The COMPACS® system
Real-time vibration diagnostics
of machinery with probability close to 1
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Certification
In 2001 the quality management system of DYNAMICS SPC was put through facultative certification. In 2018 it was recertified for compliance with standards ISO 9001:2008. Its results confirmed a high level of goods and services quality management.
In 2001 the quality management system of DYNAMICS SPC was put through facultative certification. In 2018 it was recertified for compliance with standard GOST ISO 9001-2011. Its results confirmed a high level of goods and services quality management.
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Home Publications

Study of the applicability of the partial discharge measurement method for diagnostics of insulation condition of stators of asynchronous electric motors with an operating voltage of 380 V

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Ensuring the safe operation of machine units such as pumps, compressors and other production equipment has always been one of the most relevant tasks in the industry. Failures of the mentioned machinery can often lead to malfunctions and accidents, causing losses and damaging the environment. For example, the analysis of statistics on oil refining and petrochemical industries shows that failures of machine units account for more than 70% of the total number of equipment failures in these industries.

The wide application of electric motors, including electric motors with a working voltage of 380 V, as part of machine units, necessitates the development and use of new methods for monitoring their technical condition, which allow detecting emerging defects at early stages and preventing their further development.

To assess the insulation condition of electrical machine windings, methods for controlling the parameters of partial discharges occurring in the insulation of windings are being increasingly used, which is caused by the improvement of technical and instrumental diagnostics, which allow to register and analyze such discharges.

 

Kostyukov V.N., Burda E.A. Study of the applicability of the partial discharge measurement method for diagnostics of insulation condition of stators of asynchronous electric motors with an operating voltage of 380 V // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2014. – p.228-233.

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Tags: condition monitoring diagnostics non-destructive testing electric motor diagnostics Date: 11.04.2017
Views: 439
 

Increasing diagnostic reliability of axle equipment of wheel-motor units in electric trains

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The main diagnostic task is to recognize condition of machines and units, classify them as faultless or faulty ones. The task is closely connected to false alarm or defect skipping risks.

When a method for axle equipment of wheel-motor units diagnostics is utilized there is always a chance of defect skipping or false alarm.

In rolling stock operation conditions, skipping a defect may lead to unit’s destruction, which cause not only an expensive unscheduled repair, train schedule failure, but also a technogenic hazard and transport accident.

False alarm may lead to additional repairs for units which does not require maintenance, and, consequently, make their condition even worse and decreasing rolling stock’s operating availability rates.

The paper is aimed at increasing diagnostic reliability with minimum expenses for testing procedures.

 

Kostyukov V.N., Zaytsev A.V., Teterin A.O. Increasing diagnostic reliability of axle equipment of wheel-motor units in electric trains // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2014. – p.183-190.

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Tags: condition monitoring diagnostics wheel motor unit reliability vibration analysis rolling stock Date: 04.04.2017
Views: 440
 

Research on dependency of bearing vibration parameters on axial load

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The paper is aimed at finding dependency between the RMS value of vibration parameters of rolling bearings in different conditions and the axial load.

he research is carried out by means of an experimental unit based on the COMPACS®-RPP system using drive 1602 which allows to set axial and radial load values and measure vibration radially.

The subject of research is an operable bearing, bearings with seeded defects of inner and outer race, and a bearing with rolling elements defect which occurred due to long-term service.

From the analysis of the obtained results one can make a conclusion on a rolling bearing condition having a considerable impact on RMS values’ dependency on an axial load.

The operable bearing and bearings with seeded defects of inner and outer race are lacking or have non-considerable amount of such dependency. That may testify that such seeded defects have no considerable impact on dependency between bearing vibration and an axial load.

Bearings with rolling element defects which occurred due to long-term service have RMS value considerably dependent on the applied axial load. The most sensitive to changes in axial load are RMS values of vibration displacement and vibration acceleration.

 

Kostyukov V.N., Boychenko S.N., Basakin V.V., Teterin A.O., Kudryavtseva I.S. Research on dependency of bearing vibration parameters on axial load // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2014. – p.123-127.

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Tags: condition monitoring diagnostics bearings vibration analysis vibration analysis vibration non-destructive testing Date: 31.03.2017
Views: 486
 

Research on dependency of bearing vibration parameters on radial load

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Rolling bearings are the most common and important elements applied in modern engineering. For rotary mechanical equipment – rolling bearings are node points limiting machinery operational resource in general.

The most effective method, which allows to detect both – nucleating and developed defects of rolling bearings, are vibration-acoustic method of NDT.

To make a valid assessment of rolling bearings condition – it is required to know how various factors are influencing vibration level.

The paper is aimed at studying a dependency between the RMS value of vibration parameters of rolling bearings in different conditions and the radial load.

 

Kostyukov V.N., Boychenko S.N., Basakin V.V., Teterin A.O., Kudryavtseva I.S. Research on dependency of bearing vibration parameters on radial load // Science, Education, Business: Proceedings of Russian Radio-Day Scientific and Practical Conference for scientists, teachers, students, post-graduate students, industry and connection specialists. – Omsk, 2014. – p.118-123.

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Tags: condition monitoring diagnostics bearings vibration analysis vibration analysis vibration non-destructive testing Date: 24.03.2017
Views: 484
 

Pump units diagnostic and testing bench

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One of the main components of safe accident-free operation of industrial facilities is its high-quality production and maintenance. Throughout the years a concept of increasing quality of production and repair by means of objective condition assessment of assemblies and machines is commonly used.

The concept is implemented on the basis of automated control system for safe resource-saving operation and repair of machinery – COMPACS®. The bench variant of the system operates successfully at dozens of repair productions of Russia and CIS.

One of the latest development of DYNAMICS SPC among the bench systems is a pump units diagnostic and testing control system COMPACS®-RPG. The system is implemented at Volgogradneftemash, JSC – the biggest Russian producer of pump units.

The system is intended for collaborative work with new diagnostic and test bench (DTB) for pump units produced by Volgogradneftemash, JSC in order to carry out hydraulic, quality assurance and periodic tests of pump units  with full assessment of their quality after assembly.

Through the COMPACS-RPG system, specialists of DYNAMICS SPC solved the task of providing an automatic operation of the bench with real-time calculation of all required characteristics and test protocol printing.

 

Kostyukov V.N., Boychenko S.N., Kostyukov Al.V., Kopelev O.N., Pavlov A.A., Shestov A.G., Tavolgin A.Yu., Shelestov D.S. Pump units diagnostic and testing bench // Chemistry and petroleum engineering. - 2014. - №4. - P.38-42.

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Tags: condition monitoring diagnostics vibration analysis non-destructive testing COMPACS-RPG pump diagnostics Date: 17.03.2017
Views: 502
 

Monitoring risks of fuel and power industry machinery

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The paper dwells upon the usage of the modern systems for diagnostics and comprehensive condition monitoring (DMS) for fuel and power industry machinery, which make an integral part of the reliability control system for comprehensive production facilities providing safe resource-saving operation.

The paper considers the basic principles and the most important properties and characteristics of such systems, as well as their classification by 13 main features, describes methods for DMS types determination. The paper shows the examples of system type calculation for various software and hardware, the systems’ application domains for implementation at power facilities according to the risk of fault skipping.  The paper classifies the machinery by the risk matrix considering probability of a fault occurrence and its economic, ecological and technogenic consequences.

The paper suggests more detailed classification criteria for facilities targeted by technical regulation (FTR), hazardous production facilities (HPF) and critically important facilities (CIF). As an example of the first class DMS - the stationary condition monitoring system COMPACS® is described. The system comprises all general principles of the first-class DMS building according to GOST R 53564.

 

Kostyukov V.N., Boychenko S.N., Naumenko A.P., Kostyukov An.V., Kostyukov Al.V. Monitoring risks of fuel and power industry machinery // [Electronic source]//New on Russian electric power industry. 2014. №3, p. 30-44. - URL: http://energo-press.info/журнал-новое-в-российской-электроэне/архив-новое-в-российской-электроэнер/

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Tags: COMPACS condition monitoring diagnostics vibration analysis non-destructive testing standard Date: 10.03.2017
Views: 571
 

Basic principles of technology for real-time diagnostics and monitoring of piston machines

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Technology for real-time diagnostics and monitoring of piston machines is based on collection and processing of data which are to provide detection of defects and malfunctions of piston machines with specified detalization and accuracy, as well as their danger rates.

The technology implementation comprises usage of vibration-acoustic signal structure models in case of occurrence of defects and failures of assemblies and details of piston machines, combination of diagnostic features of failures and signal parameters in case of failure occurrence, ways of vibration-acoustic signal processing and evaluation system for the vibration-acoustic signal parameters.

One of the practical ways of the technology implementation and solutions of piston machines diagnostic and monitoring tasks is introduction of the given solutions which form a database connecting diagnostic features of failures and condition of piston machines’ details into functioning algorithms of the diagnostic and monitoring system COMPACS®.

The presented methodology of monitoring and diagnostics based on measuring the parameters of secondary processes (vibration-acoustic oscillations) allows to implement the algorithms of the real-time expert system for decision-making with automatic detection (diagnosing in time with diagnostic signals’ change) of more than 20 malfunctions of assemblies, such as piston compressors of hazardous production facilities, their danger rates and issuing prescriptions to the personnel for the required maintenance actions.

 

Naumenko A.P. Basic principles of technology for real-time diagnostics and monitoring of piston machines // XX Russian scientific conference on NDT and technical diagnostics: proceedings – Moscow: Spectr Editorial, 2014. – p.358-362.

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Tags: condition monitoring diagnostics expert system piston compressor piston machine vibration analysis non-destructive testing Date: 28.02.2017
Views: 542
 

Vibration monitoring of production and transport facilities

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The paper dwells upon the experience of operating condition monitoring systems for hazardous production facilities of power, mining, metallurgy and transport industries.

The paper shows the difference between the machinery parameter monitoring systems and condition monitoring systems. Parameter monitoring systems measure parameters of physical processes, however, without determining the causes of their change. Condition monitoring systems not only determine the change of physical parameters, but also the causes of their changes.

Those systems use algorithms of a real-time automatic decision-making expert system with an automatic machinery malfunction diagnosing, automatically show the personnel which actions should be made in order to eliminate the malfunctions.

Sometimes such systems in Russia are called “vibration monitoring systems”. The term “real-time” when referring to condition monitoring means that the speed of determining parameter measuring, condition evaluation, and depiction of the diagnostic results have to be adjusted to the speed of the machine’s degradation and exceed it by a few times in order to eliminate outliners and increase reliability of the diagnosis, along with creation of time reserve for making a management decision and carrying out all necessary actions.

Technical and economic efficiency indicators for the monitoring systems application are given in the paper.

 

Kostyukov V.N. Vibration monitoring of production and transport facilities // XX Russian scientific conference on NDT and technical diagnostics: proceedings – Moscow: Spectr Editorial, 2014. – p.357-358.

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Tags: condition monitoring diagnostics expert system vibration analysis non-destructive testing Date: 17.02.2017
Views: 589
 

Reliability increase of rotary units’ vibration analysis

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EMU-train depots widely use the COMPACS®-EXPRESS vibration acoustic diagnostics systems, designed for condition evaluation of WMU of motor-driven rolling stock during scheduled maintenance and repair works.

 The diagnostics is aimed at increasing reliability and resource of technical systems. The main diagnostic task is to evaluate the condition of units and assemblies and classify it as good or faulty. That is closely connected with the risk of false alarm or defect skipping. The present work is devoted to reliability increase of rotary units’ condition diagnostics with simultaneous decrease of complexity of its usage.

An analysis of geometrical parameters of a bearing assembly resulted in dependency of vibration level from rotation frequency and defect’s size. According to the dependency, the vibration signal amplitude rate is proportional to the bearing rotation frequency and the defect’s size. Using the COMPACS®-EXPRESS systems the dependency proved valid. A diagnostic error connected with false alarm or defect skipping probability can be eliminated by using an ambiguity area limited by the highest and the lowest critical values.

The paper considers the developed approach to reduce the diagnostic error by using an ambiguity area and conducting an additional independent testing. Thus, using an ambiguity area in condition evaluation together with two independent tests, increasing complexity of its usage not more than by 2, substantially increases the reliability of rotary units condition diagnostics.

 

Kostyukov Al.V., Kazarin D.V., Zaytsev A.V. Reliability increase of rotary units’ vibration analysis // XX Russian scientific conference on NDT and technical diagnostics: proceedings – Moscow: Spectr Editorial, 2014. – p.355-357.

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Tags: condition monitoring COMPACS-EXPRESS diagnostics wheel motor unit reliability vibration analysis rolling stock vibration signal non-destructive testing Date: 10.02.2017
Views: 678
 

Real-time health monitoring systems of machinery - risk assessment

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Modern production facilities equipment operation and transport complex are unthinkable without the use of health monitoring systems. Currently, the production and transport facilities of the complex are distinguished by the degree of impact on the country’s security, economy and ecology: objects of technical regulation, hazardous production facilities, critical facilities, strategic facilities.

It is clear that various classes of systems should be used for these objects health monitoring. Principles of monitoring construction documented in the literature are reflected in the standards. Monitoring systems should provide information on the equipment (monitoring object) status in the required quantity and quality to provide observability of its technical state. Observation systems results should advance to take control actions, which provide the required stability margin processing facility, quality of its operation, create a necessary supply of technological, environmental and economic safety. These systems form the basis of automated control systems for the safe resource-saving operation of equipment in real time within the whole enterprise.

Risk decisions are determined by monitoring errors - static, dynamic, and those due to the influence of human factor. A significant effect of a static error detection on the magnitude of a dynamic error detection and of the failure omission risk due to the monitoring system has been shown. An equation of the static and dynamic errors relation, invariant to the nature of these processes and diagnostic features has been obtained.

There have been obtained numerical estimates of the dynamic error increase for linear and exponential trends of technical state degradation in the objects, invariant to their nature. Ways of improving the monitoring systems for malfunctions in objects of different responsibility depends on the basis of a modernized classification criterion.

References:

  1. Makhutov N. A., Technogenic safety: diagnostics and monitoring of potentially dangerous equipment and its operation risks// N. A. Makhutov, M. M. Gadenin, Digest: Federal
    reference book, Vol. 26, Moscow, SP "Center of Strategic Partnership", 2012. – 496 p. pp. 307-314.
  2. Kostyukov V. N., Monitoring of condition and operation risks of the equipment in real time as a basis of industrial safety// V. N. Kostyukov, N. A. Makhutov, A.V. Kostyukov. Digest: Federal reference book, Vol. 26, Moscow, SP "Center of Strategic Partnership", 2012. – 496 p. pp. 321-326.
  3. Kostyukov V. N, Boychenko S. N, Kostyukov Al. V., Automated control systems for safe money-saving operation of equipment at refining and petrochemical plants (SMSRTM – COMPACS®), Moscow, Mashinostroenie, ISBN: 5-217-02971-4, 1999, 163 p.
  4. Kostyukov, V., Monitoring of Industrial Safety, Moscow, Mashinostroenie, ISBN: 5-217-03151-4, 212 p, 2002.
  5. Kostyukov A.V., Kostyukov V. N., Improving the operational efficiency of enterprises, based on real-time monitoring, Moscow, Mashinostroenie, 2009, 192 p.
  6. Kostyukov V. N., Naumenko A.P., Bases of vibroacoustic diagnostics and monitoring of machinery: tutorial. Recommended by EMO of higher education institutions of the Russian Federation for students of higher education institutions studying in the field 200100 – "Instrument making". Omsk, OmSTU, 2011, 360 p.
  7. Kostyukov V. N., Condition monitoring of the equipment in real-time technology of safe maintenance of the XXI century, Тhe 5th International Conference on Condition Monitoring and Machinery Failure Prevention Technologies CM 2008/MFPT 2008/ 15-18 July, 2008, Edinburgh, Scotland, UK, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-31-4, 2008, pp 785-793.
  8. Kostyukov V. N, Real-Time Condition Monitoring of Machinery, The 6th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies,
    CM 2009/MFPT2009/ 23-25 June, 2009, Dublin, Ireland, BINDT & Coxmoor Publishing Co., 2009, pp. 1161-1170.
  9. Boychenko S. N., Kostyukov V. N., Equipment diagnostic expert system, The 6th International Conference on Condition Monitoring & Machinery Failure Prevention
    Technologies, CM 2009/MFPT2009/ 23-25 June, 2009, Dublin, Ireland, BINDT & Coxmoor Publishing Co., 2009, pp. 1132-1135.
  10. Kostyukov An. V., Increase of safety and operating efficiency of continuous production cycle enterprises based on real-time comprehensive condition monitoring of equipment, The 6th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2009/MFPT2009/ 23-25 June, 2009, Dublin, Ireland, BINDT & Coxmoor Publishing Co., 2009, pp. 1164-1179.
  11. Kostyukov V. N., Real-time Condition Monitoring of Equipment, The 7th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies,
    CM 2010/MFPT2010/ 22-24 June, 2010, Stratford-upon-Avon, England, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-33-8, 2010, Paper 236, 8 p.
  12. Kostyukov V. N., Real-time Condition Monitoring of machinery by the recurrent selection of the noise and periodic components of vibration, The 8th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2011/MFPT2011/ 20-22 June, 2011, Cardiff, Wales, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2011, Paper 205, 13 p.
  13. Kostyukov Al. V., Kostyukov V. N., Classification of vibration parameters trends for RTCM, The 8th International Conference on Condition Monitoring & Machinery Failure
    Prevention Technologies, CM2011/MFPT2011/ 20-22 June, 2011, Cardiff, Wales, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2011, Paper 217, 10 p.
  14. Naumenko A. P., Modern methods and means of on-line monitoring of parameters and realtime health monitoring of piston machines, The 8th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM2011/MFPT2011/ 20-22 June, 2011, Cardiff, Wales, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2011, Paper 209, 13 p.
  15. Kostyukov V. N., Real-Time Condition Monitoring of gear pumps by the recurrent selection of the noise and periodic components of vibration, The 9th International Conference on Condition Monitoring & Machinery Failure Prevention Technologies, CM 2012/MFPT2012/ 12-14 June, 2012, London, England, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-36-9, 2012, Paper 259, 11 p.
  16. Kostyukov V. N., Real-time Health Monitoring Systems of Machinery, The 10th International Conference on Condition Monitoring & Machinery Failure Prevention
    Technologies, CM 2013/MFPT2013/ 18-20 June, 2013, Krakov, Poland, BINDT & Coxmoor Publishing Co., ISBN: 978-1-901892-37-6, 2013, Paper 106, 10 p.
  17. Kostyukov V. N., Naumenko A. P., Kostyukov An. V., Boychenko S. N., Kostyukov Al. V., Standards in the field of technical condition of hazardous facilities equipment, Industrial safety, Moscow, 2012, 7, pp. 30-36.
  18. GOST R 53563-2010, Condition Control and Equipment Diagnostics. Condition Monitoring of Hazardous Production Equipment. The Order of the Organization, Moscow, STANDARTINFORM, 2010.
  19. GOST R 53564-2010, Condition Control and Equipment Diagnostics. Condition Monitoring of Hazardous Production Equipment. Requirements to Monitoring Systems, Moscow, STANDARTINFORM, 2010.
  20. GOST R 53565-2010, Condition Control and Equipment Diagnostics. Condition Monitoring of Hazardous Production Equipment. Vibration of Centrifugal Pumping and Compressor Units, Moscow, STANDARTINFORM, 2010.
  21. Malov E. A., Bronfin I. B., Dolgopyatov V. N., Kostyukov V. N., Boychenko S. N., Implementation of COMPACS® systems – providing of safe operation at the plants with continuous production cycle, Industrial safety, Moscow, 1994, 8, pp. 19-22.
  22. Kostyukov V. N., Boychenko S. N., Naumenko A. P., Tarasov E. V., Comprehensive monitoring of hazardous production facilities, Control. Diagnostics, Moscow, 2008, 12, pp.
    8-18.

 

Kostyukov V.N. Real-time health monitoring systems of machinery - risk assessment // Condition Monitoring and Machinery Failure Prevention Technologies (СМ/MFPT 2014)

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Tags: condition monitoring diagnostics vibration analysis non-destructive testing Date: 07.02.2017
Views: 686
 
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