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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Home Publications Articles

System for condition monitoring of reciprocating compressors of oil-refining industries

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Safe operation of the compressor units with reciprocating compressors (CU with RC) operating on explosive and noxious gases is possible only by continuous monitoring of their technical condition.

At most enterprises of oil-refining industry CU with RC are almost beyond their service life, and it is necessary to make an examination of industrial safety in order to prolong their service life. In addition, schedule-based preventive maintenance and repair are not economically feasible and efficient, and more than once it was proven in practice and examples of centrifugal equipment. The only way out is equipping of CU with RC with condition monitoring systems using various methods of nondestructive testing and process variables and transition to operation, maintenance of reciprocating compressors by their actual technical condition. Therefore, the development of methodology and systems for condition monitoring of CU with RC is a topical problem.

The article gives scientific definitions of condition monitoring, technical diagnostics, technical diagnosis, diagnostic feature; it presents the principles of monitoring system structure, data collection, data analysis and processing, time selection of the signals, spectral analysis, envelope analysis, trends, pattern identification, emergency shutdown and presentation of monitoring results.

 

Kostyukov V.N., Naumenko A.P. System for condition monitoring of reciprocating compressors of oil-refining industries // Refining and petrochemistry. - M.: 2006. - № 10. - p. 38-48

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Tags: diagnostics piston compressor technical condition monitoring Date: 19.10.2010
Views: 1190
 

There are no sudden accidents: Improving of the efficiency of 21-10/ZM unit operation on the basis of equipment condition monitoring

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The process of coking is widely used for processing of heavy still bottoms. It enables to improve the depth of oil refining and thus increase the enterprise profitability.

21-10/ZM unit releases through the complicated process involving hundreds of units of machine and columned-capacitive equipment. The failure of any element of a technological cycle may not only cause the decrease of quality and output but also result in emergency shutdown.  

In order to ensure reliability of production it is necessary to know technical condition of equipment in operation, timely detect assemblies with critical technical condition and prevent emergencies.

Equipping of the machinery of Omsk Refinery with the COMPACS® stationary system enabled accident elimination. So-called sudden failures stopped. 'Suddenness' occurs in case of absence of the supervision over the processes of defects emergence or development, and consequently their growth to a critical level up until the accident.

 

Kostyukov V.N., Shatalov A.A., Anisimov V.F., Tarasov E.V. There are no sudden accidents: Improving of the efficiency of 21-10/ZM unit operation on the basis of equipment condition monitoring // Oil of Russia. - M.: 2006. - №7. - p.78-81

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Tags: COMPACS technical condition monitoring Date: 05.10.2010
Views: 1065
 

Safe resource-saving operation and repair as a part of economic policy of the plant

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The necessity of accident-prevention protection of powerful compressors and other unique equipment has never raised doubts of the experts. In order to ensure technological system tolerance for disturbances, including failures of process and pump-and-compressor equipment, it is necessary to trace external and internal factors that influence the system and characterize its technical condition.

In order to manage the system condition it is necessary to take technical and organizational measures. Equipment accidents at Omsk Refinery caused safety decrease, loss of efficiency and downtime of process equipment and thus inflicted economic damage, exacerbated environmental problems.

Under the circumstances in the late 1980s the company administration had decided to implement stationary systems for equipment condition monitoring and first of all stationary vibration analysis of machinery. The specialists of Minaviaprom engine research institute, who developed and implemented the devices and systems for vibration analysis of aircraft units, got involved in the work. Later these specialists formed the main body of Scientific Production Company "Dynamics".

 

Kostyukov V.N., Pidsadnij A.S., Sagirov V.H. Safe resource-saving operation and repair as a part of economic policy of the plant // Refining and petrochemistry. - M.: 2005. - № 18. - p. 45-49

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Tags: vibration analysis resource-saving technical condition monitoring Date: 28.09.2010
Views: 1122
 

Internet technology in the COMPACS control systems for safe resource-saving operation of equipment

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Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS® solve the following problems: vibration analysis and prediction of major malfunctions of equipment with early detection, full use of resources and retention of maintainability; monitoring of execution of diagnostic instructions and personnel actions through network (Internet) engineering; elimination of design and installation mistakes; optimization of flow charts and configuration; keeping of the databases of diagnostics, works, equipment replacement and service life; reporting at all control levels of the enterprise.

The Compacs-Net® network for vibration analysis is of service in on-line monitoring of execution of instructions of automatic systems for vibration analysis. The central element of the CompacsNet® network for vibration analysis and the collector of diagnostic information is the server that periodically examines the COMPACS® stations connected to a diagnostic network and saves the findings as SQL-database.     

Internet-based technologies integrate various systems for vibration analysis of equipment condition, which are located hundreds of kilometers apart, into single information complexes used in ACS SRSM™ COMPACS®, improve observability and controllability of equipment, and increase the systems efficiency by significant reduction of maintenance costs.

 

Kostyukov V.N., Boychenko S.N., Kostyukov Al.V. Internet technology in the COMPACS control systems for safe resource-saving operation of equipment // Oil Industry. Innovative Technologies in Oil and Gas Industry. - M.: 2005. - № 10. - p. 104-107

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Tags: COMPACS diagnostics vibration analysis technical condition monitoring Date: 07.12.2009
Views: 1232
 

The COMPACS saving system ensures safe resource-saving operation of equipment at OOO LUKOIL-Volgogradneftepererabotka

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The problem of increase of anthropogenic safety and profitability is urgent for oil and gas industry in whole and especially for modern refineries with high concentration of power-intensive and potentially hazardous equipment.

One of the most promising ways to solve this problem is implementation of the technology for safe resource-saving operation of equipment on the basis of vibration analysis and real-time condition monitoring based on the new class of systems - Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS®.

 

Kostyukov V.N., Boychenko S.N., Bezzubov A.V., Mikerin O.B., Fedorinov I.A., Durosov V.M., Lvov O.S. The COMPACS saving system ensures safe resource-saving operation of equipment at OOO LUKOIL-Volgogradneftepererabotka // Automation and information technology. Special edition of 'Oil of Russia' journal. - M.: 2005. - № 4. - p. 101-105

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Tags: COMPACS vibration analysis technical condition monitoring Date: 30.11.2009
Views: 1169
 

Regulatory and methodological support of reciprocating compressor condition monitoring

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The paper presents the results of long experience of vibration analysis and condition monitoring of reciprocating compressors.

On the basis of the collected data the principles and methodological support for data collection and analysis, which enable vibration analysis and condition monitoring of reciprocating compressors, have been developed in order to determine normative values of the measured parameters.

The paper also presents some results concerning the ways to measure the parameters, collect data, and diagnose the compressors, as well as data processing scheme and some normative values.

 

Kostyukov V.N., Naumenko A.P. Regulatory and methodological support of reciprocating compressor condition monitoring // Control. Diagnostics. - M.: 2005. - № 11. - p. 20-23

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Tags: piston compressor vibration analysis technical condition monitoring Date: 25.11.2009
Views: 1141
 

Normalization of characteristics of a spectral matrix of vibrations of batch-type equipment

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The paper presents statistical analysis of distributions of characteristics of a spectral matrix of vibrations of batch-type equipment by a centrifugal pump unit.

The results of work have been used in the construction of automated expert system (ES) for diagnostics and decision-making in respect of technical condition.

The developed ES is integrated into the software of the COMPACS® stationary system for continuous vibration monitoring and vibration diagnostics, stand systems and Compacs®-micro portable device. Thus, it integrates into the system that provides measurement, storage of the measurements, ES measurements processing and automatic instructions – without the personnel being involved. Consequently, it helps to avoid subjective errors and expenditure of time. 

 

Boychenko S.N. Normalization of characteristics of a spectral matrix of vibrations of batch-type equipment // Collected articles on propulsion engineering dedicated to 175th anniversary of MSTU n.a. N.E. Bauman - M.: 2005. - p. 22-25

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Tags: COMPACS vibration monitoring vibration Date: 20.11.2009
Views: 1193
 

Сondition monitoring of reciprocating compressors

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Operative reciprocating compressors and those put into operation are almost indispensable equipment of processing trains of petrochemical enterprises. Reciprocators operating for a long time especially require condition control due to the termination of service life of some units and parts with different operating lives. 

Automated Control System of Safe Resource-saving operation and Maintenance of equipment of refineries and petrochemical plants (ACS SRSM™) COMPACS® is the most optimized system in terms of the cost of a single channel and explosion safety. ACS SRSM™ COMPACS® realizes the strategy of the minimum cost of the systems for vibration analysis and vibration monitoring.

The COMPACS® system for vibration monitoring of technical equipment enables focused and reliable condition control of the equipment, including reciprocating compressors, prevention of sudden malfunctions and shutdowns, real-time control and correction of the personnel actions by integration of the data from the systems of a single diagnostic network Compacs-Net® with a single database of the monitoring parameters. Thus, the COMPACS® system provides vibration monitoring of equipment condition and promotes transition to operation in accordance with the actual technical condition. Consequently, it reduces material costs of maintenance.

 

Durosov V.M., Kostyukov V.N., Naumenko A.P., Pidsadnij A.S. Сondition monitoring of reciprocating compressors // Chemical technique. - M.: 2004. - № 6. - p. 6-12

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Tags: COMPACS vibration monitoring piston compressor technical condition monitoring Date: 18.11.2009
Views: 1141
 

Manufacturing Execution System (MES) for safe resource-saving operation of equipment on the basis of ACS SRSM™ COMPACS

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The article presents the technology for safe resource-saving operation of equipment in real time mode (Safe Maintenance™ - SM™-technology) which was created on the basis of Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS®. The technology enables to increase the safety and efficiency of the plants with uninterrupted cycle with minimum cost of maintenance of process units.

The use of ACS SRSM™ COMPACS® makes the operation of fixed assets transparent and manageable, decreases capital output ratio, increases capital productivity and capitalization of business in whole.

 

Kostyukov V.N., Boychenko S.N., Kostyukov A.V. Manufacturing Execution System (MES) for safe resource-saving operation of equipment on the basis of ACS SRSM™ COMPACS // World of computer automation. - M.: 2004. - № 4. - p. 35-44

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Tags: COMPACS Safe Maintenance resource-saving Date: 13.11.2009
Views: 1139
 

New technology of operation of processing equipment - long-term goal of management of Russian fuel-and-energy companies

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In most Russian fuel-and-energy companies considerable proportion of the investments in production process is spent on elimination of the accident consequences, production defects and unreasonable costs of repair of fixed production assets.

The emergence of Automated Control Systems of Safe Resource-saving operation and Maintenance of equipment (ACS SRSM™) COMPACS® and SM™-technology (Safe Maintenance™) for safe resource-saving operation of equipment enabled condition monitoring at all stages of its life-cycle by timely detection of malfunctions, supervision over malfunction development, provision the personnel with the instructions on the necessity of repair or emergency shutdown, and control of the timeliness of execution of above instructions. 

Characteristic features of a new operation technology, which is being successfully implemented at refinery, petrochemical and other enterprises with uninterrupted cycle: significant economic effect tested through practice, short payback period and resource-saving safety.

 

Kostyukov V.N., Kostyukov A.V. New technology of operation of processing equipment - long-term goal of management of Russian fuel-and-energy companies // Proceedings of the meeting of chief mechanics of the enterprises JSC AK SIBUR. - Togliatti: 2004. - p. 58-62

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Tags: COMPACS Safe Maintenance resource-saving Date: 04.11.2009
Views: 1101
 
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