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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The COMPACS-RPG system for hydraulic testing control and pumping units diagnostics

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Hydraulic testing control and pumping units diagnostics within operation, production and/or after repair and testing of pumping units parameters correspondence to regulatory documentation
Pumping units test and diagnostic stand
controlled by the COMPACS®-RPG system

 

The COMPACS®-RPG system for hydraulic testing control and pumping units diagnostics

The COMPACS®-RPG system is a modification of the COMPACS® computer monitoring system and is designed for hydraulic testing control and pumping units diagnostics within operation, production and/or after repair and testing of pumping units parameters correspondence to regulatory documentation.

The system automatically detects the most dangerous unit with the worse state of health and points it out with a cursor, then issues a verbal warning via the loudspeaker and a visual warning by means of issuing the expert messages in the top right part of the screen and all the measured parameters values in the left part of the screen, mentioning the thresholds in accordance with "GOST R 53565-2009: Hazardous equipment monitoring. Vibration generated by rotodynamic pump and compressor units".

During the testing and diagnostics the following parameters are measured: pump rotor rotation frequency, pump inlet and outlet pressure, consumption, temperature of the pumped liquid, pump and electric motor bearings temperature, bearing cases vibration, temperature and liquid level in the tank, temperature and useful current of a vacuum pump, consumption current, power consumption, line voltage and frequency, supply and head pressure. The pumping unit head-capacity, energy, cavitation and vibration characteristics are determined automatically during the test and are issued in the form of an acceptance test report.

The COMPACS®-RPG system advantages

  • automatic test report formation;
  • control of three test areas is carried out both automatically and manually;
  • the system diagnoses a wide range of pumps (with a motor capacity from 4 to 400 kW) by the same sensors having the extended measuring ranges (without remounting);
  • high efficiency: two computers are used;
  • the system measuring part meets the 1st class requirements of GOST 6134-2007 "Rotodynamic pumps. Testing methods";
  • all the measuring means possess verification certificates;
  • implementation of vibration analysis, heat, electric, parametric and other non-destructive testing methods;
  • automatic shutdown of the pumping units in case of the unit or stand malfunction detection;
  • presentation of objective test data in order to control the products quality.
The screen shows the following parameters: pump bearing temperature, water temperature in a tank, water level in a tank, electric motor current consumption, vibration parameters
"PERIODIC TEST" mode
of the control station screen

 
The system for hydraulic testing control and pumping units diagnostics COMPACS-RPG software
"MONITOR" mode of the diagnostic station screen
 

The COMPACS®-RPG system structure

The system consists of a control station, diagnostic station, measuring cabinets, control cabinets, sensors and cables set.

The system hardware is located in two rooms. The control and diagnostic stations are located in an operator’s office. Control cabinets are located near the operator’s office. Measuring cabinets are located in the test areas near test and diagnostic sites.

Control and diagnostic stations are structurally implemented as the operator’s control panel, combined with a computer desk, where printer, monitor and keyboard are located.

The control station operates on the basis of an industrial computer and is designed for the pumping units test and diagnostic management, units and system elements health displaying, test reports generation, providing access to the local network for a remote debugging and internet update of the software. The industrial computer is equipped with the COMPACS®-RPG control software.

The diagnostic station operates on the basis of a diagnostic controller and serves for collection, processing, displaying and registration of the diagnostic features measurement results. The diagnostic controller is equipped with the COMPACS®-RPG automatic expert system.

Measuring and control cabinets have the form of industrial floor-standing cabinets. Control cabinets provide health and processing equipment control. Measuring cabinets provide collection and processing of the measured parameters.

Pressure sensors, pressure difference sensors, flowmeters, multifunctional measuring transducers and thermoelectric transducers are mounted stationarily. Vibration sensors, temperature and photo sensors, attached to connection cables, are kept in the measuring cabinets and are mounted on the pumping unit before testing.

The diagnostic station is connected to an auxiliary monitor, providing diagnostics and test process supervision. The control is carried out from a keyboard.

The diagnostic station software possesses several operation modes, particularly, the "MONITOR" mode. It serves for displaying of data on the system equipment health in the form of colored pictograms and text messages from the automatic expert system.

The COMPACS® systems are tested and certified by the Russian Federation Committee for Standardization, Metrology and Certification and are recommended by the Russian technical expertise to be widely implemented. SPC "Dynamics" has all the licenses and certificates to carry out any types of works from projecting to mounting the COMPACS® systems on a turnkey basis.

Engineering solutions, implemented in the system, are protected by the Russian Federation Patents on various objects of intellectual property and Сertificates of official registration for computer programs.

Warranty for supplied equipment - 12 months.

Malfunctions, automatically detected and indicated by the COMPACS®-RPG expert system

  • Bearing defects:
    • poor lubrication;
    • misalignment;
    • weakening;
    • outer race defect;
    • inner race defect;
    • rolling elements defect;
    • separator defect.
  • Gear malfunctions:
    • coupling defects.
  • Machinery malfunctions:
    • fastening defects;
    • rotor imbalance;
    • rotor wheel defects;
    • unacceptable rotor beating.
  • Unit malfunctions:
    • shafts centering violation;
    • basing and connected structures fastening problems.
  • Gas-and-hydrodynamic malfunctions:
    • cavitation;
    • hydraulic impact;
    • blow up.
  • Electric malfunctions:
    • current overloading;
    • phase misalignment;
    • stator defects;
    • rotor defects.

Test report examples, automatically generated by the system

Head-capacity characteristic of pumping unit
Head-capacity characteristic
 
Energy characteristic of pumping unit
Energy characteristic
 
Energy characteristic of pumping unit
Energy characteristic
Cavitation characteristic of pumping unit
Cavitation characteristic

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