiliary machines that are operated without a reserve, and their sudden failure leads to reduction of volume and quality of the generated electric power and, consequently, to a complete shutdown of the turbine.
In this connection, PJSC Enel Russia has begun stage-by stage procedure of equipping the auxiliary machines of thermal power stations with the COMPACS® systems.
Equipping the auxiliary machines of Reftinskaya State District Power Station with a stationary condition monitoring and automatic diagnostic system COMPACS® has allowed to eliminate accidents and, so called, “sudden failures”, to make them “gradual”, “observable” and “controlled” by timely warnings for the personnel. Thanks to that, machinery units are decommissioned for repair only after full usage of their resources and with full reparability. The automatic diagnostics carried out by the COMPACS® system ensures the after-repair commissioning of the unit with an objective assessment of its condition and guaranteed quality repair with the "Acceptable" technical condition.
Kostyukov V.N., Tarasov E.V., Putintsev S.L. DYNAMICS SPC: On Safety Guard // TOP Energoprom. - 2014. - November-December. - p. 28
All major factors causing high operational expenses and losses due to failures are revealing in machinery operation life, when cumulative damage directly depends on timeliness of failure detection and adequacy of personnel actions depending on various speed of resource losses due to wear of machinery elements. The later the personnel reacts to worsening of machinery condition the greater resources are required to restore it, and if the situation is critical the total costs may exceed the ones enough for building a new facility. In turn, personnel’s reaction rate is determined by two main factors: machinery condition observability and adequacy of reaction to its worsening which mostly is influenced by manager’s being demanding and aware of the situation’s criticality level.
Thus, it is necessary to ensure failure skipping risk monitoring in real-time, i.e. provide managers of all levels with financial assessment of the current rates of possible costs and losses to the company in existing operational conditions of hazardous production facilities. Observability of the machinery degradation process in real time and good labour discipline allow to avoid the risk of accidents.
Data on machinery condition and its malfunctions and developing defects of the most critical parts of a machine are presented by the COMPACS® systems to all levels of production management. The systems automatically, without involving diagnostic specialists, detect all major classes of machinery malfunctions and for each of them issues several prescriptions automatically diagnosing defects of centrifugal and piston compressors, pumps, air-coolers and other machinery. Multiple analysis of maintenance works carried out by system’s prescriptions has revealed that all shutdowns of machines in “Unacceptable” state due to the system’s prescriptions were really necessary. In 100% of cases not only the necessity of maintenance works, but the machinery defects detected by the COMPACS® system were proved to be real.
Kostyukov V.N., Kostyukov Al.V., Kostyukov A.V. Real-time condition monitoring of machinery // Controlling. - 2014. - №4. - P. 44-49.