A hypothesis on homogeneity of groups of the similar electric train mechanical nodes was put forward to improve the reliability of the recognition of the technical condition of the mechanical parts of the rail rolling stock and the calculation of the critical parameter values. The parameters of the node vibration generated when the train moves were collected; a new technique was developed and the statistical analysis of the measured vibration parameters of the same-type nodes was conducted within the hypothesis testing experiment.
V. N. Kostyukov, A. V. Kostyukov, D. V. Kazarin, V. V. Basakin Uniformity Evaluation of Vibration Parameters of Similar Electric Train Nodes // Izvestia Transsiba. - 2016. - No 5. - p.30-35
The paper describes the formation of SPC DYNAMICS. The company’s history dates back to 1989. In that year Vladimir Kostyukov, the founder of the company, was invited to Omsknefteorgsintez to address the problem of trouble-free equipment operation through the creation of permanently-installed systems for vibration health monitoring of pumps and compressors. The successful implementation of the first permanently-installed computer monitoring systems was the beginning of SPC DYNAMICS.
A.V. Kostyukov NPC DYNAMICA – Russian Innovations // Chimicheskaya Technika. -2016. - No 5. - p. 4-6, Cover page
Increasing scale and complexity of hazardous production facilities in petroleum refineries make it paramount to enhance the industrial safety and mitigate machinery related risks. That is why the strategy of operational efficiency improvement based on risk management has taken a special place among the strategic priorities of KazMunayGas - downstream operations. Even today the company is implementing a number of large-scale risk management projects. The projects involve the introduction of machinery health monitoring systems in the subsidiaries, since early failure detection, monitoring of failure development and timely corrective actions constitute a major safety task. The systems monitor equipment while in operation and maximize the design lifetime of the equipment. The paper presents the experience of the Pavlodar Oil Chemistry Refinery on transition to the Safe Resource-saving Operation and Maintenance of Machinery based on the real-time health monitoring systems.
The paper presents a possible approach to the assessment of the probability of omission the equipment failure, which is controlled by the monitoring system, considering the influence of a human factor as a managing part of a monitoring system on monitoring results. The aim of this paper is a selection and assessment of those components of the human factors that affect the likelihood of failure in modern monitoring systems.
V.N. Kostyukov, A.P. Naumenko Human Factor Influence on the Assessment of the Monitoring System Failure Probability // NDT World. - vol.19. - #1, pp. 72-77
About the Experience in the Operation of Reciprocating Compressors under Control of the Vibration Monitoring System V.N. Kostyukov, A.P. Naumenko (DYNAMICS SPC, Ltd.), A.P. Dudarenko (LLC KSK-Service)
The article presents the results of reciprocating compressors operation under the control of Vibration-Based Diagnostics monitoring systems. dwells upon the issues of usage of reciprocating compressors valves by various vendors and their influence on compressors' vibroactivity. An adequate evaluation of vlbra-activity of piston machines is provided by the Russian regulative database on vibration parameters.
Main differences of Russian and global methods of reciprocating compressors health evaluation, particularly, used frequency range, are presented in the article. It is shown that the approach laid in Russian standards on reciprocating compressors vibration regulations ensures true-to-life assessment of reciprocating compressors assemblies and details condition.
The examples given in the article confirm that the criteria of reciprocating compressors repair correctness assessment should be the machinery health. including its vibroactivity, not just mindless usage of new components purchased from the global brands. Practical examples of operation and monitoring of reciprocating compressors show that Russian developments and products, particularly. scientific-methodological and standards base of Vibration-Based Diagnostics monitoring, reciprocating compressors monitoring systems, reciprocating compressors valves are highly competitive with foreign ones, and sometimes even superior to them in parameters and characteristics, which is a positive factor under the conditions of current economic situation and import substitution policy.
V.N. Kostyukov, A.P. Naumenko (DYNAMICS SPC, Ltd.), A.P. Dudarenko (LLC KSK-Service) About the Experience in the Operation of Reciprocating Compressors under Control of the Vibration Monitoring System // Kompressornaya tehnika i pnevmatika- 2016 - p.39-43
Problems of technical safety and resource-saving in production and transport industries were always topical, but recently, need in their solution became more urgent. This is due both to the growth of volumes and complexity of production, and to a significant decrease in the level of personal responsibility and qualification of personnel of enterprises operating hazardous production facilities.
Besides, there are fundamental reasons of the existing machinery reliability problems at facilities, which mostly comprise hidden nucleation and development of machinery failures, as well as subjective and not timely assessment of machinery condition in real operational processes. That does not allow the personnel to carry out timely and efficient procedures in order to support high technical readiness level of the production. Consequently, the enterprise bear significant operating costs and losses from accidents and downtime of production associated with the sudden failure of process equipment.
The above-listed factors cause an urgent need for general application of automated control systems for safe resource-efficient operation and equipment repair at the hazardous production facilities.
Kostyukov V.N., Kostyukov An.V., Kostyukov Al.V. Automated control systems for safe resource-saving operation and maintenance COMPACS // Glavniy mehanik (Chief Meachnical Engineer). – 2015. – №4. – P. 66-73.
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)