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 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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Omsk Refinery: The article in the regional business newspaper "Continent Sibir"

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Omsk Refinery guarantees the quality of the production

Equipment diagnostics in automatic mode

The quality and volume of production of any enterprise, and a refinery in particular, are dependent on the condition of its main process equipment. The scheduled-preventive maintenance (SPM) until recently was considered as the only possible way to control the operation of complex equipment. However, in practice the operating conditions, the quality of previous repairs and spare parts, and other factors may differ significantly from the calculated and the hardware failure may occur much earlier than set by SPM schedule run-to-failure period will expire. Emergency shutdowns inevitably lead to economic losses for the company.

To carry out timely equipment repair it is really needed to know as accurately as possible about its actual condition. Omsk Refinery became the first company of the branch, which took up the problem seriously. Even back in 1972 the plant engaged in the development of fundamentally new methods and instruments for vibro-acoustic diagnostics of mechanisms. Today the plant has implemented 23 stationary systems COMPACS® on the main process units, which quickly alert the staff on the condition of more than 730 pumping and 20 compressor units. "Thus, almost all the "critical" equipment, which failure can lead to a decrease in technical and economic production rates to 75-90%, is under the control", - said the Omsk Refinery deputy chief mechanic Vil Sagirov. According to his words, the greatest economic effect from the implementation of the new technology can be achieved by transferring of all, including support mechanisms, to the repair on the actual technical condition. For this purpose the enterprise uses the personal system of automatic diagnostics Compacs®-micro consisting of a notebook with proprietary software, a diagnostic station and a sensor. All this fits in a standard size briefcase.

Only two these personal systems in 2005 were "ran" by the Omsk Refinery mechanics on the aromatic hydrocarbons production complex, which, however, allowed to save nearly two million rubles by increasing the equipment run-to-failure. In 2006 the Omsk Refinery management intends to acquire a few more sets of Compacs®-micro to operate them on the complex for oils, additives and lubricants production.

COMPACS® belongs to a new generation systems, capable during the units run-to-failure to monitor the particular mechanisms condition according to the parameters of vibration, temperature, and current consumption. All data in real time is displayed on the monitors of all the concerned services managers and operators. Experience has shown that the implemented technology of maintenance and repair according to the actual technical condition allowed to halve the total number of repairs and at the same time to reallocate the volumes of repairs from overhaul to permanent. As a result, the number of overhaul repairs has decreased in 10 times. The Omsk Refinery in-house development allows to minimize the risk of failures, to save millions rubles by increasing the time of the machinery and units run-to-failure.

First implemented in the Omsk Refinery, in 2004 the system COMPACS® was officially certified and approved by the refinery Department Committee of the Fuel and Energy Ministry in conjunction with the State Technical Supervision of Russia, and was included in the State Register of measuring instruments and permitted for use on the entire territory of the Russian Federation. Nowadays the unique Omsk developments are used practically at all major oil and gas production and processing enterprises of the country.

 

Authors: V. Shakhlin / 2006

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Tags: Compacs-micro COMPACS vibration technical condition Date: 22.07.2009
Views: 1691
 

"Uralkali" JSC: Response to the operation of the benchtop system of rolling bearings vibration analysis COMPACS-RPP

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In June 2004 "Uralkali" JSC implemented the system COMPACS®-RPP. 100% of all supplied to the plant bearings were subjected to the acceptance test.

In 2005 over 15,000 bearings were inspected. Percentage of defect was 27,05%. In 2006 over 28,000 bearings were inspected. Bearings that failed the acceptance test were returned to the supplier for change. Due to that the percentage of defective bearings reduced to 8,67%.

The advantages of COMPACS®-RPP include the following:

  • high speed
  • low requirements to the staff skills
  • industrial design that ensures high reliability
  • fully automatic workflow, the operator has just to set the bearing and start the process of diagnostics.

The use of the system allowed to exclude the omission of low-quality bearings in the production and, consequently, improve the reliability and extend the life of equipment in operation.

The economic effect of the system COMPACS®-RPP implementation at repair production amounted several hundreds of thousands rubles.

 

Authors: Deputy Head of Department - Head of the monitoring and operation department T.I. Shabaev / 2006

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Tags: diagnostics bearings vibration analysis COMPACS-RPP acceptance test Date: 20.07.2009
Views: 1414
 

Omsk Refinery: The article in the weekly newspaper "Kommercheskie Vesti"

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COMPACS® HAS SAVED MONEY

The global diagnostic system has reduced the number of overhauls in 10 times.

To the global diagnostic system COMPACS®, which has become a visiting card of the Omsk Refinery, will soon join the equipment for oils, additives and lubricants production, where the system of equipment vibration monitoring Compacs®-micro will be implemented. The unique elaboration of Omsk specialists allows to minimize the risk of failures at the strategic enterprise and to save millions of rubles by increasing the machinery and units run-to-failure time.

To carry out timely repair of equipment first of all we need to know as much as possible about its actual technical condition. Scheduled-preventive maintenance (PPM), which is carried out in the recommended by the equipment manufacturers terms, until recently were considered in Russia as the only possible way to control the operation of complex technics. However the factors affecting the units technical condition may differ significantly from the calculated. And the equipment failure can occur much earlier than set by the PPM schedule run-to-failure will expire. It threatens with unplanned (in fact emergency) equipment shutdowns, which in turn will lead to unreasonable economic losses for the company.

Omsk Refinery became the first company of the branch where took up seriously the solution of that problem. The used today system COMPACS® refers to the new generation systems and is deprived of drawbacks which pertained to its predecessors (a series of devices RAPID, the complex SIGMA, the systems SVK and SVIP-64). This system, developed by the DYNAMICS SPC engineers with the direct participation of the Omsk Refinery specialists, during the units run-to-failure is capable to monitor the particular mechanisms condition according to the parameters of vibration, temperature, and current consumption. All data in real time are displayed on the monitors of all the concerned services managers and operators.

The square in the diagram, indicating a particular unit, glows green – the technics is in order; glows yellow – the mode deviated from the optimal one; glows red – an urgent specialists’ intervention is necessary. Moreover, in the case of failure danger COMPACS® will give the operator a signal not only by dint of the alarming red light, but also through the voice message. Now the plants has been operating 23 stationsry systems COMPACS® on the main process units, quickly alerting personnel about condition of more than 730 pumping and 20 compressor units. According to the words of Vil Sagirov, deputy chief engineer of the Omsk Refinery, almost all the "critical" equipment, which failure can lead to a decrease in technical and economic production rates to 75-90%, is under the control.

The implemented technology of maintenance and repair according to the actual technical condition allowed to halve the total number of repairs and at the same time to reallocate the volumes of repairs from overhaul to permanent. As a result, the number of overhaul repairs has decreased in 10 times. However, he believes that even greater economic effect can be achieved if the technology will be extended to all, without exception, mechanisms which operate at the enterprise, including auxiliary ones. Hourly and daily condition monitoring of auxiliary equipment has no sense, because such control will cost too much. That is why for the auxiliary equipment the personal system of automatic diagnostics Compacs®-micro is proposed to be used; it will successfully complete the stationary system, being in fact the part of it.

Compacs®-micro consists of a notebook with proprietary software, a diagnostic station and a sensor. All this fits in a standard size briefcase, which justifies Compacs®-micro nickname – "black suitcase". Only two these "suitcases", which during the past year were "ran" by the Omsk Refinery mechanics on the aromatic hydrocarbons production complex, allowed by increasing the equipment run-to-failure, to save nearly two million rubles. Such an efficiency speaks for itself, so this year the Omsk Refinery management intends to acquire a few more sets of Compacs®-micro to operate them on the complex for oils, additives and lubricants production.

In 1998 for the system creation the team of scientists, among which appear the heads and specialists of DYNAMICS SPC, JSC "Sibneft-Omsk Refinery" and the State Technical Supervision Service of Russia, was awarded with the Russian Federation government prize in the sphere of science and technology. First implemented in the Omsk Refinery, in 2004 the system COMPACS® was officially certified and approved by the the refinery Department Committee of the Fuel and Energy Ministry in conjunction with the State Technical Supervision of Russia, and was included in the State Register of measuring instruments and permitted for use on the entire territory of the Russian Federation.

Nowadays the unique Omsk developments are used practically at all major oil and gas production and processing enterprises of the country (including the Gazprom enterprises). They are known abroad as well. The stationary system COMPACS®, for example, has been recently installed at the Bulgarian company "LUKOIL Neftekhim Bourgas AD". Besides, in order to achieve the implementive experience the Bulgarians came exactly at the "Sibneft-Omsk Refinery" JSC. It seems justified that the refinery has the fame of one of the most technologically "advanced" Russian enterprises.

 

Authors: A. Semenov / 2006

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Tags: Compacs-micro COMPACS vibration monitoring vibration Date: 15.07.2009
Views: 1577
 

"VSW service" LLC: The official letter about the expediency of using the system COMPACS-WMR

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During the time of the monitoring system COMPACS®-WMR operation from 19.12.2005 to 19.01.2006 three emergency situations were beforehand identified and prevented.

By reducing the three emergency downtimes the enterprise had a significant economic effect.

For further work, connected it with the defects detecting by edger shafts (24.06.2005; 07.07.2005, 24.11.2005 – shaft breakage), by reduction gears (top and bottom) and the hydraulic system, is appropriate:

  • to conduct the further work concerning the development and extending of the system COMPACS®-WMR;
  • to monitor the condition of the whole WRC.

 

Authors: WRC Deputy Head A.M. Kozlov, WRC Mechanics S.A. Rubanenko and O.V. Kuznetsov, Specialist A.V. Rykin / 2006

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Tags: COMPACS condition monitoring economic effect Date: 13.07.2009
Views: 1387
 

Omsk Refinery: The article in the newspaper "Sibirsky Neftyanik"

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Reference to COMPACS

In 2006, on the complex for oils, additives and lubricants production of Omsk Refinery will be implemented the system of equipment vibration monitoring Compacs®-micro. Personal "black suitcases" will be a part of the global diagnostic system COMPACS®, which has become one of the company visiting cards. The unique elaboration of Omsk specialists allows to minimize the risk of failures at the strategic enterprise, to save millions rubles by increasing the machinery and assemblies run-to-failure time.

It is not a secret that production quality and volume of any modern enterprise, and in particular Omsk Refinery, are directly dependent on the condition of its main technological equipment. The scheduled-preventive maintenance (SPM), held in periods recommended by the producers, until recently were considered in Russia as the only possible way to control the operation of complex equipment. However, in practice the operating conditions, the quality of previous repairs and spare parts, and other factors affecting the units technical condition, may differ significantly from the calculated. In this connection, the hardware failure may occur much earlier than set by SPM schedule run-to-failure period will expire. This threatens with unplanned (actually emergency) shutdowns of units, which in their turn will lead to unnecessary economic losses for the company as a whole.

To carry out timely equipment repair it is necessary to know as accurately as possible about its actual condition. Omsk Refinery became the first company of the branch, which took up the problem seriously. Even back in 1972 the plant engaged in the development of fundamentally new methods and instruments for vibro-acoustic diagnostics of mechanisms. Today the plant has implemented 23 stationary systems COMPACS® on the main process mountings, which quickly alert the staff on the status of more than 730 pumps and 20 compressor units. "Thus, almost all the "critical" equipment, which failure can lead to a decrease in technical and economic production rates to 75-90%, is under the control", - said the Omsk Refinery deputy chief mechanic Vil Sagirov. However, according to his words, the greatest economic benefit from the implementation of new technology can be achieved by transferring of all, including support mechanisms, to the repair on the actual technical condition. There is no sense to monitor their condition every minute, every hour or every day – this is too expensive. That is why it is proposed to use the personal system of automatic diagnostics Compacs®-micro, which aptly adds (being in fact a part of it) the stationary system.

Compacs®-micro consists of a notebook with proprietary software, a diagnostic station and a sensor. All this fits in a standard size briefcase, which justifies Compacs®-micro nickname – "black suitcase". Only two these "suitcases", which during the past year were "ran" by the Omsk Refinery mechanics on the aromatic hydrocarbons production complex, allowed, by increasing the equipment run-to-failure as well, to save nearly two million rubles. This year, the Omsk Refinery management intends to acquire a few more sets of Compacs®-micro to operate them on the complex for oils, additives and lubricants production.

COMPACS® belongs to a new generation systems and is deprived of drawbacks which were inherent to its predecessors - a series of devices RAPID, the complex SIGMA, the systems SVK and SVIP-64. Advanced (for the period of implementation) solutions were combined in them with one significant drawback - the human factor. This is how the company veteran, the former chief mechanic of the Omsk Refinery Victor Dolgopyatov responds: "I used to check the work of engineers and mechanics for several times. Having come into the pump part, I was waiting for 40 minutes - no one was there, even though a machinist should constantly bypass the pumps. Having come to the operator part I found them discussing something. The machinist came to me, "Viktor Nikolayevich, I have just come from the pump part- it's all right there." If the good machinist behaves in such a way, then what about others? Lack of equipment monitoring, visual information about its condition is the main cause of failures. For several times I equipped the mechanics and machinists with vibroacoustic devices with headphones and pointers - that lead to nothing good: someone’s device is out of work, someone does not use it, the sensor is placed where the vibration is less, etc. Subjective methods are not suitable, an objective control, independent of the opinions, desires and abilities of the staff, is necessary. The equipment condition should be reliably determined, simply and effectively presented, to be comprehensible to a semi-skilled specialist."

Formulated by Dolgopyatov approach became the basis of the system COMPACS®, developed by engineers of Omsk DYNAMICS Scientific & Production Center (SPC) with the direct participation of the Omsk Refinery specialists. During the units run-to-failure the system is capable to monitor the particular mechanisms condition according to the parameters of vibration, temperature, and current consumption. All data in real time are displayed on the monitors of all the concerned services managers and operators. Submission of information is realized very clearly, on the basis of traffic lights. The square in the diagram, indicating a particular unit, glows green – the technics is in order; glows yellow – the mode deviated from the optimal one; glows red – an urgent specialists’ intervention is necessary. Moreover, in the case of failure danger COMPACS® will give the operator a signal not only by dint of the alarming red light, but also through the voice message. "Originally we had to deal with a demanding male voice, but some female operators were frightened with it, especially at night, - says Vil Sagirov, deputy chief mechanic of the Omsk Refinery, the member of the first stationary systems COMPACS® tests. - Then the "Dynamics" recorded female voices of professional speakers. Now everyone is content, including me."

However, Sagirov can be more content with the economic effect, received from the new monitoring system operation. Experience has shown that the implemented technology of maintenance and repair according to the actual technical state allowed to halve the total number of repairs and at the same time to reallocate the volumes of repairs from overhaul to permanent. As a result, the number of overhaul repairs has decreased in 10 times. In 1998 for the system creation the team of scientists, among which appear the heads and specialists of DYNAMICS SPC, JSC "Sibneft-Omsk Refinery" and the State Technical Supervision Service of Russia, was awarded with the Russian Federation government prize in the sphere of science and technology. First implemented in the Omsk Refinery, in 2004 the system COMPACS® was officially certified and approved by the Committee of the refinery Department of the Fuel and Energy Ministry in conjunction with the State Technical Supervision of Russia, and was included in the State Register of measuring instruments and permitted for use on the entire territory of the Russian Federation.

Nowadays the unique Omsk developments are used practically at all major oil and gas production and processing enterprises of the country (including the Gazprom enterprises). They are known abroad as well. The stationary system COMPACS®, for example, has been recently installed at the Bulgarian company "LUKOIL Neftekhim Bourgas AD". Besides, in order to achieve the implementive experience the Bulgarians came exactly at the JSC "Sibneft-Omsk Refinery". It seems justified that the refinery has the fame of one of the most technologically "advanced" Russian enterprises.

 

Authors: I. Razin / 2006

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Tags: Compacs-micro COMPACS vibration monitoring vibration accidents prevention Date: 10.07.2009
Views: 1678
 

"Uralorgsintez" JSC: Response to the operation of the personal system of automatic vibration analysis Compacs-micro

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Since 2003 our company has been operating the personal system of automatic vibration monitoring of machinery technical condition Compacs®-micro manufactured by DYNAMICS SPC.

The system Compacs®-micro is a powerful means of operational vibration analysis of equipment, carrying out the dynamic balancing of units on the site of their installation. The system allows according to a predetermined route or arbitrarily, by selecting the required plants, sections, units and measurement points, to diagnose the technical condition of the specified and not mentioned in the itinerary units, to produce the rapid collection and analysis of the measured signals parameters and to diagnose the technical condition of the machines assemblies as according to the expert system messages and to the measured parameters values, thus providing a fast paced bypass of equipment, spending not more than 2 minutes for each point.

The system has provided an on-site automatic vibration monitoring of this or that machinery i.e. that the diagnosticians issue the conclusion to the mechanists about the technical condition of equipment on site of its maintenance.

Built-in automatic expert system for decision support of software Compacs®-micro is invariant to the type of the diagnosed equipment and can detect defects in various stages of their development.

The MicroMonitor, which is controlled by only two buttons, is certified according to the explosion protection class 0ExiallCT6 and can be used for explosive objects which contain hydrogen-air mixtures.

In our opinion, the system Compacs®-micro, has paid off within a few months of operation and brought the work of LNT company to a qualitatively new level.

 

Authors: Chief mechanic S.V. Bonadysenko, LNT Engineer A.M. Melnik / 2005

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Tags: Compacs-micro vibration monitoring vibration analysis Date: 08.07.2009
Views: 1451
 

Omsk State Technical University: Response to the scientific methods and learning activities of DYNAMICS SPC

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DYNAMICS Scientific & Production Center (SPC) is a well-known research team dealing with vibrometry and technical diagnostics of compressor equipment of potentially hazardous facilities. In this direction the team has a good academic achievements and a significant advance in the design of continuous monitoring systems COMPACS® with series-parallel distributed data structure for different industries, machinery and sensors.

Long years in the sphere of technical diagnostics enabled DYNAMICS SPC to gain experience, knowledge and skills to solve not only the technical problems and but also the objectives connected with the specialists training in the field of non-destructive testing. DYNAMICS SPC leading experts D.Sc. (Eng.) V.N. Kostyukov and Ph.D. (Eng.) A.P. Naumenko, lecture the profile disciplines to the students of Omsk State Technical University, specialty 190200 "Apparatus and methods for quality control and diagnostics", and the engineers S.N. Boichenko and A.V. Kostyukov prepare to defend their theses for the degree of Ph.D. (Eng.). Thus, the staff of DYNAMICS SPC is able to conduct training in non-destructive testing methods of a high scientific and technological level.

The material-technical basis of DYNAMICS SPC contains the computer technics and modern equipment. The proper laboratory facilities:

  • for bearings quality diagnostics;
  • for dynamic balancing of cradle-mounted pump rotors;
  • for balancing of electric motors rotors;
  • for diagnostics of ready-fitted pumps and motors,

allow to study and simulate the processes which lead to the destruction of the unit and the accident at work. The laboratory facilities have a methodological description.

Based on the above, we can make a conclusion that the human capacity, methodological and logistical support of DYNAMICS SPC are sufficient for the specialists' training in non-destructive testing methods of chemical, petrochemical and oil and gas industries machinery.

 

Authors: Dean of the Faculty of Radio Engineering of Omsk State Technical University Prof. V.P. Kismereshkin / 2005

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Tags: COMPACS diagnostics pump-and-compressor units non-destructive testing monitoring Date: 06.07.2009
Views: 1439
 

"LUKOIL-Volgograd Refinery" LLC: Response to the operation of the personal system for automatic diagnostics Compacs-micro

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Since 1997 our company has been exploiting the personal systems for automatic diagnostics Compacs®-micro manufactured by DYNAMICS SPC.

The system Compacs®-micro is a convenient and reliable means of rapid diagnostics of equipment. The system is rather easy to manage, has a thought-out interface. The system Compacs®-micro allows measuring as on a predetermined route, and in a certain way. It permits not only to measure different parameters, but due to built-in expert system it automatically receives to the diagnostician’s headphones or on the display of the portable diagnostic station the diagnostic messages about the unit technical condition.

The time for issuance of the conclusions on the unit condition is reduced to a few minutes; analysing of the identified defects is carried out on-site; prompt measures to prevent accidents are taken in the early stages of development; repairs and maintenance of the units are planned effectively.

As long as the system is invariant to the type of surveyed equipment, there is no need to use different devices, constantly readjusting them.

The system Compacs®-micro keeps a history of measurements for each unit, which allows not only to analyze the unit condition, but also to identify the fundamental causes of the failures and to plan more effectively the route of the equipment survey.

The MicroMonitor, which is controlled by only two buttons, is certified according to the explosion protection class 0ExiallCT6 and can be used for explosive objects.

We believe that the system has paid off due to reducing costs connected with the liquidation of consequences of equipment accidental failure, and due to decreasing costs of unwarranted repairs (the system permits to pass to the repair of processing equipment according to its actual technical condition) and due to identifying of defective repair.

 

Authors: Head of Technical Supervision Service, V.M. Popov / 2005

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Tags: Compacs-micro accidents prevention technical condition Date: 03.07.2009
Views: 1367
 

Aprelevka depot: Response to the operation of vibration analysis system COMPACS-EXPRESS

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During operation of the vibration analysis system COMPACS®-EXPRESS at the depot Aprelevka from 23/10/03 to 25/01/05 the following positive characteristics were noted: reliability, ease of management, the rate of diagnosis, that meets the modern requirements of diagnostic-wheel motor units of electric trains.

The use of vibration monitoring system COMPACS®-EXPRESS at the depot Aprelevka due to the parallel measurement of vibration from all sensors, allowed to conduct a rapid diagnosis of technical condition of the wheel-motor units of rolling stock for shorter periods of time, which increased the WMU diagnostiс station capacity compared with "manual" devices.

Other advantages of the system COMPACS®-EXPRESS are:

  • archiving of test results in a database for the entire operational period;
  • low requirements for the personnel qualification (it is required to install correctly the magnetic sensors in the measuring points);
  • high reliability of diagnostic results due to continuous automatic monitoring of the WMU current condition while testing;
  • the system allows to detect the hidden defects of bearings and gear reducers, to predict the WMU technical condition for the next period of operation;
  • WMU launching from the control panel COMPACS®-EXPRESS and the test report printout comprising with the results of automatic diagnosis.

During COMPACS®-EXPRESS operation at the depot Aprelevka were noted the reliability of invalid WMUs detection and the lack of their pass to the operation with defects.

 

Authors: Head of Depot Aprelevka / 2005

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Tags: COMPACS-EXPRESS vibration analysis wheel-motor unit Date: 01.07.2009
Views: 1297
 

"VSW service" LLC: The official letter on the shaft service with the use of systems COMPACS

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Since September 2005 maintenance and repairs of the mill have been carried out according to COMPACS® system prescriptions. As a result we fulfilled operations, connected with lifting of shafts fastening, testing of WRM lubricating system (reduction gear, indigenous and edger shafts) and deformation tool fastening.

In general, according to the directions of COMPACS® we accomplished out maintenance and repair work about 30 times.

Ultimately, due to the statements of COMPACS® the state of the mill improved significantly - the number of "red" and "yellow" sites reduced.

To improve the accuracy of diagnosis-making it is expedient to expand the system. The first step is to increase the number of vibration sensors (to set 6 sensors on a reducer), thermocouples (to set 12 sensors on a reducer), and to provide temperature control of a workpiece with the results recording in COMPACS®. Secondly, it is necessary to provide access to COMPACS® of DYNAMICS SPC specialists through the Internet channel.

I consider it necessary to expand the system COMPACS®.

 

Authors: Mechanic of SMP S.A. Rubanenko / 2005

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Tags: COMPACS diagnostics sensor Date: 29.06.2009
Views: 1362
 
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