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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"Angarsk Petrochemical Company" JSC: Response to the condition monitoring system COMPACS operation on the 225/1 unit of the Refinery

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Today the COMPACS® system on the 225/1 covers 42 units of dynamic equipment. The maintenance personnel constantly uses the system readings, timely reacting on all the changes.

Such as, for instance, on 02.06.2014 according to the COMPACS® system readings an overhaul with N-10A pump bearings replacement was carried out. On 15.10.2014 г. according to the COMPACS® system readings N-10 pump bearings replacement was carried out.

By the results of many years of operation the COMPACS®, system has proved its high efficiency allowing to eliminate planned repairs and conduct condition-based repairs, causing the output of the whole units recourse.

 

Authors: First Deputy Director General - technical director of "Angarsk Petrochemical Company" JSC I.E. Kuzora, Refinery Deputy chief mechanical engineer. A.A Dvornikov, Refinery Shop No. 8/14 Manager V.V. Guter, 225/1 Refinery unit Manager А.А. Petrilyak / 2014

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Tags: COMPACS accidents prevention Date: 21.11.2014
Views: 873
 

"Angarsk Petrochemical Company" JSC: Response to the condition monitoring system COMPACS operation on the 39/7 3М unit

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The COMPACS® system system on the 39/7 unit is operated since 2007. Today, 46 units of dynamic equipment are covered by the system. Due to the COMPACS® system implementation the maintenance personnel can supervise the machinery condition in real-time by means of continuous computer monitoring and automatic diagnostics of its condition.

Therefore, on 01.09.2014 according to the COMPACS® system readings on the N-7/1 pump bearing replacement and centering was carried out.

The COMPACS® system implementation allows to carry out only the condition-based repairs of equipment, which allows to output the whole units recourse, as well as provide support of the high level of technical readiness of equipment and accident prevention.

 

Authors: First Deputy Director General - technical director of "Angarsk Petrochemical Company", JSC I.E. Kuzora, Chief mechanical engineer 3M I.S. Chalbyshev, Manager of Shop № 101 ЗМ S.А. Aktuganov, Mechanic on VC and VD 3M A.G. Zubov / 2014

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Tags: COMPACS condition monitoring diagnostics accidents prevention Date: 21.11.2014
Views: 841
 

"Angarsk Petrochemical Company" JSC: Response to the condition monitoring system COMPACS operation on the 36/2М ЗМ unit

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The COMPACS® system on the 36/2M unit is operated since 2010. Today, 22 units of dynamic equipment are covered by the system. Due to the COMPACS® system implementation the maintenance personnel can supervise the machinery condition in real-time by means of continuous computer monitoring and automatic diagnostics of its condition.

Therefore, on 02.09.2014 the COMPACS® system readings shown growths of vibration acceleration parameter on the N-4 unit and issued a recommendation "Check the pump bearing". The pump was repaired and the bearings were replaced.

The COMPACS® system implementation allows to carry out a quick assessment of the units condition, as well as to reduce the number of downtimes due to the unit faults.

 

Authors: First Deputy Director General - technical director of "Angarsk Petrochemical Company", JSC I.E. Kuzora, Chief mechanical engineer 3M I.S. Chalbyshev, Manager of Shop № 101 ЗМ S.А. Aktuganov, Mechanic on VC and VD 3M A.G. Zubov / 2014

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Tags: COMPACS vibration accidents prevention Date: 21.11.2014
Views: 896
 

"Angarsk Petrochemical Company" JSC: Response to the condition monitoring system COMPACS operation on the 35-11/1000 unit of the Refinery

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In 1995 the unit 35-11/1000 was equipped with the COMPACS® system for the first time. The system was providing monitoring of 57 units of dynamic equipment.

Today 66 units are operated under the constant control of their condition. The maintenance personnel constantly uses the system readings, timely reacting on all the changes.

By the results of many years of operation the COMPACS® system has proved its high efficiency providing timely failure detection and issuing of recommendations on the COMPACS® system monitor for the maintenance personnel and, thus, providing the increase of safety and uninterruptedness of the technological process.

 

Authors: First Deputy Director General - technical director of "Angarsk Petrochemical Company", JSC I.E. Kuzora, Deputy chief mechanical engineer of the Refinery A.A Dvornikov, Refinery Shop No. 8/14 Manager V.V. Guter, Manager of Refinery Shop 35-11 / 2014

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Tags: COMPACS accidents prevention Date: 21.11.2014
Views: 907
 

"Angarsk Petrochemical Company" JSC: Response to the condition monitoring system COMPACS operation on the 21-10/ЗM unit of the Refinery

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Today the COMPACS® system on the 21-10/ЗМ covers 48 units of dynamic equipment. The maintenance personnel constantly uses the system readings, timely reacting on all the changes.

For example, on 07.09.2014 according to the COMPACS® system readings, an observation of the N-2A pump was carried out with the further decision about the unit overhaul was made.

The COMPACS® system implementation allows to carry out only the condition-based repairs of equipment, which allows to output the whole units recourse, as well as provide support of the high level of technical readiness of equipment and accident prevention.

 

Authors: First Deputy Director General - technical director of "Angarsk Petrochemical Company", JSC I.E. Kuzora, the Refinery Deputy chief mechanical engineer AA. Dvornikov, Refinery shop No. 17/19 Deputy head A.V. Gotovsky, 21-10/3M unit Mechanic B. V. Fedorov / 2014

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Tags: COMPACS accidents prevention Date: 21.11.2014
Views: 973
 

"Tobolsk-Neftekhim" LLC: Response to the COMPACS condition monitoring system for the shop DBO-10 machinery

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In 1998 in one of the biggest shops of "Tobolsk-Neftekhim", LLC - DBO-10 shop, condition of more than 36 of the most important pump units were monitored by the COMPACS® system.

In 2012 they were joined by 13 more pump units. Today, all this units’ condition is controlled by the 108 vibration channels and 36 current strength measuring channels.

When the condition of the controlled units is changing to worst (if case when nominal value of vibration parameters of bearing assemblies are above the threshold values) the COMPACS® system issues voice and written warnings and recommendations to improve the situation and names the most probable cause of the unit’s condition worsening.

Due to the above-mentioned as well as the Compacs-Net® diagnostic network operating at the enterprise and allowing the personnel in charge to get the information on the condition of pump units from their working places, connected to the intra-plant computer network, the personnel of the enterprise became able to reduce the downtime of pump units caused by the unscheduled repairs. That helps to release the product in full amount and in time.

 

Authors: Mechanic of ESTZ Kokan K.L.,Shop manager of DBO-10 Poluyanov I.S. / 2014

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Tags: Compacs-Net COMPACS accidents prevention Date: 07.11.2014
Views: 997
 

"Angarsk Petrochemical Company" JSC: Response on operation of the COMPACS system for condition monitoring of machinery at GK-3 unit

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The COMPACS® system нat GK-3 unit operates since 1995. The system covers 180 items of dynamic equipment. The unit’s operating personnel constantly uses the system’s readings, timely reacting to all the changes in them.

Here is the resent case, for example. According to the COMPACS® system data, on 19.08.2014 there was a rapid growth of vibration acceleration value at the N-19/1 unit, the unit’s state exceeded "Unacceptable" rate. During the examination made by the maintenance personnel the defect of a bearing was found, during the repair the bearing was replaced and re-lubricated.

Results of long-term operation of the COMPACS® condition monitoring system have approved its high efficiency, providing timely detection of malfunctions with issuing of recommendations to the operating personnel, thus, ensuring increase in safety and uninterruptedness of technological process, support of high level of technical readiness of the processing equipment, and accident prevention.

 

Authors: Acting First Deputy of the Director General – Technical Director M.V. Zamyatin, Refinery Chief Mechanic Deputy A.A. Dvornikov, Shop №11superintendent P. V. Laptev, Mechanic of Shop №11of the Refinery V.Andreev / 2014

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Tags: COMPACS condition monitoring accidents prevention Date: 03.10.2014
Views: 1073
 

Anisovka depot: Response on operation of the COMPACS-EXPRESS-TR3 system

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Anisovka depot of the Privolzhskaya Railway uses the system of comprehensive diagnostics of EMU-trains’ sections COMPACS®-EXPRESS-TR3 for more than 6 years. During this time the system has established a reputation as modern means of final checking of MDRS (Motor Driven Rolling Stock) repair quality, as well as adjustment and setting of the most critical equipment and assemblies of MDRS.

The system covers a big range of diagnosed equipment types and provides diagnostics of all the most important sub-systems of MDRS of the majority of EMU-train series, operated by Russian Railways. The system is an effective tool, with no analogues, indispensable in every MDRS depot.

COMPACS®-EXPRESS-TR3 an everyday guarantor of high-quality repair of Privolzhskaya Railway’s MDRS, ensures safe and uninterrupted operation of suburban train service.

 

Authors: Chief engineer of Anisovka depot О.М. Shibanov / 2014

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Tags: COMPACS-EXPRESS-TR3 diagnostics electric multiple unit MDRS Date: 03.10.2014
Views: 1030
 

Bezymyanka depot: Response on operation of the COMPACS-EXPRESS-TR3 system

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The ensuring of the high-quality repair of a motor-driven rolling stock is a first-priority problem, which is successfully solved in the Bezymyanka depot by usage of the system of comprehensive diagnostics of EMU-trains’ sections COMPACS®-EXPRESS-TR3.

The system successfully operates in the depot since March, 2011. During the operation period hundreds of repaired train-sections were fully diagnosed.

The system has developed a reputation as a modern reliable instrument providing MDRS electric sections condition assessment and operation adjustment of the majority of systems and machines, such as: electropneumatic brake system, control circuits, power and auxiliary circuits, wheel-motor units, collectors, and, also, condition of an electric insulation resistance.

For instance, on the 1st of September, 2014, the diagnosing of the wheel-motor units of ED428403-28404 EMU-train section has detected the malfunction of a small gear in WMB reducer №3, after decommissioning and examination of the reducer the malfunction was proved to exist. Therefore, omission of the malfunction which could cause an accident soon, was prevented.

Continuous monitoring of the high-quality repair of EMU-trains in Bezymyanka depot is a guarantee of safety and uninterrupted operation of suburban train service of Kuybyshev Railway.

 

Authors: Chief engineer of Bezymyanka depot А.А.Cherkasov / 2014

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Tags: COMPACS-EXPRESS-TR3 diagnostics electric multiple unit MDRS Date: 03.10.2014
Views: 1000
 

Ramenskoye Depot: Response to the on-board systems for EMU-train equipment condition monitoring COMPACS-EXPRESS-3 operation

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The first experimental on-board system for condition monitoring COMPACS®-EXPRESS-З was commissioned in the train depot Ramenskoye of Moskow Railways, on the train of ED4M-0133 series in 2009. The system conducts real-time condition monitoring of the following EMU-train units: axle equipment, traction electric motors, compressor, transducer, compressed-air braking system, and allows timely detect ion of the malfunctions appearance and developing, displaying the information on the diagnostic controller in the driver’s cabin in the form of an expert system’s message. Also, all the information on the bearing assemblies, compressed-air brake system and electric circuits of the train in operation forms and archives in a form of condition reports for each car and the whole train and is automatically transmitted to the Compacs-Net® diagnostic network server in the depot.

Currently, on-board monitoring system, allowing to control the condition of the depot electric multiple unit stock and timely detect the causes of malfunctions, to carry out condition-monitored prevention of defects in train functioning , are equipping EMU-trains of ED4M-0022, 0026, 0048, 0352, 0353 and 0462 series. The COMPACS®- EXPRESS-3 on-board monitoring system in complex with the COMPACS®-EXPRESS-TR1 and the COMPACS®-EXPRESS-TR3 stationary diagnostic systems is a part of the ACS SMSRTM™ EMU COMPACS® - automatic control system of safe-money-saving operation and repair of EMU-train machinery, which main efficiency matters are:

  1. increase of EMU-train run-to-failure period and interval between repairs of the machinery;
  2. decrease of the EMU-train machinery failures and reduction of emergency and downtime losses;
  3. decrease of the EMU-train and its equipment repair duration and consumption of materials.

The on-board system for condition monitoring COMPACS®-EXPRESS-3 became an important element of modern railway transport for providing safety of its operation.

Thus, on 14.07.2014 during the commissioning of ED4M-0462 train, the COMPACS®-EXPRESS-3 on-board monitoring system detected the late response of the pressure regulator in the cars 046201 and 046209, issuing the information on the diagnostic controller display in the form of an expert system message "CHECK_PR, PM".

 

Authors: Chief of the Ramenskoye depot A.A. Kadushkin / 2014

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Tags: Compacs-Net condition monitoring electric multiple unit COMPACS-EXPRESS-3 MDRS Date: 16.09.2014
Views: 1068
 
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