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DYNAMICS SPC

DYNAMICS SPC

10 Products

108 Rabinovicha St., Omsk, Russia
DYNAMICS Scientific & Production Center
Omsk, Sib 644043
P: +7 3812 25 42 44

The COMPACS systems - Automatic Vibration Analysis and Condition Monitirong of Machinery in Hazardous Production Facilities.

The COMPACS Dynamic Equipment Vibration Analysis System

The COMPACS Dynamic Equipment Vibration Analysis System

Category: Industrial Automation

The COMPACS computer monitoring system for machinery health control and accidents prevention

The stationary equipment monitoring system COMPACS® serves for safe ecological resource-saving operation of fire explosive production facilities, accidents prevention, production failures and units health control by means of stationary computer monitoring. The COMPACS® system automatically provides vibration analysis extrapersonal diagnostics, monitoring and health forecast of the units, issuing recommendations for operators and chief executives on the nearest urgent actions to be taken by means of the diagnostic network.

Condition (Health) Monitoring – is diagnostics of the main equipment and its assemblies malfunctions with a probability close to 1, on continuously adjoining such time intervals when the machinery condition does not change significantly. The machinery condition monitoring allows to detect timely the destructive loads, defects and malfunctions and to take efficient actions on the restoration of the acceptable condition and to stop the malfunctions developing.

The COMPACS® system is an all-purpose comprehensive machinery condition monitoring system which possesses a flexible distributed parallel-serial architecture, providing a high speed and accuracy of the information processing (scanning rates for rotating equipment are less than 0,02 min per channel, for stationary equipment - on a real-time basis), which allows to carry out the following main principles:

  1. Information Completeness Principal provides a diagnostic criteria choice, which reduces the failure omission probability.
  2. Sufficiency Principal determines a choice of the minimal sensors number, which provides observability of the machinery health.
  3. Invariance and Collective Identification Principal regulates selection of collective diagnostic principles, invariant to the machine construction and connection with its health parameters.
  4. Structural Flexibility and Programmability Principal provides realization of an optimal parallel-serial system structure.
  5. Measuring Path Faultiness Correction Principal carried out through computational methods (correction of sensors nonlinear effect, gain-phase characteristics, match-converting links, etc.) allows to provide high metrological characteristics of diagnostic and monitoring systems with small equipment costs.
  6. Principal of Self-diagnostics and Automatic Check-up of the measuring and controlling system channels provides an easy launch, maintenance and repair of separate channels, metrological and functional system reliability, its survival rate and adjustability to the constant changing real production conditions.
  7. User-friendly Interface with Maximal Information Capacity of the Display Principal allows an operator to identify the technological system general health, at mere sight of the display and to get a designator instructions on the nearest urgent actions.
  8. Multilevel Structure Principal allows specialists with different qualification and responsibility levels to operate the system.

The COMPACS® comprehensive monitoring system uses such non-destructive control methods, as vibration, acoustic emission, thermal, electric, vortex-current, acoustic, optical and other. The complex usage of this methods allows to control both rotating (pumps, compressors, etc.) and static equipment (columns, reactors, tanks, pipelines) on the single soft-hardware platform and in the common information environment, which constitutes the COMPACS®-AE system.

Vibration sensors allow to measure 3 vibration parameters simultaneously: vibration acceleration, velocity and vibration displacement. Joint analysis of vibration acceleration, velocity, vibration displacement and their growth rates, stochastic and spectral-correlation characteristics of vibration parameters allows to detect the defects at the formation stage, which has been proved by the 20-years operating experience of the COMPACS® system, implemented at hundreds of factories of 12 industries.

The comprehensive stationary equipment monitoring system COMPACS® belongs to the first class systems (according to the RF GOST R 53564-2009) and can be used for the comprehensive processing station monitoring, including objects of the first, second and third categories with the dangerous units automatic blockage function, and provides the safe resource-saving machinery operation according to the actual health.

Usage of the COMPACS® monitoring system allows an enterprise to pass to the resource-saving machinery operation according to the actual condition, which is allowed by the appropriate national standards of the Russian Federation: GOST R 53565-2009 "Condition Monitoring of Dangerous Industrial Objects Equipment. Vibration of centrifugal pump and compressor units", GOST R 53564-2009 "Condition Monitoring of Dangerous Plants Equipment. Monitoring systems requirements", GOST R 53563-2009 "Condition Monitoring of Dangerous Industrial Objects Equipment. Regulations", other normative-technical documents of the Russian Federation. The COMPACS® system allows to avoid groundless repairs and substantially enlarge the machinery operational periods.

http://www.dynamicsru.com/products/compacs-m/


The COMPACS-AE Static Equipment Condition Monitoring System

The COMPACS-AE Static Equipment Condition Monitoring System

Category: Industrial Automation

The COMPACS®-AE system is a part of the comprehensive COMPACS® computer-aided monitoring system that can be used independently. It is designed for continuous monitoring and evaluation of hazardous production facilities health, such as coke drums, reactors, pipelines and other static equipment without decommissioning. Monitoring is carried out according to parameters of vibration, acoustic emission (AE), temperature, pressure, stress-strain state and others, with detection of cracking and deviations in the technological process.

The COMPACS®-AE system monitors the condition of materials, detects the presence, location and category of acoustic emission sources in real time. The system displays the health state of column and vessel equipment and pipelines as a surface development. If any defect, the system indicates its location, type, growth rate and hazard rate. The personnel can take timely measures, plan repair works and prevent accidents. To carry out repairs the personnel do not inspect the entire surface of vessels or pipelines. They just repair the places automatically indicated by the system.

The COMPACS®-AE System Advantages

  • Display of the readings as coloured pictograms. where green is acceptable, yellow is actions required, red is unacceptable, and user-friendly diagrams with numeric parameter values.
  • Reliable signal detection in high level industrial noise conditions, integral in-service equipment health estimation, localization of acoustic emission sources that are the areas of origin and/or growth of defects.
  • Use of the data obtained from the system to calculate the equipment resource that prolongs its operation time without decommissioning.
  • Multistage signal processing including pre-filtering, signal processing and detection of acoustic emission pulses at the hardware level. Pulse filtering during the discrimination of events.
  • Creation of diagnostic features vector for each signal channel.
  • Location of AE sources under a priori uncertainty of material performance, facility wall constructions and acoustic wave propagation. It is based on a facility 3D model using statistical data for a specified monitoring interval, depending on both the facility operation mode and its process cycle.
  • Automatic detection of AE sources by plotting the clusters with increased activity on the event location map using adaptive criteria based on probabilistic models.
  • Monitoring of AE sources state, evaluation of their hazard by the activity dynamics based on the exponential model of defects development, the built-in expert system with automatic personnel instructions.
  • Full system self-test from the check of the signal channel, the sensor’s cable integrity, the sensor fault, the sensor-to-facility acoustic contact, the sensor installation that is geometrical sensor arrangement on the facility, to the estimation of location accuracy and the system dead time.

http://www.dynamicsru.com/products/compacs-ae/


The Compacs-Net Enterprise Diagnostic Network

The Compacs-Net Enterprise Diagnostic Network

Category: Industrial Automation

The Compacs-Net® enterprise diagnostic network

The Compacs-Net® enterprise diagnostic network - is a powerful tool for transmission and presentation of information on the equipment health diagnosed by the stationary vibration analysis systems COMPACS®, stand systems for product quality diagnostics and the Compacs®-micro portable systems.

Using the Compacs-Net® network the information on the diagnosed equipment health is transferred to the company’s managers, the related departments, divisions - the network users - so that they can control the equipment operation and maintenance and implementation standards.

The diagnostic network Compacs-Net® is one of the main elements of the state-based operation technology, as a timely receiving of the information on the equipment health allows managing process of maintenance and repair making scheduled preventive maintenance unnecessary.

The Compacs-Net® enterprise diagnostic network advantages

  1. wide networking capabilities of the server provide the user’s work and data exchange between the diagnostic stations COMPACS® by both wireline/wireless network or by dial-up lines;
  2. several modems or modem pools can be connected to speed-up access to the information;
  3. transmission and presentation of the information is performed by using a standard HTTP protocol in the form of Web-pages;
  4. any network technology can be used (connection to the Internet, local network, mail server, etc.).

The Compacs-Net® Server makes it possible for the network users to receive the following information:

  1. information on the equipment health diagnosed by the vibration analysis systems COMPACS® and the Compacs®-micro;
  2. results of tests, carried out on the stand system COMPACS® for diagnostics of products manufacturing quality;
  3. general list of the company’s equipment and each process unit that requires urgent repair, being repaired at the moment or being in "Action required" or "Unacceptable" state;
  4. repair schedules;
  5. trends of any diagnostic parameter measured by the systems;
  6. temporal realizations, signal spectra measured by the systems for further processing;
  7. print-outs of any information presented by the Compacs-Net® network;
  8. diagnostic information at a set past moment (object state history).

The Compacs-micro Personal System for Automatic Vibration Analysis

The Compacs-micro Personal System for Automatic Vibration Analysis

Category: Industrial Automation

The Compacs®-micro™ personal system for automatic vibration analysis is a means of prompt equipment diagnostics and one-, two- or three-site dynamic balancing of units.

The Compacs®-micro™ system diagnoses the units and mechanisms condition based on the expert system messages and signals analysis (spectra, envelope, cepstra, etc.).

Vibration analyzer 8710 makes a prompt collection and analysis of measured signals’ parameters, by means of required units, sections and measuring points selection.

The system carries out the diagnostics according to the a preliminary established route, arbitrarily or with the help of measuring points automatic recognition technology. Also, the device helps to make an evaluation of the units condition according to GOST R 53565, GOST ISO 108 16-3, GOST 20815, GOST 30576 standards.

Vibration analyzer provides data transmission to the outer media (tablet, laptop, stationary PC, diagnostic station of the computer monitoring system COMPACS®), via Wi-Fi or micro-SD card.

The Compacs®-micro™ personal system includes:

  1. Vibration analyzer 8710 with a set of sensors: vibration sensor (with a magnetic fastening, pin-connected, vibroprobe), rpm sensor, in-built temperature sensor.
  2. The Compacs®-micro™ software.
  3. Personal diagnostic station - PDS (personal computer, laptop or tablet on the basis of Windows XP, 7, 8, supplied on customer's choice).

The Compacs®-micro™ advantages

  1. The system operates within the framework of the real-time health monitoring systems of the enterprise machinery - ACS SMSRTM™ COMPACS®.
  2. Automatic diagnostics of the equipment health using parameters of vibration, temperature and a shaft rotational speed.
  3. Built-in function of automatic assessment of the equipment condition according to GOST R 53565, GOST ISO 108 16-3, GOST 20815, GOST 30576 standards.
  4. Visual messages concerning the machinery condition issuing on a display of the device.
  5. Verbal messages of the expert system issuing on the headphones.
  6. Automatic calibration and self-diagnostics of the system.
  7. Vibration analyzer uses the technology of the automatic recognition of measuring points - TARMP™.
  8. Ergonomic construction, colour touch-screen 46x59mm (240x320 pixels).
  9. The data saves to the micro-SD memory card, 2 Gb, FAT16 file system.
  10. The function of one-site balancing of machinery rotors during operation.
  11. The function of one- two- or three-site balancing of machinery rotors during operation.
  12. Noncontact measurement of the unit temperature by means of the built-in infra-red thermometer.
  13. Wireless interface for the contact with a personal diagnostic system or the COMPACS® systems for route download and update, transmission of the data on unit condition, time implementations of the vibration signals.
  14. Spectral express-analyses of the vibration signals by means of built-in facilities.
  15. The analysis of the vibration signal time implementations with a random quantity of discrete values, aliquant 2 (together with the outer PDS).
  16. Analysis of signals in a range of 2 to 12560 Hz with the number of spectral lines < 32768 with frequency < 0,01 Hz.
  17. Real-time trends.
  18. Software in-built bearing database, containing more than 3000 items of Russian and world-spread types of bearings.
  19. Explosion-proof construction of 0ExiaIICT3 class.

The Compacs®-micro™ system has 2 operation modes:

  • off-line - without PDS.
  • on-line – with PDS.

The route can also be implemented by the manual input of measuring points, or with automatic identification if the unit is properly equipped, or preliminary established.

http://www.dynamicsru.com/products/compacs-micro/


The COMPACS-RPP System for Vibration Analysis of Rolling Bearings

The COMPACS-RPP System for Vibration Analysis of Rolling Bearings

Category: Industrial Automation

The COMPACS®-RPP system for vibration analysis of rolling bearings is a modification of the computer monitoring system COMPACS® and serves for an objective evaluation of rolling bearings health and detection of defects, influencing their service life.

The COMPACS®-RPP stand system is designed for rolling bearings vibration analysis and provides bearings sorting to three quality categories:

  1. recommended for application on the equipment of the 1st hazard category with rotation frequency up to 3000 rpm and more;
  2. recommended for application on the equipment of the 2nd hazard category with rotation frequency not more than 1500 rpm;
  3. recommended for application on the equipment of the 3rd hazard category with rotation frequency not more than 1000 rpm.

The COMPACS®-RPP system structure

The system consists of a diagnostic station (control panel section, diagnostic controller, monitor, keyboard, UPS, laser printer), the COMPACS®-RPP software, bearing test stands (drive unit for bearing running), a set of bearing mandrels, a spark marker and a set of special keys.

Diagnostic station is connected to the monophase power supply network with a voltage of 220±22V, 50 Hz frequency and power consumption not more than 200 Wt.

Time of bearing diagnostics with a test report printing on the system printer does not exceed 3 minutes, excluding time for bearing preparation and mounting on and dismantling from the stand, marking and packing.

The COMPACS®-RPP system can be equipped with any of 3 bearing stands or their combination: 1602, 1607, 1608.

  1. drive 1608 – provides vibration analysis of bearings with an inner diameter from 7 to 35 mm, an outer diameter not more than 100 mm; the drive is completed with 11 mandrels;
  2. drive 1602 – provides vibration analysis of bearings with an inner diameter from 40 to 120 mm, an outer diameter not more than 310 mm; the drive is completed with 16 mandrels;
  3. drive 1607 – provides vibration analysis of bearings with an inner diameter from 130 to 300 mm, an outer diameter not more than 500 mm; the drive is completed with 14 mandrels.

The drives control is carried out by means of the diagnostic station on the basis of an industrial controller with an automatic control circuit and the built-in COMPACS®-RPP software package, providing an automatic vibration analysis of bearings, as well as archiving and printing of results.

http://www.dynamicsru.com/products/compacs-rpp/


The COMPACS-RPM System for Diagnostics and Dynamic Balancing of Cradle-Mounted Pump Rotors

The COMPACS-RPM System for Diagnostics and Dynamic Balancing of Cradle-Mounted Pump Rotors

Category: Industrial Automation

The COMPACS®-RPM system is a modification of the COMPACS® computer monitoring system and is designed for diagnostics of pump bearing supports assembly quality, with the possibility of a double-plane dynamic balancing of cradle-mounted pump rotors in their own bearings.

A new way of "SVOS™-balancing" ensures a smooth rotor acceleration to the nominal rotation frequency. In case of imbalance detection within the acceleration, the system carries out the dynamic rotor balancing on the reached frequency. The balancing is carried out in a wheel and a half-coupling planes from the pump side. The imbalance measurement accuracy is not worse than the second class balancing according to GOST 22061-76 or ISO 1940-73. SVOS™-balancing allows to eliminate imbalance on frequencies, which are less than the nominal rotation frequency, which decreases dynamic loads and provides integrity of the tested rotor bearing assemblies in case of a wrong mounting or a highly-imbalanced rotor.

The quality of cradle-mounted pumps repair, evaluated according to digital signal processing and measurement results, are displayed as colored pictograms (green – "ACCEPTABLE", yellow – "MEASURES REQUIRED", red – "UNACCEPTABLE") and diagrams with numerical parameters values.

The COMPACS®-RPM system measures and carries out a diagnostics on the vibration parameters (vibration acceleration, velocity and vibration displacement) of current consumption, temperature and rotation frequency.

The COMPACS®-RPM system carries out a complete analysis of vibration signals by means of fast Fourier transformation, digital filtering and envelope selection. The tested equipment data can be saved in the system archive.

The COMPACS®-RPM system has a built-in automatic expert system, which allows an automatic detection of the following malfunctions defects of inner and outer races, mounting misalignment, end shield misalignment, imbalance, fastening defects and others.

The COMPACS®-RPM system advantages:

  1. new "SVOS™-balancing" method;
  2. built-in automatic expert system capable to diagnose bearings mounting defects;
  3. comprehensive analysis of vibration signals using algorithms of fast Fourier transformation, digital filtering envelope determination;
  4. archiving the diagnostic results in the special database, displaying of parameters trends on the monitor and printing them out;
  5. printing of test reports on the pump rotor balancing;
  6. easy maintenance and self-diagnostics of the built-in system;
  7. high reliability and long service life;
  8. successful industrial operation at the Russian Federation refineries located in Angarsk, Achinsk, Volgograd, Omsk, Moscow, Szyran, as well as in Mozyr (Belarus) and Pavlodar (Kazakhstan).

http://www.dynamicsru.com/products/compacs-rpm/


The COMPACS-RPE System for Electric Motors Diagnostics

The COMPACS-RPE System for Electric Motors Diagnostics

Category: Industrial Automation

The COMPACS®-RPE system is a modification of the COMPACS® computer monitoring system and is designed for electric motors after-repair health diagnostics.

The system provides vibration parameters control (vibration acceleration, velocity, vibration displacement), measured in front end and tail motor bearing planes in vertical, horizontal and axial directions, useful current, measured in accordance with voltage phases, front end and tail motor bearings temperature and the motor rotor rotation frequency.

The system has a built-in automatic expert system, which allows an automatic detection of the following malfunctions: defects of inner and outer races, separator, rolling elements, rotor and stator contact, weakening of fitting, enlarged clearance, compressed bearings, end shield misalignment, stator windings defect (electrical imbalance), electric motor rotor imbalance and others.

The COMPACS®-RPE allows to diagnose from 1 to 8 electric motors simultaneously and ensures the electric motors commissioning with a maximal potential resource.

The electric motor quality, evaluated according to digital signal processing and measurement results, are displayed as colored pictograms (green – "ACCEPTABLE", yellow – "MEASURES REQUIRED", red – "UNACCEPTABLE") and diagrams with numerical parameters values.

The system carries out a complete analysis of vibration signals by means of fast Fourier transformation, digital filtering and envelope selection.

The tested equipment data can be saved in the system archive.


The COMPACS®-RPE system advantages:

  1. built-in automatic expert system capable to diagnose the electric motors failures;
  2. comprehensive analysis of vibration signals using algorithms of fast Fourier transformation, digital filtering envelope determination;
  3. printing of the test report after the electric motor diagnostics and archiving the results;
  4. prevention from putting low-quality electric motors into operation;
  5. easy maintenance and self-diagnostics of the built-in system;
  6. successful industrial operation at the Russian Federation refineris located in Angarsk, Achinsk, Berezniki, Volgograd, Omsk, Sizran, Yaroslavl, Khabarovsk, as well as in Burgas (Bulgaria).

The COMPACS®-RPE system structure:

  1. diagnostic station;
  2. universal measuring module (UMM);
  3. vibration transducers, thermal transducers, current sensors, RPM sensor FD-2;
  4. connection cable;
  5. maintenance documentation.

http://www.dynamicsru.com/products/compacs-rpe/


The COMPACS-USD System for Ultrasonic Control of Plain Bearings

The COMPACS-USD System for Ultrasonic Control of Plain Bearings

Category: Industrial Automation

The COMPACS®-USD system is a modification of the COMPACS® computer monitoring system and is designed for plain bearings health diagnostics. The system evaluates half bearings with diameter from 90 to 500 mm, width from 12 to 360 mm and a lining thickness from 0,7 to 10 mm with a housing thickness from 5 to 20 mm. The expert system is based on ultrasonic pulse-echo technique of non-destructive testing.

Bearings health monitoring within tests is carried out automatically and is displayed as a colored defectogram and a text protocol, and can be printed.

During the diagnostic process the system issues an audio signal as soon as a defect is detected.

The system has a database of controlled half bearings types, which can be filled up and edited. The database contains information on plain bearings numbers, parameters, housing and lining materials.

The system allows to diagnose plain half bearings with a complex geometry (grooves, lugs, oil passages, etc.).

The system automatically classifies detected defects according to occurrence depth and nominal geometrical parameters of half bearings.

A half bearing is serviceable, if there are no defects in its housing, and the total area of lining defects does not exceed 15%.

The COMPACS®-USD system structure:

  1. a diagnostic station on the basis of an industrial controller, providing an automatic control of plain half bearings and colored ink-jet printing of test results;
  2. drive unit 1605 with ultrasonic flaw detector and a sensor.

Plain bearings defects identified by the COMPACS®-USD system:

  • lining defects:
  1. lining detachment from housing,
  2. lining discontinuity,
  3. lining thickness deviation from the nominal one.
  • housing defects:
  1. housing discontinuity,
  2. housing thickness deviation from the nominal one.

http://www.dynamicsru.com/products/compacs-usd/


The COMPACS-RPG System for Hydraulic Testing Control and Pumping Units Diagnostics

The COMPACS-RPG System for Hydraulic Testing Control and Pumping Units Diagnostics

Category: Industrial Automation

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:

  1. automatic test report formation;
  2. control of three test areas is carried out both automatically and manually;
  3. 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);
  4. high efficiency: two computers are used;
  5. the system measuring part meets the 1st class requirements of GOST 6134-2007 "Rotodynamic pumps. Testing methods";
  6. all the measuring means possess verification certificates;
  7. implementation of vibration analysis, heat, electric, parametric and other non-destructive testing methods;
  8. automatic shutdown of the pumping units in case of the unit or stand malfunction detection;
  9. presentation of objective test data in order to control the products quality.

http://www.dynamicsru.com/products/compacs-rpg/


The COMPACS-CNC Condition Monitoring System for CNC Machines

The COMPACS-CNC Condition Monitoring System for CNC Machines

Category: Industrial Automation

The COMPACS®-CNC system is a modification of the COMPACS® computer monitoring system and is designed for condition monitoring of metal-cutting tools (drills) of STH 400 machining center by means of vibroacoustic diagnostics.

The COMPACS®-CNC system allows:

  1. to detect beforehand a tool dulling;
  2. to save products through a timely personnel informing on the tool (drill) state;
  3. to block the machining center according to the tool (drill) wear state.
  4. High reliability of diagnostics by the COMPACS®-CNC system is provided during diagnostics of the metal-cutting tool (drill) from carbon, alloy and fast-cutting tool steel and within processing of items made of corrosion-proof (stainless) common steel with a structurally heightened processibility, structural alloy steel and duraluminium.

The COMPACS®-CNC system advantages:

  1. built-in automatic system of expert messages generation on the basis of diagnostic parameters, measured in real time;
  2. health diagnostics is carried out according to vibration parameters only, which simplifies the system usage on machines with an enclosed operation area;
  3. simple maintenance;
  4. system operation does not require a special education and working skills.

http://www.dynamicsru.com/products/compacs-cnc/