The COMPACS® system
Real-time vibration diagnostics
of machinery with probability close to 1
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In 2001 the quality management system of SPC Dynamics was put through facultative certification. In 2016 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 SPC Dynamics was put through facultative certification. In 2016 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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"Novokuibyshevsk Petrochemical Company" JSC: Response to the COMPACS-RPP Bearing Vibration Analysis System

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"Novokuibyshevsk Petrochemical Company" JSC has been operating the COMPACS®-RPP bearing vibration analysis system since 2007. All the bearings supplied to "Novokuibyshevsk Petrochemical Company" JSC for replacement purposes are subject to acceptance tests. Every year we test more than 3.5 thousand bearings. Bearings that fail acceptance tests are returned to the suppliers for replacement.

The advantages of the COMPACS®-RPP include the following:

  • reliable operation of the system;
  • simplicity of operation and maintenance;
  • low requirements to personnel qualification: personnel need no vibration and diagnosis knowledge;
  • automatic diagnosis of the tested equipment (bearings) and the system hardware;
  • automatic archiving of diagnosis results that allows restoring the test reports;
  • industry design with high reliability;
  • the system implements equipment life extension technology that according to the test results breaks down bearings into three quality categories with the following recommended speed: up to 1000 rpm (low-speed), up to 1500 rpm (medium-speed) and 3000 rpm and above (high-speed).

The system allowed us to exclude poor quality bearings from production and, consequently, to improve the reliability and increase the life of all our equipment.

Following our eight year cooperation we express our gratitude to you and your co-workers for organization and performance of works for maintaining serviceable condition and smooth operation of the COMPACS®-RPP bearing vibration monitoring system.

Throughout the whole period of the system operation the specialist of DYNAMICS SPC has been carrying out inspections, diagnosis and repair in a timely manner with appropriate quality and subject to the standards at a high professional level. Thank you!

 

Authors: Acting head of department - chief engineer of "Novokuibyshevsk Petrochemical Company" CJSC D.M. Meshalkin / 2016

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Tags: condition monitoring vibration analysis rolling bearings COMPACS-RPP Date: 20.09.2016
Views: 754
 

"Tomskneftekhim", LLC: Response to the COMPACS-RPP Bearing Vibration Analysis System

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"Tomskneftekhim", LLC has been operating the COMPACS®-RPP bearing vibration analysis system since 2007. All the bearings supplied to "Tomskneftekhim", LLC for replacement purposes are subject to acceptance tests. Every year we test more than 7.5 thousand bearings. Bearings that fail acceptance tests are returned to the suppliers for replacement.

The advantages of the COMPACS®-RPP include the following:

  • reliable operation of the system;
  • simplicity of operation and maintenance;
  • low requirements to personnel qualification: personnel need no vibration and diagnosis knowledge;
  • automatic diagnosis of the tested equipment (bearings) and the system hardware;
  • automatic archiving of diagnosis results that allows restoring the test reports;
  • industry design with high reliability;
  • the system implements equipment life extension technology that according to the test results breaks down bearings into three quality categories with the following recommended speed: up to 1000 rpm (low-speed), up to 1500 rpm (medium-speed) and 3000 rpm and above (high-speed).

The system allowed us to exclude poor quality bearings from production and, consequently, to improve the reliability and increase the life of all our equipment.

Following our eight year cooperation we express our gratitude to you and your co-workers for organization and performance of works for maintaining serviceable condition and smooth operation of the COMPACS®-RPP bearing vibration monitoring system.

Throughout the whole period of the system operation the specialist of DYNAMICS SPC D.V. Dvukhzhilov has been carrying out inspections, diagnosis and repair in a timely manner with appropriate quality and subject to the standards at a high professional level.

Your company has shown complete professionalism, high skills of your specialists, technological literacy and proper quality of works performed.

 

Authors: Head of Unified Technical Customer Service V.B. Tolmachev / 2016

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Tags: condition monitoring vibration analysis rolling bearings COMPACS-RPP Date: 05.07.2016
Views: 703
 

"Gazprom dobycha Orenburg" LLC: Response to the rolling bearings vibration analysis system COMPACS-RPP

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The COMPACS®-RPP system has been operating in inventory and procurement management of "Gazprom dobycha Orenburg" LLC since 2005. The bearings supplied for the repair works are the subject to the acceptance testing. The average quantity of tested bearings amounts to 800 items per year. The expert system specifies defects of internal and external bearing cage, rolling bodies and separator.

Database of the bearings includes the information about number of the bearing, inner and external diameter, quantity of rolling bodies, their diameter and angle of contact. The software allows to edit information on the bearing’s parameters using the operator's panel. The calculation of the bearing frequency including rotating frequency during bearing testing is conducted automatically.  It is possible to store the information on the tested bearings’ signals in a special archive.

The bearings that have not completed the acceptance testing shall be returned to the supplier for their replacement. There is a practice of running used bearings in order to diagnose their condition and see whether they can be remounted at the machinery.

The system has the following advantages:

  • High speed of operation;
  • Low requirements for the specialists’ qualification;
  • Industrial version providing high reliability;
  • Completely automatic work process, the operator only mounts the bearing and runs the diagnostics process.

The system allows to eliminate commissioning of defected bearings and consequently raise the reliability and increase the residual life of the machinery.

The long-term continuous operation of the COMPACS-RPP system became possible as a result of the highest quality work of the specialist of DYNAMICS SPC D.V. Dvuhzhilov. During the whole operation period he has been carrying out the system’s maintenance. Thank you!

 

Authors: Chief Engineer I.V. Andreev / 2016

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Tags: condition monitoring vibration analysis rolling bearings COMPACS-RPP Date: 03.06.2016
Views: 729
 

"LUKOIL-Volgograd Refinery", LLC: Response to well-qualified works on commissioning of the COMPACS system

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Limited liability company "KIP-Electromontazh" wishes to express gratitude for making well-qualified works on commissioning of the COMPACS® system for condition monitoring of machinery implemented at the UPHN KTU PPN unit of "LUKoil-Volgograd Refinery", LLC.

All works were done within short timeframes with proper quality and meeting all standards on a high professional level.

Looking forward to our further mutual cooperation.

 

Authors: Director General of "KIP-Electromontazh", LLC Bondarenkov А.P. / 2016

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Tags: COMPACS monitoring Date: 16.05.2016
Views: 595
 

Pavlodar Oil Chemistry Refinery: Article in Newspaper "Neftepererabotchik"

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The COMPACS®: reliable operation of machinery

On 27 November, 2015 the COMPACS® vibration analysis system implemented in shop №1 (LK-6U) was presented to Pavlodar Oil Chemistry Refinery specialists by a production company from Omsk – DYNAMICS SPC. In the presented material we are going to explain what kind of system it is and how it works.

The COMPACS® is a stationary condition monitoring system for pumps and compressors created by DYNAMICS Scientific & Production Centre.

Pavlodar Oil Chemistry Refinery works with this company for a long time. In 2004 in shop № 10 (ex repair-mechanical base of the refinery, now - Total Service partnership) Russian test benches for console pumps running and bearings acceptance testing were implemented, which considerably improved the operation of machinery. At the time they proved themselves to be reliable and responsible partners. In 2015, within the investment program for 2015-2017, Pavlodar Oil Chemistry Refinery established a long-term contract with the Omsk company for implementation of the condition monitoring system for pumps and compressors. With this contract 41 pumps at the S-100 (ELOU-AT) unit of the shop №1 was equipped during the overhaul with the COMPACS® system by the specialists from Omsk and Tayan service company. Condition monitoring of the pumps is carried out by vibration analysis and parametrical methods of non-destructive testing (vibration, heat, ultrasound, electrical, eddy current, acoustic, optical) by means of 122 vibration sensors, 122 temperature sensors and 41 current sensors. Integrated use of these methods ensures condition control of rotating equipment (pumps, compressors).

From now on, pump units are surely protected from unexpected breakdown. As told by the COMPACS® developers – the system can significantly reduce the number of accidents at the site of its implementation. Indeed, our Russian partners live up to our expectations: for only one month of the COMPACS® system operation 4 accidents at LK-6U were prevented due to timely detection of N-118, N-119, N-123 and N-131 pumps defects.

How does this miraculous system works? As explained by our colleagues and the developers, the system works extremely simple. The data on the machinery condition is transmitted from sensors via the diagnostic network Compacs-Net®, Pavlodar Refinery computer network, and the COMPACS®-User software to the particular monitors located in operator room of the shop №1 and personal computers of mechanical engineers of S-100 unit and shop №1, vibration diagnostic engineers, deputy chief mechanical engineer of Pavlodar refinery. That allows our specialists to monitor condition of each pump directly from their offices.

So that plant workers could promptly detect malfunctions of pumps, specialists of DYNAMICS SPC developed a color scheme and sound system for the COMPACS®. For example, green color at the monitor indicates that the equipment has normal condition, yellow informs that there is a problem and you need to take actions to solve it, and red indicates that the situation is critical and there is an urgent need to shut down the unit. Just like a traffic light. If on the screen there is a gray color – it means the equipment is in reserve. Besides, the system verbally provides information on the number of the pump and the position where there is a problem and issues an expert advice: what kind of problem occurred, and which steps it is necessary to take to prevent an accident.

Sergey Khudyakov, mechanical engineer of C-100 unit of shop № 1 shared his true impression of this unique system: "From the first days of its operation, the COMPACS® began to pay off. Thanks to the development of our Omsk partners, the shop was able to prevent problems in a number of positions of pumping units, which could lead to an emergency shutdown of not only the equipment, but also of a complex process, and perhaps even the entire plant. Although, at first glance, there were no signs of an accident. An advantage of this system is that it is now possible to switch from preventative maintenance to the operation of the equipment according to its actual technical state in real time. In addition, the COMPACS® not just report problems, but also offers specific measures to eliminate them. Moreover, it seems logical that, in due time by eliminating defects in the equipment, we thereby reduce the cost of repair of pumps and the acquisition of spare parts for them."

Experts of Omsk company DYNAMICS SPC have implemented their "child" not only on the LK-6U complex, but also at the KT-1. There, during the overhaul they equipped five compressors in gas and air compressor rooms with a stationary system for vibration analysis. And they are planning to implement the COMPACS® at 76 pumps in the shop № 3 in the first quarter of 2016.

 

Authors: Reporter of Pavlodar Oil Chemistry Refinery corporate newspaper "Neftepererabotchic" Alyona Lepp / 2015

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Tags: COMPACS condition monitoring pump-and-compressor units resource-saving accidents prevention machinery Date: 26.01.2016
Views: 859
 

Saratov Refinery: Response to operation of the COMPACS-RPP system for vibration analysis of rolling bearings

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The COMPACS®-RPP system was implemented at Saratov Refinery in 2006. All bearings supplied to the plant are subjected to the acceptance testing. The expert system of the bearing defect diagnostics is built on the principle of spectrum analysis of vibration signal envelope and indicates the exact defects of bearings: inner and outer race, rolling bodies and separator of bearings.

Bearing database includes information about bearing number, inner and outer diameter, number of rolling bodies, their diameter and contact angle. The software allows to edit the information according to the bearing’s parameters from the operator’s panel. The calculation of bearing frequencies considering a rotation frequency during the bearing testing is automatic. There is an ability to store the information according to the signals of tested bearings in a special archive.

Bearings which have failed to pass the acceptance test are to be returned to the supplier for replacement.

The system’s advantages are the following:

  • High speed of operation;
  • Low requirements to the personnel skills;
  • Industrial design providing high reliability;
  • Fully automatic operational process, the operator needs only to place a bearing and start the diagnostic process.

The system’s application has allowed to eliminate the commissioning of defected bearings and, consequently, to increase reliability and life-span of operated machinery.

 

Authors: Head of shop №14 Finaev V.S. / 2015

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Tags: condition monitoring vibration analysis rolling bearings COMPACS-RPP Date: 08.12.2015
Views: 761
 

Saratov Refinery: Response to operation of the COMPACS system for vibration analysis and condition monitoring

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In 2005, a stationary system COMPACS® was implemented at the Saratov Refinery. Under the control of the COMPACS® system which carries out continuous condition monitoring at the ELOU-AVT-6 unit, 29 of the most important machines were located. The unit’s condition monitoring is conducted by means of vibration analysis method of NDT through vibration and current sensors.

In 2011, number of units which condition was monitored by the COMPACS® system was increased by 55. Now constant condition control of the most important pump units is carried out through 81 current force measuring channels.

Implementation of the COMPACS® system provides condition monitoring of processing equipment in real-time, as well as timely personnel’s reaction to the change of its condition due to both emergence of failures of various assemblies and parts, and operational process disturbance. This allows safe resource-saving and condition-based operation of processing equipment.

 

Authors: Mechanical engineer of ELOU-AVT-6 unit, of production №1 Kosolapov V.Y. / 2015

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Tags: COMPACS condition monitoring vibration analysis machinery Date: 08.12.2015
Views: 751
 

"Gazpromneft - Omsk Refinery" JSC: Article in "Neftegazeta" Newspaper

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We must reduce the mean time between repairs

The Omsk Refinery set the target of 97-98% operational availability by 2020. In the first quarter of 2015 we reach 96% so we can't stop now.

To carry out repair by cycles remains the most important action for us.

This kind of repair causes many organizational difficulties but refuse it would have been an unattainable luxury for any Refinery. From the first cycle we gathered an economical benefit of more than 1,5 bill. rubles.

In general, the way repair is conducted in 2015 at Omsk Refinery will influence the economic condition of the enterprise for the next few years.

The important task is to increase the mean time between repairs from the standard two-years to three-four-years cycle. Solving this task will give a considerable advantage of the peers. As a matter of fact, we have reached these results, although, there is a contravention of the law, and we’re doing our best to eliminate the contravention.

The main point of the issue is the development and implementation of the condition control system and risk evaluation of machine operation between shutdown repairs.

That’s why the project of machinery monitoring under the COMPACS® system is a key economically viable tool of Omsk Refinery. The COMPACS® is a fine instrument to bring us to Smart Plant, and which we should successfully apply. However, in that relation we have not much to boast of. The analysis of the system’s operation in 2014 had showed that some of the machinery can work in "red- yellow" zone for quite a long time - from 90 to 3000 hours.

One of the pumps at the unit 35/11-1000 was operating in a "red-yellow" zone for more than 5 thousand hours, or about 8 months. General statistics of failure causes is the following: 43,8% — failures due to degradation, 37,2% — operation mode violation, 10,6% — bad quality of repairs, 8,2% — bad quality of design, and 1% is caused by a human factor.

 

Authors: Deputy technical director of reliability and repairs, chief mechanical engineer Sergey Samkov / 2015

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Tags: COMPACS condition monitoring pump-and-compressor units resource-saving accidents prevention Date: 17.11.2015
Views: 976
 

Altayskaya Depot: Response to the operation of the COMPACS-EXPRESS-TR3 system for comprehensive diagnostics of units of EMU-trains

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The system for diagnostics of units of EMU-trains COMPACS®-EXPRESS-TR3 has been successfully operating in the Altayskaya depot since 2008. More than 3100 technical readiness reports were created when diagnosing wheel-motor units (WMU), isolations, pantographs, pneumatic braking system, electric control circuits, power and auxiliary circuits of electric trains.

Today, the Altayskaya depot uses three different systems for WMU vibration analysis. Although, the traction motor control unit causing rotation of the wheel pair in a set mode is included in the COMPACS®-EXPRESS-TR3 only. Besides, to test WMU with the COMPACS®-EXPRESS-TR3 requires much less labour force and time (more than 10 times in comparison to other systems used) due to application of 6 vibration sensors and fully automatic diagnostics with prompting on maintenance and repair of WMU assemblies.

Considering the positive experience of the system’s operation, the Altayskaya depot is looking forward to further cooperation with the COMPACS®-EXPRESS-TR3 and recommends to all reaserch&development personnel of DYNAMICS SPC to consider the variant of the COMPACS® system for application at all technological positions, which would allow to have a common regulatory base of diagnostic parameters, and, consequently, to increase the observability of maintenance and repair of EMU-trains.

 

Authors: Acting chief engineer A.V. Yashin / 2015

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Tags: COMPACS-EXPRESS-TR3 diagnostics electric multiple unit MDRS Date: 10.11.2015
Views: 750
 

"Tobolsk-Neftekhim" LLC: Response to operation of the COMPACS vibration analysis system for pump units

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Issues connected with uninterrupted operation provision and search for means of improvement of resource–saving technologies are vital for Tobolsk-Neftekhim, LLC. That has become a main reason for cooperation with DYNAMICS SPC and implementation of the COMPACS® vibration analysis and condition monitoring system for pump units.

Since 1998, one of the largest shops of the Tobolsk-Neftekhim, LLC’s - DBO-10 – has 36 the most important pump units equipped with the COMPACS® system providing constant control of their technical state.

In 2012, 13 more pump units were added to them. Currently, the units’ state is constantly supervised through 108 vibration channels and 36 current strength measurement channels.

If the state of supervised units is worsening along with an increase of the nominal vibration parameter values the COMPACS® system issues verbal and text warnings and recommendations for the staff to solve the problem and the most probable cause of the unit’s state worsening.

The successful application of the COMPACS® system can be explained by its following advantages:

  • during its operation the automatic monitoring of the pump units’ state is carried out;
  • it does an electronic archiving of the monitoring data - trends of parameters, signals, logs of machinery state, which helps to carry out search, view and printing of necessary data;
  • unit state is displayed on the screen in easy for comprehension tree-coloured array;
  • the system has an in-built expert system giving prompting messages about the most probable reasons of the units’ state worsening, helping the staff to conduct the operating procedure saving the units’ service life by their accident-free operation.

Due to mentioned above, as well as the Compacs-Net® diagnostic network set in the enterprise which allows the specialists and managers in charge of safe operation of the machinery to get the information on the pumps’ state from their own workplaces, if they are connected to the intraplant network. Consequently, the enterprise staff reduces the pump units’ downtime caused by unscheduled repairs, and ensures timely and full production.

 

Authors: DBO-10 shop manager Armantovich A.N., mechanic of the United Client Services Kokan K.L. / 2015

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Tags: Compacs-Net COMPACS condition monitoring nondestructive testing vibration analysis pump-and-compressor units resource–saving Date: 06.10.2015
Views: 793
 
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