The COMPACS® system
Real-time vibration diagnostics
of machinery with probability close to 1
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Certification
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

Self-diagnostics of vibration diagnostic systems

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Self-diagnostics of the firmware is the most important feature of modern systems for vibration diagnostics and vibration monitoring containing thousands of measuring channels and tens of thousands of diagnostic features. 

We have developed the system for vibration diagnostics and vibration monitoring with self-diagnostics of overall measuring and transforming channel, which is realized by the signal injection into the circuit of detecting element of the sensor and its further analysis by the firmware.

The system ensures reliable diagnosing of failure of the sensor or cable routings. The system displays a message in the form of a "blue" corner at operator's desk situated in petrochemical complex, and at the stations of users of vibration diagnostic network, including the specialists of control equipment and automatics. This solution ensures quick elimination of causes of malfunction and failure, high metrological reliability, high availability, possibility of trailbuilder operation by actual technical condition.

 

Kostyukov V.N. Self-diagnostics of vibration diagnostic systems // Control. Diagnostics. - M.: 2002. - № 9. - p. 18-22

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Tags: vibration monitoring diagnostics sensor Date: 06.09.2009
Views: 1144
 

Diagnostics of quality of assembling and mounting of equipment

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Operation of complicated productions including hundreds and thousands of units of machine and process equipment is only possible with the information on its technical condition being submitted to the company administration. Repair and modernization of equipment, reconstruction of sections, shops and factories require reasoned decisions based on reliable information on the causes of insufficient productivity, frequent repairs, downtimes, production malfunctions and emergency situations.

Information on the equipment condition (diagnosis) is obtained through the means of technical diagnosing, and their reliability is determined by the prescribed methods of diagnosing, measurement precision, diagnostician skills and quality of adjustment of devices to informative characteristics of the signals of diagnosed object.

The article presents some results of development and application of the systems for vibration analysis and monitoring of assembling and mounting of machines and units. Their use has prospects for engineering because it enables to increase reliability and service life of output products without significant reconstruction of manufacturing and process base and subsequent huge expenses.

 

Kostyukov V.N. Diagnostics of quality of assembling and mounting of equipment // Assembling in mechanical and instrument engineering. - M.: 2002. - № 7. - p. 25-32

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Tags: diagnostics vibration analysis monitoring Date: 05.09.2009
Views: 1053
 

Randomized filtration in the problems of equipment vibration analysis

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In order to create faultless systems for vibration analysis and vibration monitoring in conditions of a priori uncertainty concerning the parameters of the signals, noise and the types of diagnosed units it is necessary to solve the problem of the signals filtration under conditions of correlated noise.

In such a case auxiliary independent random variable is usually introduced. By means of this variable the correlation between averaged values is eliminated through a random selection of these values according to 0 or 1 value of auxiliary random variable.

The paper presents the method and system of increase of reliability of the results of vibration analysis and vibration monitoring by randomized averaging of certain diagnoses with detection of randomizing characteristics by vibration parameters of diagnosed machine on the basis of extreme characteristics of spikes of vibration phase.

 

Kostyukov V.N. Randomized filtration in the problems of equipment vibration analysis // Control. Diagnostics. – M.: 2002. - № 7. - p. 18-19

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Tags: vibration monitoring vibration analysis Date: 05.09.2009
Views: 1035
 

Vibration analysis of centrifugal compressor condition

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During run-to-failure period of the units the COMPACS® systems continuously monitor their condition by the parameters of vibration, temperature and consumption current. Thus, the COMPACS® systems ensure efficient vibration analysis and notify the personnel about inappropriate modes of equipment operation, critical defects of pumping units, dynamic loads, modes of friction, and free distances in the bearings of centrifugal compressors, condition of bearings and gears, driving multipliers, crank-crosshead gear, valves and cylinder-piston group in reciprocating compressors.

The systems for automatic vibration analysis and condition monitoring of equipment are very effective. Thus, elimination of downtime of millionth reforming unit at the expense of unfounded halting of hydrogen compressor, which is the heart of the unit, in a day covers the expenses for the system implementation.

 

Kostyukov V.N., Starikov V.A., Tarasov E.V. Vibration analysis of centrifugal compressor condition // Compressors and pneumatics. - M.: 2002. - № 2. - p. 27-29

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Tags: COMPACS vibration analysis vibration centrifugal compressor technical condition Date: 04.09.2009
Views: 1131
 

Increase of production efficiency on the basis of implementation of the COMPACS automatic systems for diagnostics and condition monitoring of machines

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Fast developing malfunctions are the most dangerous for operation and production economy. In order to ensure malfunction observability it is necessary to carry out continuous diagnostics with automatic delivery of objective results to the personnel. The system for diagnostics and monitoring detects malfunctions, monitors their development and promptly notifies the personnel about the necessity of equipment repair or shutdown.

Implementation of the COMPACS® systems containing vibration analysis sensors, sensors of axial and radial displacement, rotation frequency, pressure, level, temperature, and current enables use of equipment during the whole operating life provided retention of its maintainability and production safety. Need for the systems for continuous monitoring of equipment, which ensure profitability based on resource-saving safety, is dictated by the necessity of transition to a new level of reliability, safety and effectivity by the implementation of modern high-degree technologies of petrochemical productions.

 

Kostyukov V.N., Kostyukov A.V., Kostyukov Al.V. Increase of production efficiency on the basis of implementation of the COMPACS automatic systems for diagnostics and condition monitoring of machines // Chemical technique. - M.: 2002. - №2. - p. 16-22

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Tags: COMPACS diagnostics vibration analysis resource-saving monitoring Date: 03.09.2009
Views: 947
 

Controllability of machines in the diagnostics of build quality

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The paper presents a new tried-and-true method for controllability (the product suitability for diagnostics by specified technologies) of machines and units to diagnosing without their dismantling at all stages of their life cycle. This method enables reduction of number of vibration transducers installed on the unit, which simplifies vibration measurement and diagnostics.

All developed sensors have a number of features and advantages that ensure their application with minimal costs: differential construction and output, self-diagnostics of detecting element, high precision and low power consumption, wide range of operating frequencies.

The developed method for unit controllability showed itself to good advantage during the implementation of the systems for diagnostics and monitoring of thousands of units of petrochemical complexes. In addition, this method is a part of the strategy for minimal cost diagnostics that is developed by DYNAMICS Scientific & Production Center (SPC). The novelty of its solutions is confirmed by the patents for invention.

 

Kostyukov V.N. Controllability of machines in the diagnostics of build quality // Assembling in mechanical and instrument engineering. - №5. - M.: 2001. - p. 41-42

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Tags: diagnostics vibration monitoring Date: 02.09.2009
Views: 1077
 

Repair of locomotive units on the basis of the COMPACS resource-saving technology

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COMPACS®-EXPRESS permanent station for condition monitoring of wheel motor units (WMU) of electric multiple units and linehaul electric locomotives realized on the basis of the COMPACS® system enables simultaneous diagnostics of quality of all WMU of a certain locomotive, several locomotives on a random basis or overall train according to conditions of repair shop.

The implementation of COMPACS®-EXPRESS permanent station for vibration analysis with automatic control over WMU enables to increase reliability and objectivity of evaluation of technical condition of WMU parts, and reliability of the results by automatic continuous vibration monitoring of current status of the unit on a trial basis, self-diagnostics of the sensors and overall measurement process. Thus, the quality of repair and reliability of electric stock are increasing as well. 

 

Kostyukov V.N., Avilov V.D., Borodulin A.G., Kovbasa N.I. Repair of locomotive units on the basis of the COMPACS resource-saving technology // Resource-saving Technologies in Railway Transport: materials of the IV Research and Practice Conference. - M.: 2001 - p.IX-1-IX-2

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Tags: COMPACS-EXPRESS wheel motor unit vibration analysis technical condition monitoring Date: 29.07.2009
Views: 1094
 

Normalization of vibration parameters in reciprocating compressor diagnostics

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The developed models and determined mechanisms of initiation and development of vibration and other processes accompanying operation of units of petrochemical complex enable their normalization in order to determine relative boundaries between different conditions of the units.

Experimentally proved fact underlying the methodology of normalization of machinery vibration parameters is that under normal operation of various units the values of vibration parameters are below certain values which can be used as the limits.

Adaptive expert system (ES) for diagnostics enables to accumulate the information on the law of variation of the unit condition and use the determined mechanisms for the purpose of diagnostics. High complexity of equipment of petrochemical complex and short timing of the diagnosing and decision-making necessitate ES creation. Methodological approaches and firmware of condition monitoring enable elimination of main causes of equipment failures, minimize the flow of requirements for maintenance and make a major contribution to the company profitability on the basis of resource-saving safety.

 

Kostyukov V.N. Normalization of vibration parameters in reciprocating compressor diagnostics // Consumers and manufacturers of compressors and compressor equipment - 2001: Proceedings of the Seventh International Symposium. - St. Petersburg: 2001. - p. 90-93

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Tags: diagnostics vibration resource-saving vibration parameter Date: 22.07.2009
Views: 1021
 

Diagnostics and prediction of condition of the units of petrochemical complexes by vibration parameter trends

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The rate of change of diagnostic features (vibration parameters) is uniquely determined by the weighted sum of the rates of change of relevant errors of the unit. The rates of change of vibration parameter trends supplement the space of orthogonal diagnostic features that enables to increase the reliability of diagnosing and reduce diagnostic error.

Numerous acts of failure of various mechanisms of the units, which were investigated by the analysis of vibration parameter trends, are exponential. Exponential trends of malfunction development on a short interval of time make up a group of sudden failures of equipment that cause significant economic and environmental losses in petrochemical complexes.

Growth rates of vibration parameters and vibration parameter values are independent diagnostic features. The use of growth rates of vibration parameters as independent diagnostic feature put a new spin on the diagnostics. It is confirmed by the patents and vibration standards for safe operation of the units of petrochemical complexes, which well in advance anticipated the boldest suggestions for vibration normalization.

 

Kostyukov V.N., Kostyukov Al.V. Diagnostics and prediction of condition of the units of petrochemical complexes by vibration parameter trends // Omsk Research Bulletin. - Omsk: 2001. - № 17. - p. 109-112

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Tags: diagnostics vibration parameter technical condition Date: 20.07.2009
Views: 1022
 

Control of equipment of petrochemical plants on the basis of the COMPACS automatic systems

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The article presents new tried-and-true method of controllability (suitability of the product for diagnostics by certain technologies) of machines and units to be diagnosed without dismantling at all stages of their life cycle. 

This method enables to reduce the number of vibration transducers mounted on the unit; hence vibration measurement and diagnosing become more easy.

All developed sensors have a number of features and advantages that ensure their application with minimal costs: differential construction and output, self-diagnostics of detecting element, high precision and low power consumption, wide range of operating frequencies.

The developed method for unit controllability showed itself to good advantage during the implementation of the systems for diagnostics and monitoring of thousands of units of petrochemical complexes. In addition, this method is a part of the strategy for minimal cost diagnostics that is developed by DYNAMICS Scientific & Production Center (SPC). The novelty of its solutions is confirmed by the patents for invention.

 

Kostyukov V.N. Control of equipment of petrochemical plants on the basis of the COMPACS automatic systems // Proceedings of industry conference of chief mechanics of refineries and petrochemical plants of Russia and CIS. - Kirishi: 2000. - p. 186-199

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Tags: COMPACS diagnostics sensor monitoring Date: 15.07.2009
Views: 1086
 
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