Source: http://www.dynamicsru.com/publications/articles/?curPos=50
Timestamp: 2019-04-20 01:14:25+00:00

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The most important result of Soviet era of vibration monitoring development is a prove of considerable impact that errors in assembling and operation of machine have on its residual life, and also possibility of predicting the residual life span by the vibration diagnostics results.
For production and transport industries the fundamental reasons of high costs and losses are determined by subtle occurrence and development of faults, as well as poor observability of actual processes of machinery deterioration during its whole lifespan.
Stability can be achieved by means of observability and controllability, when all monitoring processes are coupled together and monitoring time does not exceed the shortest interval of machinery fault development.
The shortest monitoring period can be achieved by the in-built automatic expert system revealing all main problems to the personnel operating the machine and forwarding this information through the automatic diagnostic network to the managers and production heads.
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.
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.
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.
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The prime means of machinery operability support is preventive maintenance. The intervals between maintenance/repairs as well as their size and contents depend on the statistical data. That method does not consider special features of the particular assembly, its actual operation conditions, such as stochastic loads on the machines, or operation procedure, etc. A machinery maintenance system based on such approach has several disadvantages.
Switching from preventive maintenance to condition-based maintenance allows considerably (in a few times) increase run-to-failure period and decrease operational costs. The real-time condition monitoring of machines and their parts ensures an objective assessment of condition during operation. The second component of the innovative technology for maintenance, repair, run-to-failure growth and reduction of cost required for a demanded condition support is detection of faulty parts of the machine before repair and an accurate assessment of their condition after the repair.
Kostyukov V.N., Naumenko A.P., Kostyukov Al.V., Boychenko S.N. Real-time condition monitoring – innovative technology of maintenance and repair production // Territoriya NDT (NDT Territory). - 2014. - №1. - p.66-69.
Vibration analysis provides a comprehensive assessment of a piston machine’s condition by outer vibration of its casing, and makes an effective instrument for investigating dynamic processes’ quality during assembling, production, defects detection and their critical growth during operation. The highest efficiency rate can be reached by ensuring the condition monitoring of not only a piston machine, but all conjugated mechanisms and attached assemblies.
Internal combustion motors are the most important types of piston machines for which vibration-acoustic diagnostics allows to provide safe accident-free operation with the longest possible operating life.
A DMS is a system (or machine) which product is current information on the condition of the machinery and possible danger, with required commentary (prognosis of residual operating life, prompting on the nearest urgent actions to be made, etc.) and a set risk level.

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