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 9001:2015. Its results confirmed a high level of goods and services quality management.
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System for comprehensive condition monitoring of equipment of hazardous production facilities – ways and technologies of realization

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To ensure the reliability of production it is necessary to be acquainted with technical condition of operated equipment in any time, to know exactly the assemblies with critical technical condition and to assume the measures in time to prevent emergency situations. Production output of petrochemical enterprises makes comprehensive technological process, which includes a few hundred units of technological equipment. Failure of any elements operation in the process flow can lead not just to quality or production volume decrease, but to emergency breakage.

Prediction of such failures can be carried out just in the case of comprehensive monitoring of a whole unit, including monitoring of dynamic equipment (pumps, compressors) and static equipment (columns, reactors, reservoirs, furnaces).

The COMPACS® system uses widespread methods of non-destructive testing: vibration, acoustic emission, thermal, electrical, vortex-current, acoustic, optical, and, in automatic mode, carries out the assessment of machinery equipment technical condition, and so ensuring displaying current technical condition by color pictogram, gives warning to the personal with speech transaction and recommendations for the nearest urgent actions, which have to be carried out to ensure equipment operation without breakdowns. Usage of these methods together, not separately, allows to control any equipment.

Machinery equipment with the stationary system COMPACS® allowed to eliminate breakdowns and exclude "sudden" failures, occurred in the places, where the nucleation and development of the malfunctions up to its critical level can`t be traced and, as a result, causes an emergency situation.

 

Kostyukov V.N., Kostyukov A.V. System for comprehensive condition monitoring of equipment of hazardous production facilities – ways and technologies of realization // Kompleksnaya bezopasnost (Complex safety). - 2012. - pp. 45-47

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Tags: COMPACS diagnostics vibration analysis industrial safety monitoring Date: 27.03.2015
Views: 1368
 

Modern methods and means of on-line monitoring of parameters and real-time health monitoring of piston machines

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The paper is devoted to the current development and prospect development of modern methods and means of condition monitoring and diagnostics of reciprocating compressors in hazardous industries. The analysis of well-known monitoring systems enables determination of points for installing sensors in compressors and their assemblies including the controlled assemblies. The principles of condition control presented in monitoring systems have been studied. Technology of condition monitoring systems was examined.

The most systems receive diagnostic signals by means of stationary systems called on-line monitoring systems, in which equipment condition is estimated at the moment of signal receipt according to the measured parameter value without analyzing the causes of its change. In addition, the lack of automatic expert systems of diagnostics and lengthy diagnostic period exceeding the time of defect development testify that the examined on-line monitoring systems are parameter monitoring systems.

Methodology, implementation technology and principles of construction of real-time condition monitoring systems have been analyzed. The methodology of real-time condition monitoring and diagnosing is based on measurement of parameters of indirect processes (vibroacoustic oscillation) that requires installation of 5 sensors or less in a cylinder. The measurement of direct structure and thermodynamic parameters is provided as well.

The condition monitoring system is based on algorithms of real-time decision-making expert system with automatic detection (i.e. diagnostics during measurement of diagnostic signals) of more than 23 malfunctions of compressor assemblies and a hazard degree. The system also provides personnel with the instructions on compensatory control. Scientifically grounded diagnostic period enables reduction of static and dynamic errors by 5% that enables condition monitoring of the most significant equipment and overall production complex.

 

Naumenko A.P. Modern methods and means of on-line monitoring of parameters and real-time health monitoring of piston machines // The Eighth International Conference on Condition Monitoring and Machinery Failure Prevention Technologies (CM-2011/MFPT-2011)

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Tags: condition monitoring diagnostics piston compressor vibration analysis Date: 20.03.2015
Views: 1359
 

Developing and realization of condition monitoring for rotor systems in oil-and-gas industry

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One of the types of high-risk machinery of oil-and-gas facilities is rotor units: pumps, compressors, separators with wide range of power, pressure, speed, costs, working environments, temperatures and operational resources. Failures and accidents of such machinery can be connected with considerable economic losses and possibilities of severe emergencies.

In order to ensure and increase the resource and safety of rotor machinery for the last twenty years the member-companies of Scientific and Production Unit "RISKOM" were developing methods and systems:

  • prompt discrete condition diagnostics of the equipment according to the requirements of normative-technical documentation;
  • continuous condition diagnostics of supporting elements by the common criteria and vibration activity parameters;
  • continuous and discrete monitoring of rotor units condition based on the results of the current diagnostics and forecast of dangerous conditions (accidents, failures).

These developments allowed for the first time to shape and begin the implementation of a new stage – risk monitoring of rotor units for petrochemical industry. Its methodological nature is the following: by the current condition diagnostic and monitoring data there are quantitative evaluation of accident risk occurrence rates, growth of economic expenses and risks caused by the equipment degradation, reduction of safe run-to failure operation and growth of expenses for diagnostics, monitoring, and reasoning of safe residual life prolonging.

 

Makhutov N.A., Kostyukov V.N., Leshchenko V.V., Kostyukov A.V. Developing and realization of condition monitoring for rotor systems in oil-and-gas industry // Kompleksnaya bezopasnost (Complex safety). - 2012. - p. 35

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Tags: diagnostics pump-and-compressor units accidents prevention monitoring Date: 13.03.2015
Views: 1373
 

Research of dependence of current consumption parameters of electric motor on its health

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Operation of motors in unsatisfactory technical condition leads to financial losses, connected with unpredictable equipment breakdown and caused by this violation of technological process. And also, it leads to considerable electric energy expenditure, caused by an increased current consumption.

In some cases, the diagnostics by the current or consumption capacity, perhaps, is the only one method of non-dismountable diagnostics of electric equipment. Such problem occurs during the diagnostics of air coolers and wind-powered generators. Such facilities have restricted access in terms of vibration sensors mounting, at the same time the mounting of current consumption sensors and control of consumed and outputted electric power do not involve any difficulties.

Spectrum-current analysis is the procedure of monitoring of current and voltage signals on motor terminals and their further analysis aimed at detection of electric and mechanical malfunctions (defects) of electric motors.

 

Boychenko S.N., Tkachenko A.A. Research of dependence of current consumption parameters of electric motor on its health // Nauka, obrazovanie, biznes (Science, education, business). - 2012. - pp. 199-200

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Tags: electric motor diagnostics Date: 24.02.2015
Views: 1426
 

Selection of method for diagnostics of auxiliary machine system of electric trains

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Operation of electric motors in unacceptable condition leads to material loses connected with unpredictable failure of the equipment and technological process breakdown produced by this failure, and also considerable expenditures of electrical energy, caused by increased power consumption.

One of these methods is based on that fact that the auxiliary machine systems of each section are independent in terms of ranked measured values. It allows to mark out sections with current references deviation from train`s average values, thereby it points out the section with developing malfunction in the supporting machine system.

It is perspective to develop method for condition diagnostics of electric trains based on spectral analysis of consumption/ generated current. This analysis allows to specify the condition of machine`s different elements and detect specific types of malfunctions.

Physical principle lying in the basis of this method is that any disturbance in the operation of electric and mechanical parts of the machine leads to change of magnetic flux in air gap and, consequently, to a change of a momentary electric current value. Accordingly, the presence of particular frequencies of fixed value in a current of a spectrum of three-phase feed system of auxiliary machines testifies the development of particular malfunctions of a unit.

Thus, for the continuous monitoring of auxiliary machine system it is enough to install three current sensors to the corresponded line conductors of transformation generator.

 

Tsurpal A.E. Selection of method for diagnostics of auxiliary machine system of electric trains // Nauka, obrazovanie, biznes (Science, education, business). - 2012. - pp. 202-205

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Tags: diagnostics electric multiple unit MDRS Date: 13.02.2015
Views: 1383
 

Condition monitoring and diagnostics of rolling bearings of high-voltage electric motors during their operation

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During the operation of high-voltage motors at hazardous industries, it has been proved that, bearings do not work out the operating time assigned by the manufacturer. The report covers issues on the condition monitoring and diagnostics of the defects in rolling bearings of a high-voltage motors during theirs operation, defines the causes of a premature emergence and development of the defects as well the measures worked out for ensuring safe and prolonged operation of the rolling bearings of high-voltage motors.

The collection and analysis of vibration parameters of electric motors during their operation is performed by means of the real-time condition monitoring system. A spectral matrix of defects frequencies has been developed on the basis of the analysis of rolling bearings vibration source. The spectral analysis of vibration parameters showed the presence of frequency components that reveal defects of the bearings. As a result of vibration analysis, a number of defects in the rolling bearings have been revealed and proved during the motor repair and inspection of its bearings for likely defects.

The condition monitoring and diagnostics of the rolling bearings during the operation of the electric motors have allowed:

  • timely decommissioning of the motor with the damaged bearings as well as prevention of accidents which may have occurred with the unit that dispenses fire explosive products;
  • detection of the principal cause of frequent failures of the rolling bearings, which is application of the bearings in inappropriate working conditions and non-fulfillment of auxiliary measures recommended by manufacturers of bearings to prolong lifetime of the equipment;
  • submitting of recommendations on use of the bearings in the motor.

 

Kostyukov V.N., Tarasov E.V. Condition monitoring and diagnostics of rolling bearings of high-voltage electric motors during their operation // Condition Monitoring and Diagnostic Engineering Management (COMADEM-2011), pp. 824-833

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Tags: vibration analysis rolling bearings electric motor diagnostics Date: 06.02.2015
Views: 1341
 

Condition monitoring and diagnostics of rolling bearings of high-voltage electric motors during their operation

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During the operation of high-voltage motors at hazardous industries, it has been proved that, bearings do not work out the operating time assigned by the manufacturer. The report covers issues on the condition monitoring and diagnostics of the defects in rolling bearings of a high-voltage motors during theirs operation, defines the causes of a premature emergence and development of the defects as well the measures worked out for ensuring safe and prolonged operation of the rolling bearings of high-voltage motors.

The collection and analysis of vibration parameters of electric motors during their operation is performed by means of the real-time condition monitoring system. A spectral matrix of defects frequencies has been developed on the basis of the analysis of rolling bearings vibration source. The spectral analysis of vibration parameters showed the presence of frequency components that reveal defects of the bearings. As a result of vibration analysis, a number of defects in the rolling bearings have been revealed and proved during the motor repair and inspection of its bearings for likely defects.

The condition monitoring and diagnostics of the rolling bearings during the operation of the electric motors have allowed:

  • timely decommissioning of the motor with the damaged bearings as well as prevention of accidents which may have occurred with the unit that dispenses fire explosive products;
  • detection of the principal cause of frequent failures of the rolling bearings, which is application of the bearings in inappropriate working conditions and non-fulfillment of auxiliary measures recommended by manufacturers of bearings to prolong lifetime of the equipment;
  • submitting of recommendations on use of the bearings in the motor.

 

Kostyukov V.N., Tarasov E.V. Condition monitoring and diagnostics of rolling bearings of high-voltage electric motors during their operation // Condition Monitoring and Diagnostic Engineering Management (COMADEM-2011), pp. 824-833

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Tags: vibration analysis rolling bearings electric motor diagnostics Date: 06.02.2015
Views: 57
 

Analysis of malfunctions of wheel-motor units of motor-driven rolling stock for the purpose of their diagnostics

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One of the most important assemblies of electric rolling stock is a wheel-motor unit. Its faultless operation determines abilities of transport to fulfill their main functions.

One of the main requirements to the wheel-motor units is a set operational resource. Operation of rolling and sliding friction systems, such as ball- and roller-bearing assemblies, traction gears, commutator-and-brush device and other devices, which are the elements limiting the train resource in general, and depend on the vibration condition, quality of manufacture, repair and assembly.

It is reasonable to carry out the diagnostics of these facilities both during operation and maintenance with the required diagnostic depth.

Typical for these malfunctions is high level of noise, vibration, impact sound. By the deviations and higher levels of these parameters with the help of vibration analysis means it is possible to trace the defect development up to the moment when the usage of defected element is inexpedient or impossible in terms of operation.

Vibration analysis is based on the analysis of vibration process features changes, presupposing that the vibration signal of the operation unit contains all the information on the interactions of its details.

 

Basakin V.V. Analysis of malfunctions of wheel-motor units of motor-driven rolling stock for the purpose of their diagnostics // Nauka, obrazovanie, biznes (Science, education, business). - 2012. - pp. 136-140

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Tags: diagnostics wheel motor unit vibration analysis rolling stock MDRS Date: 23.01.2015
Views: 1446
 

Choice of reciprocating compressors units for real time health monitoring

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The main purpose of condition monitoring systems (health monitoring systems) of piston compressors is maintenance of their safe and accident-free operation. The majority of modern piston compressor monitoring systems use direct measurement of structural parameters and thermodynamic process parameters. The quantity of structural parameters that can be measured by means of the sensors installed into assemblies does not guarantee sufficient control of technical condition of compressor assemblies and parts.

Measurement of compressor's thermodynamic parameters is an effective method of compressor's condition control in case the compressor squeezes technologically stable gases. Otherwise thermodynamic parameters mostly characterize technological working conditions of a compressor and not its technical condition.

The most effective monitoring covers condition of assemblies and details that are subject to frequent repairs. It should be noted that such assemblies and details determine safe exploitation of a compressor.

In order to reduce the cost of monitoring system's purchase and maintenance it is reasonable to measure the parameters of indirect processes, for example, vibration. Vibration sensors are easy to operate because they are mounted directly on a case of a compressor and its assemblies.

The paper presents data about repairs and faults of piston compressors at different oil-refining plants. On the basis of statistical data processing the most vulnerable assemblies and frequent faults are detected. In addition repair cost of a compressor is estimated. On the basis of the data obtained through processing the location of sensors to diagnose compressor assemblies and to detect defects by vibration parameters was detected.

The paper contains a block diagram of monitoring system of piston compressors based on a real-time condition monitoring system COMPACS® that has been functioning at oil-refining plants. Trends and parameters of vibration acoustic signals indicating emergence and development of compressor defects and malfunctions were analyzed. Emergence and development of defects and malfunctions in a compressor were illustrated by the analysis of trends and parameters of vibration acoustic signals. The analysis of data of COMPACS® monitoring system confirms high efficiency of compressor health monitoring systems that use vibratory (vibration acoustic) signals analysis.

 

Kostyukov V. N., Naumenko A.P. Choice of reciprocating compressors units for real time health monitoring // Condition Monitoring and Diagnostic Engineering Management (COMADEM-2011), pp. 824-833

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Tags: diagnostics piston compressor vibration analysis Date: 16.01.2015
Views: 1395
 

Experience of monitoring systems design and operation

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Low objectiveness of condition assessment and lack of observability of hidden processes of condition degradation of potentially dangerous and critically important units, caused by the wear and inadequate actions of maintenance and repair personnel. These are the fundamental reasons of operational problems of the units.

Operational losses can be minimized by timely and purposeful maintenance on the basis of real-time condition monitoring results and usage of full resource of the units, eliminating unscheduled (emergency) shutdowns and repairs providing high level of safety and technical readiness.

The existing regulatory framework of international standards determines only the general approaches to the monitoring problem solving by measuring of parameters of different processes, including vibration measurement.

Joint usage of various methods of diagnostics and non-destructive testing for condition control of potentially dangerous and critically important units, on one hand, is a complicated and actual task, since it is necessary to develop a complex of diagnostic features based on various parameters of physical processes. On the other hand, various types of units demand specific decisions on choosing of the diagnostic methods and parameters.

The solution of this problem can be made on the basis of fundamental research works, adequate approbation of the decisions and the developed systems operation in real conditions of potentially dangerous and critically important units functioning.

Many years of DYNAMICS SPC experience in design, implementation and operation of real-time monitoring systems for dangerous production facilities without shutdown, demounting and decommissioning at Russian enterprises and abroad allowed to develop not only methodological bases and brand-new technological decisions and means of real-time condition monitoring, but, also, regulative-and-methodical documents, which determine the classification and main technical requirements to monitoring systems, operational norms of vibration for several types of machines and mechanisms, and principles of dangerous production facilities monitoring.

 

Kostyukov V. N., Naumenko A.P. Experience of monitoring systems design and operation // Monitoring – Nauka i bezopasnost’ (Monitoring - Science and Safety). - 2012. - pp.108-119

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Tags: COMPACS diagnostics vibration non-destructive testing standard monitoring Date: 13.01.2015
Views: 1369
 
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