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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Department of the West Siberian District of the State Technical Supervision Service of Russia: Conclusion on possibility of COMPACS application at the petrochemical complex

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Conclusion on the possibility and expediency of the comprehensive monitoring system COMPACS® application in chemical and petrochemical enterprises and refineries of Russia by the results of testing and trial operation.

1. Work on creation and implementation of computer systems for technical condition monitoring of petrochemical industries equipment have been conducted by "Sibneft-Omsk Refinery" JSC and DYNAMICS SPC since 1989, according to the instructions of the Ministry and government bodies of supervision, set out in the following documents:

1.1. Letter from GU GM and GE of the Ministry of Petrochemical Industry of the USSR N19-1-14/1318 dated 25/07/1989.

1.2. Letter from the Ministry of Petrochemical Industry of the USSR N12-L-1/178 dated 28/03/1991.

1.3. Letter from GU PO of the State Ministry of Internal Affairs of the USSR N7/2/338 dated 02/04/1991.

2. The system of comprehensive monitoring of the PCC equipment COMPACS®, developed and submitted for testing by DYNAMICS SPC, brings together the various methods of diagnosing and non-destructive testing (NDT) - vibration analysis, thermal, electrical, eddy current, acoustic emission, by the process parameters (pressure, level, temperature, changes in linear dimensions, etc.) and an expert system of decision-making support on the management of the equipment condition, ensuring real-time CIP monitoring and diagnostics without decommissioning of machine (pumps, compressors, motors, fans, etc.) and process (reactors, columns, pipelines, etc.) equipment.

3. At present "Sibneft-Omsk Refinery" JSC operates the system of comprehensive monitoring COMPACS® at a process unit 21-ZM-10 (31 pumping units, 2 air-coolers, 4 coking chambers).

4. The system COMPACS® provides an automatic generation of the current assessment and prediction of future technical condition of the pump-and-compressor and production equipment that allows to operate it according to its technical condition and create repair schedules for the current and coming periods.

5. The system COMPACS® provides a visual display of the equipment current state, issues recommendations to the staff, concerning the immediate urgent actions, and automatic verbal warnings without operator’s intervention. The system archives the results of measurements and displays the graphs of diagnostic features deviations over time (trends), brings the data on the status of equipment in the enterprise diagnostic network Compacs-Net®, registers the textual and graphical information on the condition of equipment in the "Log-book of mechanical engineer" and on the printing device.

6. Analysis of the process equipment failures statistics and indications (alerts) of the system COMPACS® concerning the unit 21-10-ZM, carried out by comparing the archives of databases and causes of PCE breakdowns, based on the information of mechanics, electricians of facilities and technical supervision data, has shown that the implementation of the system of comprehensive monitoring of PCC equipment COMPACS®:

6.1. Allows reducing 12 or more times the number of the equipment emergency breakdowns due to early personnel warning of an invalid state of the diagnosed equipment.

6.2. Allows to reduce 4 or more times the number of repairs as well as to carry out a high quality redistribution of repairs amounts from overhauls to permanent, resulting in 10 or more times decrease the number of expensive repairs.

6.3. Allows controlling the course of the process to ensure reliability and longevity of technological equipment.

6.4. Provides a reliable diagnosing the bearings defects, cavitation modes of pumps operation, violations of shaft alignment and balancing of rotating parts, weakening of pumps and motors fastening to the foundation, face seals failures, over 70% of which are due to unacceptably high levels of pumps and motors vibration.

6.5. Provides a reliable diagnosing of reactors bodies defects by acoustic-emission methods, the degree of strain and tension by methods of displacements and temperature fields parameters measurement.

6.6. Provides a low laboriousness and high rate of of process equipment diagnosing (not more than 1 second per a sensor) that can detect high-growth defects.

6.7. Provides a creation of a diagnostic network of technical supervision and transfer of information on the status of the equipment to a higher authority (a dispatcher, chief mechanic services and chief power engineer) to control the processes of the quipment operation.

6.8. The systems are highly reliable, simple to install and operate.

6.9. Implementation of comprehensive condition monitoring systems of PCC equipment allows to make repair according not to the SBPM system but to the actual technical condition and expected failures.

7. On the basis of the submitted materials and the systems testing by the members of the committee, the committee reached the following conclusion:

CONCLUSION:

1. Implementation of comprehensive condition monitoring system of PCC equipment COMPACS® provides a sharp decline in the number of sudden failures of all diagnosed equipment of the process unit and increases its reliability

2. High reliability, low cost and simplicity of the system use distinguish it from Western counterparts.

3. The widespread implementation of comprehensive condition monitoring systems of PCC equipment at Russian enterprises will allow to operate and repairing the pump-and-compressor as well as the processing equipment by the actual technical condition, and will result in the great economic and environmental benefits and is necessary, according to the opinion of the committee.

4. The Committee recommends that:

1) design organizations include the systems of comprehensive real time condition monitoring of machinery and production equipment, when carrying out projects of reconstruction and construction of process units;

2) chemical, petrochemical and refining enterprises equip the existing, reconstructed and re-input production capacities with these systems;

3) the designer-producer of the comprehensive monitoring systems - DYNAMICS SPC - together with concerned organizations prepare a guidance document, which regulates the procedure of implementing the requirements and recommendations, set out in the enterprises under the control of the State Technical Supervision Service of Russia.

 

Authors: Head of Omsk Department of the State Technical Supervision Service of Russia S.N. Medvedev / 2003

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Tags: COMPACS vibration analysis technical condition monitoring Date: 01.06.2009
Views: 1223
 

Department of the West Siberian District of the State Technical Supervision Service of Russia: Conclusion on possibility of COMPACS application at enterprises

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Conclusion on the possibility and expediency of the real-time condition monitoring system ACS SRM™ COMPACS® application in chemical and petrochemical enterprises and refineries of Russia by the results of testing and trial operation.

1. Work on creation and implementation of the systems of technical condition vibration monitoring of PCC pumps-and-compressors equipment have been conducted by JSC "Sibneft-Omsk Refinery" and DYNAMICS SPC since 1991, according to the instructions of the Ministry and government bodies of supervision, set out in the following documents:

1.1. Letter from GU GM and GE of the Ministry of Petrochemical Industry of the USSR N19-1-14/1318 dated 25/07/1989.

1.2. Letter from the Ministry of Petrochemical Industry of the USSR N12-L-1/178 dated 28/03/1991.

1.3. Letter from GU PO of the State Ministry of Internal Affairs of the USSR N7/2/338 dated 02/04/1991.

1.4. Test report of the system of vibration monitoring and prediction of the technical condition of the bearings of centrifugal mechanical-technological plants SVIP-64M dated 30.07.1991.

2. Real-time condition monitoring system for on-condition maintenance, developed by DYNAMICS SPC, is a set of stationary systems COMPACS®, portable vibration analysis systems Compacs®-micro and diagnostic network Compacs-Net®.

The system provides an automatic assessment generation of current and prediction of future technical condition of equipment that allows its on-condition maintenance and creation of repair schedules for the current and coming periods.

The system allows by means of continuous monitoring of parameters of the main technological equipment, controlled by the stationary systems COMPACS®, and periodic vibration monitoring of auxiliary equipment, controlled by the portable vibrodiagnostic systems Compacs®-micro, through their work in the diagnostic network Compacs-Net®, to carry out an automatic vibration diagnostics and monitoring of the machinery technical condition.

The system provides a visual display and gives a voice message corresponding to the state of the technological equipment.

Built-in expert system automatically determines and predicts the failure of the monitored equipment and gives recommendations to the staff for further actions.

The system archives the results of measurements and displays the graphs of diagnostic features deviations over time (trends).

 

Authors: Head of Omsk Department of the State Technical Supervision Service of Russia S.N. Medvedev / 2003

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Tags: COMPACS vibration analysis pump-and-compressor units ACS SMSPM™ monitoring Date: 29.05.2009
Views: 1084
 

"Achinsk refinery" JSC: Response to the operation of the COMPACS-KSA Alarm Control System

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In 2002 specialists of the scientific and production center "Dynamics" assembled and put into regular operation 5 systems of the COMPACS®-KSA Alarm Control System at FPS, Title 79 and gas compressor LK-6US plants. Under continuous monitoring are 13 pump and two compressor units by the parameters of vibration, current, temperature, pressure and level.

If the level of the measured parameter exceeds the threshold, the system alerts, thus warning the customer to take appropriate measures. Built-in self-control and self-test system allows to monitor effectively the serviceability of cables and sensors, as well as the proper functioning of equipment units.

The main result achieved after the implementation of systems is the exception of sudden failure of controlled equipment and increase of its operation reliability by means of early informing of the staff about the malfunctions location and causes.

Systems have proved the positive side, they are sufficiently reliable and easy to learn by personnel.

 

Authors: Chief Mechanic S.V. Gavrin / 2003

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Tags: condition monitoring vibration analysis Date: 27.05.2009
Views: 1138
 

"LUKOIL-Volgograd Refinery" LLC: About equipping with the stationary vibration monitoring systems

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In accordance with your request, the Department of mechanical-and-power and metrological supply considered the materials concerning the implementation into the "LUKOIL-Volgograd Refinery" of the DYNAMICS SPC system of dynamic equipment vibration monitoring and the materials associated with the choice of the SPM Instrument Int.GmbH alternative system.

We believe that under the circumstances, the most rational is the continuation of work on the COMPACS® development, as representing the most objective data on the technical condition of the unit and allowing the use of the accumulated potential for its maintenance in the enterprise (including diagnostic network Compacs-Net®), the system reduces the cost of expenses for the further development of vibration monitoring.

Considered by you, the alternative system by the SPM Instrument Int.GmbH has the following major drawbacks:

  • it controls only the state of the bearing assembly, not allowing an objective assessment of the whole unit functioning;
  • it significantly increases the cost of the project.

Taking this into account, we consider inexpedient to carry out any operations connected with the implementation of the SPM Instrument Int.GmbH monitoring system, including the plant 16 and Shaim oil unit equipping.

 

Authors: Department head of mechanical-and-power and metrological supply A.V. Bezzubov / 2003

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Tags: Compacs-Net COMPACS vibration monitoring Date: 25.05.2009
Views: 1295
 

"Sibur-Khimprom" JSC: response to the operation of monitoring systems COMPACS in the workshops

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The specialists of DYNAMICS SPC has been providing implementation of stationary and portable systems for vibration analysis of rotary equipment condition in the enterprise since 2001. During this time, COMPACS®-RPP System for Vibration analysis of Rolling Bearings has been implemented and operated in repair department, which allows to evaluate the rolling bearings state and detect defects affecting their life, units failure under unsatisfactory state of rolling bearings, discarding them at the stage of configuration and preparation for repair.

2 portable systems of automatic diagnostics of equipment COMPACS®-Micro are implemented and operated in the technical supervision department, as a powerful means of operational control of the equipment and dynamic balancing of the units on site. This allowed to control the entire stock of pump-and-compressor equipment of the enterprise.

There have been developed a program of equipping the enterprise with software and hardware systems COMPACS® for 2001-2003.

The main result achieved after the systems implementation is the exception of sudden failures of diagnosed equipment and improvement of operation reliability through the timely warning of the staff by the system.

The systems are used by workshop mechanics for quality control of pump and compressor units, motors after repair.

COMPACS® systems have showed good results, keep high reliability, ease of use for the staff and according to technical characteristics are equal to the best foreign analogues. The cost of the system implementation is 5-10 times lower than the foreign ones, and is totally paid off during the first year of operation.

 

Authors: Chief Engineer Luria V.B., First Deputy Director General Stryuk Y.V. / 2002

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Tags: Compacs-micro COMPACS COMPACS-RPP Date: 22.05.2009
Views: 1160
 

"Astrakhangasprom" LLC: Analytical note to the results of implementation of COMPACS monitoring system

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ANALYTICAL NOTE
to the results of implementation of COMPACS® monitoring system at the production units №3 of Astrakhan Gas Processing Plant "Astrakhangasprom" LLC

COMPACS® system, performing continuous full-time monitoring of pump-and-compressor units state with continuous recording of all measured parameters on hard disk, provided reliable emergency shutdown protection of the equipment during run-to-failure of the 3d production units at AGPP in 2001 and 2002. There were no incidents with surface safety valve (SSV) during this period, but in 2000 there were 3 incidents with the pumps:

  1. H-58 / 2 - because of untimely stop of the pump by heating of bearing assembly due to poor lubrication - operational failure;
  2. H-99 - because of self-unfastening of mounting bolt of the clip by improper bolt tightening and the hit of the bolt to the flow part, which led to bolt jamming and damage of the driving screws - operational failure;
  3. H-58 / 2 - because of untimely stop of the pump by heating of bearing assembly due to poor lubrication or defective bearing installation - operational failure.

Analysis of the incidents allows us to conclude that the origin of the incidents is as follows:

  • low quality of elements fabrication and pump maintenance;
  • low quality of operation .

Implementation of COMPACS® Stationary Systems of Vibration Analysis and Condition Monitoring allowed to the observe the state after repairs and during operation, thus excluding human factor and providing an objective assessment of units condition:

  • by equipment commissioning;
  • during equipment operation (timely inform the staff about the emerging problems).

The calculation of the annual economic effect of the monitoring system COMPACS® implementation

The implementation of COMPACS® system allowed to change the structure of pump-and-compressor units repairs at U-731, U-732, U-734 of AGPP. Current and midlife repairs are carried out by the indications and recommendations of COMPACS® system for the actual state of the pumping unit between general maintenance. The repairs of piston-type and centrifugal units, which have positive results of diagnostics, were postponed 30% of the deadline or performed according to the schedule of preventive maintenance and repair.

Cost variance for performed pump repairs before the implementation of the system in 2000 and after the implementation in 2001 will amount the annual saving.

Over 2002 the tendency towards cost reduction of the repairs is held, so it is reasonable to expect stable annual saving.

The number of non-performed midlife repairs and overhauls of pump-and-compressor units was 37 in 2001 and in 2002 - 57 non-performed repairs.

During midlife and general repairs bearings and mechanical seals were replaced. The cost of rolling bearing for the pumps № 216 is 204 rubles, № 66 414 - 824.7 rubles and the cost of mechanical seal is 53 881 rubles as of 2001.

Number of bearings for one pump: № 216 - 2 pcs. and № 66 414 - 2 pcs, mechanical seal - 1pc.

The cost of spare parts from the non-performed additional midlife repairs and overhauls will amount annual saving in 2001.

Conclusions:

  1. Positive results of the implementation and operation make it appropriate the further systems expansion at the equipped units together with the connection of new units and parameters, particularly for condition control of pump face seals, bearing body temperature, etc. and equipment of the 1st, 2nd and 5th production units by the systems.
  2. To increase the effectiveness of the systems, it is necessary to provide training of specialists working with COMPACS® system, provide the metrological service AGPP by test and calibration facilities.
  3. To reduce the cost of scheduled maintenance it is necessary to provide on-condition maintenance of the units equipped with the system COMPACS®.

 

Authors: Deputy Head of Industrial Safety and Technical Supervision Department V.P. Kiyashko, Principal Engineer Pavlov V.A. / 2002

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Tags: COMPACS condition monitoring vibration analysis pump-and-compressor units Date: 20.05.2009
Views: 1189
 

"Astrakhangazprom" LLC: Report on COMPACS monitoring systems operation at the units of the third production

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COMPACS® system reliably informs the staff on the of pump-and-compressor equipment condition and timely warns against the pre-fault and emergency conditions.

COMPACS® systems, carring out a strategy of minimal cost diagnostic (SMCD) have a minimum number of sensors on the unit (two vibration sensors per one double-seat pump unit instead of 12 in traditional schemes), so the unit must be stopped at the first warnings according to the Company Specification comb. 421451.002 CS (p.2.5). The concretization of the reasons of its intolerable condition should be carried out after shutdown by the staff concerning system recommendations.

Systems implementation excluded severe unit accidents and hereto related shutdowns, increased unit run-to-failure, facilitated repair structure from overhauls towards midlife and operating repairs, reduced the cost of maintenance, spare parts and equipment up-grade.

Positive results of the implementation and operation make it appropriate the further systems expansion at the equipped units together with the connection of new units and parameters, particularly for condition control of pump face seals, bearing body temperature, radial and axial shaft movements, etc. and equipment of the units of the 1st and 2nd production by the systems.

To increase the effectiveness of the systems, it is necessary to provide training for specialists working with COMPACS® system, prepare factory instruction on the system, provide the metrological service AGPP by test and calibration facilities.

 

Authors: Chief Engineer of Astrakhan Gas Processing Plant V.M. Berdnikov, Deputy Head of Industrial Safety and Technical Supervision Department V.P. Kiyashko, Senior Mechanic of third production of Astrakhan Gas Processing Plant M.v. Chigirin / 2002

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Tags: COMPACS pump-and-compressor units sensor accidents prevention Date: 18.05.2009
Views: 1094
 

"Silvinit" JSC: Report on the stationary condition monitoring system COMPACS

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At present time information technology is widely used in the accounting department, economic service (corporate information system ALFA) and process management (Automatic Process Control System) of Novosolikamsk Potash Combine SKRU-3. Further development of information technology has led to software for the equipment condition monitoring, repair and maintenance management. The use of condition monitoring systems allows obtaining updated information about actual state of the units, their wear degree and the origin and development of defects.

In order to improve the maintenance management and to gain experience in the use of stationary diagnostic systems the stationary system COMPACS® of DYNAMICS SPC was installed in the drying department SKRU-3 of "Silvinit" JSC in May 2000.

25 units were diagnosed: conveyor drives, drier drums, mixers, smoke exhausters, powerful blasts. The following defects were detected by the system: poor lubrication of bearing assemblies, bearing defects, misalignment, non-rigid unit fastening, coupling defects, gearing defects, blasts and smoke exhausters imbalance, increased temperature of assemblies and units, increased current of motor.

According to the indications of the diagnostic system the following work was performed: balancing, centering, unit tensioning, bearing replacement, bearing lubrication, replacement of gears with defective gear sets, motor replacement.

The diagnostic system allows the staff to make timely processing steps under equipment degradation, assess the state of repaired units without the help of technical diagnostics service, identify and remove a significant part of the malfunctions.

Since May 2002 the system COMPACS® has been working correctly. The system has demonstrated its working capacity and reliability in equipment defects detecting. During the system operation the equipment condition has improved.

Conclusions:

During operation of COMPACS® system there appeared the following problems with the equipment repair management:

  • There is no acceptance test of rolling bearings, as a result a part of the units was not improved.
  • The units (electric motors, pumps, smoke exhausters) after-repair condition is not better than before the repair. The units after repair do not pass the final check.
  • The acceptance act of COMPACS® system is not signed and the equipment is not reflected on companies books.
  • The workplace operating instructions for COMPACS® system are not developed.

Further development of information technology, creation of new diagnostic equipment and software significantly increase the level of equipment operation and maintenance management. Proposals of DYNAMICS SPC by equipping the mine SKRU-3 with stationary monitoring system are rather interesting, but need to be worked out and require more profound technical and economic assessment.

 

Authors: Chief Engineer V.V. Konovalov, Deputy Chief Mechanic F.L. Neklyudov, Chief Power Engineer V.I. Babenyshev, Deputy Chief Engineer for Automation - Chief Metrologist S.M. Lozkov / 2002

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Tags: COMPACS reliability technical condition monitoring Date: 15.05.2009
Views: 1246
 

"Syzran Refinery" JSC: Response to the stationary system for vibration analysis COMPACS

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During testing of the stationary system for vibration analysis COMPACS® at the unit CDU / VDU-6 there were detected the following:

1) 6 pumps and 8 motors had problems with bearing lubrication. The problem was quickly solved by lubricant adding or replacement. This allowed bringing the equipment into "green" zone, i.e. safe operation.

2) The pump N-17 / 2 had the defective rolling bearing. The defect was undetected (visually). The pump was put out of operation and during scheduled shutdown the bearing was replaced.

3) The system showed bad basing and unit misalignment on 3 pumps. As a result of appropriate measures to eliminate these defects, all units were carried to the normal technical condition.

4) The staff of the unit had studied very quickly how to work with the system, as well as mechanics, electricians and engineers.

Summing up the first results of operation of the stationary system for vibration analysis COMPACS® of DYNAMICS SPC at the unit CDU / VDU-6 of "Syzran Refinery" JSC in Omsk in September, 2001 it should be noted that:

1) The system is simple-to-operate.

2) The staff can prevent unscheduled equipment shutdown with the help of this system.

3) There exists the possibility of timely unit maintenance with minor material and labor expenses in the shortest possible time.

4) The system provides safe equipment operation.

5) We consider that force and funds, spent on unscheduled repairs, are cut down.

6) Further implementation of pump-and-compressor equipment with stationary system for vibration analysis COMPACS® in our plant, will make it possible to change the system of schedule-based preventive maintenance and repairs of pump-and-compressor equipment to the system of condition-monitored maintenance.

 

Authors: Deputy Chief Mechanic Nadrshin K.A. / 2001

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Tags: COMPACS vibration analysis pump-and-compressor units Date: 13.05.2009
Views: 1228
 

"Sibneft-Omsk Oil Refinery" JSC: Response to the work of DYNAMICS SPC in expert examination of the equipment industrial safety

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Scientific and Production Center "Diagnostics, Machinery Reliability and Complex Automatisation" DYNAMICS SPC is a longtime business partner of the plant. For over ten years, the Centre performs a wide range of working, developing and implementing modern high-performance production diagnostic monitoring systems for pump-and-compressor equipment and etc.

One of the activities of the Centre is expert examination of industrial safety of chemical and other fire explosive and hazardous industries and facilities. To solve these problems the Centre established a laboratory for Non-Destructive Testing and Technical Diagnostics, staffed with highly qualified specialists in industrial safety and non-destructive testing, advanced equipment of "Time Group", "Krautkrammer", "Diaton - RAC", systems and instruments for vibration diagnostics developed by DYNAMICS SPC.

Besides classical NDT methods: ultrasonic, magnetic, capillary, (color), metal hardness measuring, they also apply advanced NDT methods for diagnostics such as vibration analysis and acoustic emission.

The Centre performs work on tight schedule and with high quality through highly qualified specialists and modern equipment. During 1999 and 2000, the Centre carried out industrial safety examination of more than 1,200 units of various equipment types of "Sibneft-Omsk Oil Refinery" JSC. Service life of the operative equipment was extended on the basis of data and calculations, thus saving significant funds that would have been spent on the replacement of equipment that worked out its resource, specified by the manufacturer.

I consider it expedient and profitable further cooperation with DYNAMICS SPC, which approved itself as a reliable business partner that can quickly and efficiently solve complex technical problems.

 

Authors: Deputy Director General - Chief Engineer of "Sibneft-Omsk Oil Refinery" JSC P.A. Abrashenkov / 2001

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Tags: nondestructive testing vibration analysis pump-and-compressor units acoustic emission monitoring Date: 11.05.2009
Views: 1295
 
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