APPLICATION OF THE MODIFIED BOX METHOD FOR IDENTIFYING THE EQUIPMENT MACRODEFECTS AT HAZARDOUS PRODUCTION FACILITIES

Authors: 
Receipt date: 
08.09.2017
Section: 
Year: 
2017
Journal number: 
УДК: 
658.58
DOI: 

10.26731/1813-9108.2017.4(56).19-27

Article File: 
Pages: 
19
27
Abstract: 

On the basis of a conducted analysis it was noted that it was relevant to apply rapid methods of technical diagnosis in order to improve the quality of technical state evaluation for industrial equipment of refinery, chemical, petrochemical, oil and gas extraction plants. It is possible to use the spectra of machinery facilities natural vibration frequencies for conducting their technical diagnosis.  A calculating and experimental methodology for rapid diagnosis of industrial equipment macrodefects is suggested. It is based on the monitoring of deviations from the "reference" spectrum of natural vibration frequencies during the operation. For these purposes, it is suggested to use the finite element method in combination with the methods of optimal design of the constructions. However, it is suggested to minimize the target function with Box complex method. To improve convergence in finding the best solution, the original algorithm of the method has been modified to reflect explicit limitations by introducing a bounce factor. The best value of the bounce factor, which provides the highest rate of convergence, is determined by experimental means. The methodology has been tested and verified using a number of test tasks, as well as using various industrial equipment during the bench testing and using the operating process units of JSC "Angarsk petrochemical company" and JSC "Angarsk polymer plant". For illustration, the results of the bench testing of the calculating and experimental diagnostic methodology of macrodefects are shown with the example of the DN 25 pipeline model (33.5×3.2). It is shown that stepped sine excitation method can be used for the experimental investigation of the pipeline's own characteristics.

List of references: 

1.   STO–SA–03–004–2009. Trubchatye pechi, rezervuary, sosudy i apparaty neftepererabatyvayushchikh i neftekhimicheskikh pro-izvodstv. Trebovaniya k tekhnicheskomu nadzoru, revizii i otbrakovke : utv. OAO VNIKTIneftekhimoborudovanie protokol No. 5 ot 16.12.2008 [STO–SA–03–004–2009. Tubular furnaces, tanks, vessels and apparatuses of oil refining and petrochemical industries. Requirements for technical supervision, revision and rejection: approved by OAO VNIKTINEFTEHimoborudovanie, protocol No. 5 dated 16.12.2008]. Volgograd, 2010, 75 p.

2.   Vlasov V.T., Dubov A.A. Fizicheskie osnovy metoda pamyati metalla [The physical basis of the metal memory method]. Moscow: TISSO Publ., 2004, 424 p.

3.   GOST R ISO 24497–1–2009. Kontrol' nerazrushayushchii. Metod magnitnoi pamyati metalla. Ch. 1. Terminy i opredeleniya : utv. prikazom Federal'nogo agentstva po tekhnicheskomu regulirovaniyu i metrologii ot 7.12.2009 [GOST R ISO 24497–1–2009. Non-destructive testing. Method of magnetic memory of metal. Part 1. Terms and definitions: approved by the Order of the Federal Agency for Technical Regulation and Metrology dated 7.12.2009]. No. 586. St. 2010.

4.   GOST R ISO 24497–2–2009. Kontrol' nerazrushayushchii. Metod magnitnoi pamyati metalla. Ch. 2. Obshchie trebovaniya : utv. prikazom Federal'nogo agentstva po tekhnicheskomu regulirovaniyu i metrologii ot 7.12.2009 [GOST R ISO 24497–2–2009. Non-destructive testing. Method of magnetic memory of metal. Part 2. General requirements: approved by the Order of the Federal Agency for Technical Regulation and Metrology dated 7.12.2009]. No. 587. St. 2010.

5.   GOST R ISO 24497–3–2009. Kontrol' nerazrushayushchii. Metod magnitnoi pamyati metalla. Ch 3. Kontrol' svarnykh soedine-nii : utv. prikazom Federal'nogo agentstva po tekhnicheskomu regulirovaniyu i metrologii ot 10.10.2009 [GOST R ISO 24497–3–2009. Method of magnetic memory of metal. Part 3. Inspection of welded joints: approved by the Order of the Federal Agency for Technical Regulation and Metrology dated 10.10.2009]. No. 499. St. 2010.

6.   Ivanov V.I., Vlasov. I.E. Nerazrushayushchii kontrol': spravochnik. Vol. 7. Metod akusticheskoi emissii [Non-destructive testing: A reference book. Vol. 7. Method of acoustic emission]. Moscow: Mashinostroenie Publ., 2006, 829 p.

7.   Panin S. V. et al. Kombinirovannyi metod issledovaniya deformatsii i razrusheniya obraztsov iz uglero - uglerodnogo kompozitsionnogo ma-teriala po dannym akusticheskoi emissii, korrelyatsii tsifrovykh izobrazhenii i tenzometrii [Combined method for studying deformation and fracture of samples of the carbon-carbon compositional material from acoustic emission data, correlation of digital images and strain gauges]. Vestnik nauki Sibiri [Siberian Journal of Science], 2012, No. 4 (5), pp. 129–138.

8.   PB 03–593–03. Pravila organizatsii i provedeniya akustiko - emissionnogo kontrolya sosudov, apparatov, kotlov i tekhnolo-gicheskikh truboprovodov : utv. postanovleniem Gosgortekhnadzora Rossii ot 9.06.2003. No. 77. [PB 03-593-03. Rules for the organization and conduct of acoustic and emission control of vessels, apparatuses, boilers and technological pipelines: Decree of the Gosgortechnadzor of Russia of 9 June 2003 No. 77].

9.   Bykov S.P., Inshakov D.V., Kuznetsov K.A. Primenenie akusticheskoi impul'snoi reflektometrii v nerazrushayushchem kon-trole trub teploobmennikov [Application of acoustic pulse reflectometry in non-destructive control of heat exchanger tubes]. Khimicheskoe i neftegazovoe mashinostroenie [Chemical and petroleum engineering], 2014, No. 10, pp. 41–43.

10. STO 00220227–043–2016. Truboprovodnye sistemy. Metody akusticheskogo kontrolya. Metod akusticheskoi impul'snoi reflektometrii [STO 00220227-043-2016. Pipeline systems. Methods of acoustic control. Method of acoustic pulse reflectometry]. Irkutsk: IrkutskNIIkhimmash Publ., 2016, 26 p.

11. Konovalov A.M., Kugushev V.I., Yakovlev A.Yu. Dva perspektivnykh napravleniya dlya defektoskopii treshchin s ispol'zovaniem sobstvennykh kolebanii ob"ekta kontrolya [Two perspective directions for defect inspection of cracks using the natural oscillations of the object of control]. Kontrol'. Diagnostika [Control. Diagnostics], 2017, No. 8, pp. 52–58.

12. Moskovenko I.B., Kovarskaya E.Z. Ispol'zovanie chastot sobstvennykh kolebanii pri nerazrushayushchem kontrole fiziko-mekhanicheskikh svoistv materialov i izdelii [The use of natural frequencies for non-destructive control of physical and mechanical properties of materials and products]. V mire nerazrushayushchego kontrolya [NDT World], 2012, No. 4 (58), pp. 13–16.

13. Kogushev V.I. Metodika obnaruzheniya znachitel'nykh defektov zheleznodorozhnykh koles po rezul'tatam izmereniya chastot ikh sobstvennykh kolebanii [A technique for detecting significant defects of railway wheels based on the results of measuring the frequencies of their natural oscillations]. V mire nerazrushayushchego kontrolya [NDT World], 2010, No.2(48), pp. 72–74.

14. Ravin A.A., Proskuryakov K.B. Analiz vibratsionnykh kharakteristik rabochikh lopatok osevykh kompressorov [Analysis of vibration characteristics of working blades of axial compressors]. Sudostroenie [Shipbuilding], 2012, No. 2, pp. 54–56.

15. Savin S.N. Sitnikov I.V., Danilov I.L. Sovremennye metody tekhnicheskoi diagnostiki i monitoringa kak sredstvo bezopasnoi ekspluatatsii stroitel'nykh konstruktsii [Modern methods of technical diagnostics and monitoring as a means of safe operation of building structures]. V mire nerazrushayushchego kontrolya [NDT World]. 2008, No. 4 (42), pp. 14–18.

16. Trutaev S. Yu. et al. Otchet NIR. Razrabotka metodologii ekspress-diagnostiki defektov promyshlennogo oborudovaniya po spektru sobstvennykh chastot kolebanii [Research report. Development of a methodology for express diagnostics of defects in industrial equipment from the spectrum of natural frequencies of oscillations]. Irkutsk: IrkutskNIIkhimmas Publ., 2017, 62 p.

17. STO–00220227–044–2016. Oborudovanie opasnykh proizvodstvennykh ob"ektov. Raschetno-eksperimental'nye metody is-sledovaniya. Vved. 01.09.2016 [STO-00220227-044-2016. Equipment of hazardous industrial facilities. Calculation-experimental methods of research. Introd. 01/09/2016.]. Irkutsk: IrkutskNIIkhimmash Publ., 2016. 52 p.

18. Trutaev S. Yu., Kuznetsov K. A. Sposob monitoringa napryazhenno - deformirovannogo sostoyaniya ob"ektov povyshennoi opasnosti [A way of monitoring the stress-strain state of high risk facilities]. Patent RF no. 2626391S1, MPK G01M 7/00 (2006.01); patent applicant and holder is Irkutsk Research and Design Institute of Chemical and Petroleum Engineering No. 2016135360/28(055362) ; applied Aug 30, 2016, Bull. No. 21, 7 p.

19. Minashina I. K., Zakharova E.M. Obzor metodov mnogomernoi optimizatsii [The review of methods of multidimensional optimization]. Informatsionnye protsessy [Information processes], 2014, Vol. 14., No. 3, pp. 256–274.

20. Moiseev N.N., Ivanilov Yu.P., Stolyarova E.M. Metody optimizatsii [Optimization methods]. Moscow: Nauka Publ., 1979, 352 p.

21. Niordson F.P., Pederson P. Obzor issledovanii po optimal'nomu proektirovaniyu konstruktsii [Review of research on the optimal design of structures]. Mekhanika [Mechanics], 1973, No. 2, pp. 136–152.

22. Reitman M.I. Shapiro G.S. Metody optimal'nogo proektirovaniya deformiruemykh tel: postanovki i sposoby resheniya [Methods of Optimal Design of Deformable Bodies: Formulations and Solutions]. Moscow: Nauka Publ., 1976, 265 p.

23. Bezdelev V.V., Buklemishev A.V. Programmnaya sistema COMPASS. Rukovodstvo pol'zovatelya [COMPASS software system. User guide]. Irkutsk: Irkutsk state techn. univ. Publ., 2000, 120 p.

24. Bandi B. Metody optimizatsii. Vvodnyi kurs. [Basic optimization methods. An introductory course]. Moscow: Radio i svyaz' Publ., 1988, 128 p.

25. Savin A. N. Parallel'nyi variant algoritma uslovnoi optimizatsii kompleksnym metodom Boksa [Parallel variant of the algorithm of conditional optimization by the complex Box method]. Izv. Sarat. gos. un-ta [News of Saratov University], 2012, Vol.12., No. 3, pp. 109–117.

26. Gill Ph. E., Murray W.,‎ Wright M.H. Practical Optimization. Emerald Group Publishing Limited, 1982, 418 p. (Russ.ed.: Gill, F. Myurrei U., Rait M. Prakticheskaya optimizatsiya. Moscow: Mir Publ., 1985, 509 p.).

27. Ewins D. J. Modal testing: theory, practice and applications. 2nd edition, 2000, 400 p.