Dynamics Scientific, Inc. USA

Tasks Performed by the Real-Time Diagnostic COMPACS® System

The COMPACS® system automatically carry out in real-time:

1. Diagnostic of the technical state of equipment, as well as prediction of most malfunctions (>95-98%) of equipment with early detection, keeping full performance and strong maintainability;

2. Control over the following of prescriptions and personnel actions

3. Development of repair plans based on the actual condition of the equipment. The system warns the staff about the next urgent actions;

4. Collecting diagnosis and maintenance data into databases and providing reports at all levels of enterprise management;

5. Elimination of the root causes of equipment failures;

6. Elimination of design and installation errors;

7. Vibration control systems are certified to the most stringent explosion-proof requirements (0ExiaIICT6).

Positive Impact of the Implementation of the Monitoring System

Implementing equipment condition monitoring systems enables:

On industrial sites:

  • Monitoring the technical state of equipment.
  • Increasing process stability.
  • Saving on operational costs.
  • Saving on materials, components, and spare parts.
  • Restructuring repair schedules towards more frequent maintenance.
  • Providing control and automatic diagnostics of equipment after repair and installation.

In repair facilities:

  • Improving repair quality.

Within the company:

  • Enhancing personnel management.
  • Reducing the volume and duration of major repairs.
  • Optimizing equipment fleets.
  • Eliminating design errors and speeding up commissioning.

What Types of Rotating Equipment are Monitored by Our System?

The COMPACS system carries out automatic vibration monitoring of the technical condition of various types of dynamic equipment, namely:

• centrifugal and piston compressors

• pumping units 

• electric motors 

• gearboxes

• multipliers

• fans 

• blowers 

• air coolers 

• centrifuges

• gears

– in total more than 2560 types of rotating mechanisms, including diagnostics rotating equipment defects 

What Defects of Rotating Equipment are Detected by the COMPACS System?

List of faults and destructive processes, diagnosed in real-time by the artificial intelligence of the COMPACS system:

CENTRIFUGAL MACHINES

BEARING:

• lack of lubrication

• misalignment

• looseness

• outer race fault

• outer race deformation (out-of-roundness, pitting, spalling)

• inner race fault

• inner race deformation (out-of-roundness, pitting, spalling)

• rolling element fault

• cage fault

• bearing oil-film failure

HYDRO-GAS-DYNAMICS:

• cavitation

• hydraulic impact

• air break

MACHINE:

• fastening problems

• rotor imbalance

• impeller faults

• shaft cut

• intolerable rotor runout

• intolerable axial thrust

• coupling fault

MACHINE TRAIN:

• shaft misalignment

• rotating mass imbalance

• lubrication problems

• loosened fastening to the base and attached structures

• gear faults

TEMPERATURE:

• overheating

• uneven heating

• intolerable gradients

ELECTRICS:

• current overload

• voltage unbalance

• stator faults

• rotor/stator misalignment

• squirrel cage faults

• air gap eccentricity

• rotor eccentricity

PISTON MACHINES

VALVE:

• broken springs, plates

• leakage

• condensate flow-in (hydraulic impact)

• process upset

MAIN BEARING:

• babbitt wear

• looseness

• lack of lubrication

ROD:

• gland wear

• bent rod

• broken rod

SLIDER-CRANK MECHANISM:

• babbitt wear

• part loosening

• lack of lubrication

• increased rod-slider clearance

CYLINDER PISTON GROUP:

• ring wear

• liner wear

• part loosening

• lack of lubrication

• condensate flow-in (hydraulic impact)

• process upset

MACHINE TRAIN:

• loosening of body components

• rotating mass imbalance

What Types of Static Equipment are Monitored by Our System?

The real-time diagnostic COMPACS system is designed for static equipment monitoring in operation. The system ensures industrial safety by eliminating the possibility of emergencies. One of the most effective methods for diagnosing the technical state of static equipment is acoustic emission monitoring. Using embedded physics-based AI, the COMPACS system identifies and locates cracks, leakages, and other malfunctions in static equipment such as:

  • Coke drums;
  • Columns
  • Vessels;
  • Tanks;
  • Pipelines;
  • Towers;
  • Reactors.

What defects and malfunctions of fixed equipment are detected by the COMPACS system?

Here is a list of defects and destructive processes, diagnosed in real-time by the artificial intelligence of the COMPACS® system

CRACKING PROCESSES:

• passive AE source

• active AE source

• critically active AE source

• catastrophically active source of AE

• catastrophic rise in pulse energy

• catastrophic rise in pulse number

PROCESS WEAR:

• unacceptable linear strain of body

• unacceptable rate of linear body strain

• unacceptable local deformation of the body

• unacceptable rate of local body deformation

• overheating

• unacceptable temperature drop

LEAK, HOLE:

• leak

LOW HEAT EXCHANGE EFFICIENCY:

• tube bundle deposits