DYNAMICS SPC and vibration analysis systems' COMPACS history
Piston compressor diagnostic instrument PARK-1
The development of methods and means of vibroacoustic diagnostics has started in 1972, when PARK-1, the device for piston compressor diagnostics, was created and implemented on a test bench in serial production.
In this device methods of compressor defects diagnostics according to the cyclogram of its work with stochastic averaging of results in various frequency bands were realized. The device allowed to diagnose such production defects of compressors, as the often escape of the piston, defects of suction and delivery valves, concentricity of a rotor in a stator, etc.
It had been used on test and running station of compressor DH2-1010 in serial production, which provided nearly one million compressors per year. Piezoelectric electrometers IS-218 were used as sensors, but than they were replaced by IS-312, IS-313, since they had wider frequency diapason.
PARK-1 had the first expert system of production QUALITY monitoring.
The automatic complex for experimental studies of vibroacoustic processes in pumps and units SIGMA
Since 1975 people began to developed methods and means of diagnostics and forecasting of gear fuel pump and hydraulic unit state. SIGMA - powerful and automated complexes for experimental investigations of vibroacoustic processes in gear fuel pump and hydraulic unit in pilot and serial production were created.
SIGMA complexes allowed to produce time and spectral analysis with the help of S5-3 analyser with loop oscillograph N-115 tape, record vibroacoustic signals and their envelopes in frequency diapason from dozens Hz to hundreds kHz per magnetograph N-048 tape, measure and print on EUN-23 printer and PL-150 the number values of diagnostic features with the following trend and vibration spectrum processing using computers Minsk-32 and ES.
During seven years of systems operation, through them passed thousands of serial-production units and dozens of units having long-term and accelerated testings in pilot production. The main pattern of vibroacoustic signals formation caused by unit production and operational defects were found. Also patterns and stages of destruction were defined and created methods of in-place unit diagnostics during a running and acceptance testing and forecasting of their potential operation recourse.
The diagnostic devices of units in serial production and RAPID operation
On the basis of SIGMA the series of RAPID - devices for unit diagnostics in serial production and operation were created. The devices were exhibit on Progress-83 and were honoured with silver and two bronze USSR Exhibition of Economic Achievements medals.
During the devices acceptance, customers stated severe metrological specifications: «If you measure vibration, please point out parameter, frequency range, amplitude range, error in accordance with GOSTs». Thus, it was necessary to dispel the illusions and normalize errors in frequency rate higher than 3000 Hz, specially, when mounting a sensor on magnet or probe.
Methods of vibroacoustic diagnostics considering machining by chip removal – deep casing drilling, turbine blade milling, gear blades and teeth grinding, tough alloy turning operation, had been actively developing in the same period - 1975-1985.
1986-1988. Microprocessor usage was actively studied by example of electric heading machine for workpiece punching with automatic control according to the temperature of a workpiece. In that case wear of the matrix and puncheon is evaluated with vibroacoustic parameters signal. Also in that period a few systems of detail ion-plasmous evaporation automatic control and automatic control of hard-alloy tool solder according to the temperature in high frequency current units were developed.
In RAPID systems first Automatic Expert system on the basis of pseudo-coherent selection of Noise and Periodical Components (NPC) with acoustic signal envelope was used.
First stationary pump unit state monitoring system SVK-1
On spring, 1989 the chief mechanic of Omsk Refining V.N. Dolgopyatov assigned a task to diagnose pump units on the Refining technological units: «I had been checking the work of mechanics and drivers – went to the pump chamber, stay there for 40 minutes – nobody there, although the driver is obliged to check the pumps constantly; went to the operator room – they are here, discussing something, the driver says to me: «Viktor Nikolayevich, I have just been to the pump chamber – it’s OK!». If a good employee does that, what can you expect from a bad one? The main reason of accidents is the lack of visual data on the equipment state. I had equipped mechanics and driver with vibroacoustic devices and headphones and cursor for a few times – that has done no good: Some have device, that does not work, some do not work with device themselves, some place a sensor in the place, where vibration is lower, etc. Subjective methods do not suit, since an objective control, which does not depend on staff’s opinions, needs and skills, is required. Equipment state monitoring should be reliable, easy-presented and be clear to the one who graduated from vocational school!». The systems were built on that approach.
SBK-1 system was the first stationary vibration control system for pump unit state, implemented on Omsk Refinery in October, 1990. It has automatically detected 5 main malfunctions: bearing, cavitation, centering, balancing and fastening quality.
Before the system development, there was a researching period of big pump unit vibration characteristic in order to detect places and methods of sensors mounting, list of diagnosed parameters required, and threshold values of vibration parameters. Methodological and firmware for RAPID systems developed since middle 70th for aero-engine pump units diagnostics had been used for researches.
The research revealed, that machinery state control by vibration velocity parameter only (according to the required regulations) requires 12 sensors mounting on the unit, also the diagnostic method is complicated and often leads to omission of unit malfunctions. On the basis of information completeness principal a minimal diagnostic features list required was defined (vibration acceleration, velocity, vibration displacement) for reliable unit state control using minimal vibration sensors number.
SBK-1 system controlled the operation of 2 propane pump units with capacity of 500 kW of deasphalting unit 36/1-3. This system contains elements, which were present in all the following developments: 3 vibration parameters calculation from one sensor signal; full hardware self-control, including sensors.
The system measures vibration in 4 places of every pump unit – on pump and engine bearings. The system uses analog electric units for signal processing, digital indicators and light-emitting diodes for equipment state data display, unconditional logic elements and mechanical switches for its operation control. Protocol printing was provided, but the personnel asked to make the data to be issued on KSP, in order to reduce its paper expenditures we have had to develop a unit, changing recording speed according to the equipment state.
The system did good on 36-1/3 unit and issued first affirmative diagnose on the electric motor bearing damage, which was confirmed after its disassembling and worked till the August 1993 when it was replaced by the COMPACS® vibration monitoring system.
The first stationary system of pump unit computer monitoring with in-built vibration analyser SVIP-64
SVIP-64M diagnostics and prognosis system of centrifugal pump unit bearing state, having 64 sensors was implemented on АВТ-10 unit of Omsk Refinery in July, 1991.
It already included an exotic for those days PC АТ286, mounted on the shop unit. PC display application as the unique mean of data issuing has solved problems with equipment state indication, since other decisions are too awkward and could not give enough facilities to issue unit state and tendencies of its change or forecast.
PC also solved problems of data collecting from local diagnostic stations, forecast parameters calculations by means of autoregression equation - moving average, data archiving, simultaneous issuing of 2 different vibration parameters trend diagrams in different time scales and its forecast, measure protocols printing, issuing of the system full self-control results.
Control of the operation modes was carried out via the menu. Configuration of firmware for system adjustment to unit configuration is implemented in a special menu option.
The whole software package was written in EGA graphic mode on C programming language under DOS. This software package, according to the modern classification applied to SCADA (Supervision Control and Data Acquisition) ММI-type systems (Man-Machine Interface) was, apparently, one of the first systems of such kind not only in Russia, but in the world.
That was the period when standards of pump unit vibration parameters were defined. It is necessary to point out, that standards values, defined at that time on a small unit sampling according to the method developed, were changed after massive implementation of the COMPACS® systems, when they were specified and confirmed by State Technical & Mining Inspectorate of Russia.
During the stationary systems development a great consideration was given to the place choice and vibration sensors placement method. Traditional methods, such as stud fastening, magnetic fastening or glue fastening are either required of unit construction improvement (which is unacceptable) or not reliable enough in real operation conditions.
There was developed sensor fastening method, which does not requires unit construction improvement, which met the requirements of State Technical & Mining Inspectorate and was operational-reliable enough and allowed to gather maximum information from minimal number of sensors.
The main requirements for system sensors are formulated and implemented, first of all, bigger output – up to 100 pCl/m/s2 - for operation on long cable lines up to 500 m or more, providing their faultless operation during the whole operating life of the system (not more than 10 years).
Sensors construction had been continually improved, considering real operation experience. The following items were developed: vibration sensors with magnetic fastening, special constructions thermocouples, current sensors, rotation frequency sensors, pressure sensors, level sensors, motion sensors, etc.
Therefore, methods of providing checkability of the explosion-proof units with no improvement required were developed, as well as sensor and their fastening accessories constructions, implementing minimal cost diagnostic strategy - MCDS™ in case of acceptable recognition error.
DYNAMICS SPC Foundation, the stationary vibration monitoring systems COMPACS® and Management Directive
Due to successful implementation of first stationary computer monitoring systems on 11 of June, 1991, "Diagnostics, machinery reliability and complex automation" Scientific and Production Center - DYNAMICS SPC was founded in Omsk.
From 1991 to 1994 10 units in Omsk Refinery were equipped with first computer pump-and-compressor unit state monitoring with in-built automatic expert system – the COMPACS® Computer Monitoring System for Accidents Prevention and Machinery State Control.
The system implementation was accompanied with creation of strong regulatory and methodological base, which foundation was a Management Directive "Centrifugal electric-driven pumps and compressor units, equipped with the computer monitoring systems for accidents prevention and state control COMPACS®. Vibration operational regulations" approved by Ministry of Fuel and Energy and State Technical & Mining Inspectorate of Russian Federation in 1994.
In this document for the first time in the world not only vibration velocity and vibration displacement were regulated for different units, but also a vibration acceleration and vibration parameter growth. And the most important fact is that this document allowed condition-monitored operation of the equipment and PPR in case of COMPACS® systems implementation.
February, 1994, the COMPACS® Computer Monitoring System for Accidents Prevention and State Control was accepted by Ministry of Fuel and Energy and State Technical & Mining Inspectorate commission of Russian Federation and recommended for wide implementation. Sensors, modules and systems in complex with software were certificated and accepted by Ministry of Fuel and Energy oil-refining department commission, together with State Technical & Mining Inspectorate. The COMPACS® systems were certified by Gosstandart, included in public register of measuring means and permitted to be used in territory of Russia by State Technical & Mining Inspectorate of Russian Federation.
In 1995 massive implementation of systems in Russian enterprises has started. Before 1998 systems were successfully implemented in Angarsk petrochemical company, Tobolsk petrochemical company, Volgograd petrochemical company, Achinsk petrochemical company, Slavneft-Yaroslavsky Refinery.
The first equipment health monitoring systems COMPACS®
1993-1994 development and implementation of the first computer pump-and-compressor units monitoring system with in-built automatic expert unit state evaluation system COMPACS®.
1994 The COMPACS®-RPE stand system for vibration, temperature and current diagnostics of electric motors state.
1994 The COMPACS®-REB stand system for electric motor rotor balancing — automatic size and position of electric motor rotor disbalance assessment at one launch.
1994 The COMPACS®-RPM system for diagnostics and dynamic balancing of cradle-mounted pump rotors.
1994 The COMPACS®-RPP stand system for rolling bearings vibration analysis.
1994 The first Compacs-Net® enterprise diagnostic network with telephone and commute channels on eight factories of Omsk Refinery.
1995 The Compacs®-Micro personal system for automatic vibration analysis on the basis of microcomputer for diagnostics of units which are not connected to stationary systems .
1996 In locomotive depot Moskovka of West-Siberian railway in schedule-based repair shop TR-1 was implemented the bench-test system for automatic diagnostics of wheel-motor electric train units COMPACS®-EXPRESS.
Institute of Radio electronics, Service and Diagnostics – NEI IRESD (Nongovernmental Educational Institution)
In 1997 DYNAMICS SPC together with colleagues established a nongovernmental educational institution (NEI) the "Institute of Radio electronics, Service and Diagnostics – IRESD", for non-destructive control specialists training.
In November 2002 it received a certificate on governmental accreditation of higher education institute from Federal Service for Supervision in the Sphere of Education and Science and in 2005 the certificate was confirmed.
In 2007 full-time and distant post-graduate course was established in NEI IRESD.
Creation of the ACS SMSRTM™ COMPACS®
In 1997 the technology and the Automated Control Systems for Safe-Money-Saving Real-Time Maintenance of equipment (The ACS SMSRTM™ COMPACS®), which unite stationary health monitoring systems, stand systems of units and assemblies quality control, the Compacs®-Micro personal systems for automatic vibration analysis into the one diagnostic network Compacs-Net®.
In 1999 the book "The Automated Control Systems for Safe-Money-Saving Real-Time Maintenance of refinery and petrochemical plants equipment (The ACS SMSRTM™ COMPACS®)" was published:
The implementation of technologies for safe money-saving real-time maintenance of complex plant units, including hundreds and thousands of machines, units and other kind of equipment, is nowadays impossible without methods and means of in-place technical diagnostics, which provide automatic evaluation and forecast of unit state and safe operation interval during their functioning in all range of working modes and factors which influence modern manufacturing.
In this monograph has been made an attempt to resume the development of the COMPACS® systems of computer monitoring and diagnostics of machinery equipment for the first 10 years of DYNAMICS SPC and companies-consumers of its goods in the fields of petrochemicals and refinery.
For this years there were developed and implemented on different stages of refinery equipment operating life about a hundred of the stationary diagnostic systems COMPACS® for monitoring and forecasting of unit and machinery technical state, based on vibration acoustic method of non-destructive control, which provided accidents and production failure prevention and rapidly decreased number of unit downtimes caused by such reasons. The quality of unit and assembly repairs had a substantial growth, due to the implementation of diagnostic systems, providing repair quality control on the enterprise.
Russian Federation Government Award
In 1998 for the paper "Stationary systems of machine equipment safe operation continuous monitoring of potentially dangerous productions of chemical, petrochemical and oil and gas processing industry" and widespread introduction of the stationary monitoring and vibration analysis systems COMPACS® the following group of authors was awarded with the Russian Federation Government Award in Science and Engineering: Malov E.A. (State mining inspection of the Russian Federation), Bronfin I.B. Dolgopyatov V.N. (Omsk Refinery), employees of DYNAMICS SPC – Kostyukov V.N., Boychenko S.N., Meling A.Y., Tarasov E.V., Pavlenko B.A.
Formation and development of Russian monitoring school
Vladimir Nikolaevich Kostyukov - Chairman of the board of directors of DYNAMICS SPC, Doctor of Technical Science, Professor, Russian Federation Government Award-winner, 3-level specialist in vibration analysis, acoustic emission, visual control and control by measurement.
He is an author of more than 340 papers and inventions in the field of technical diagnostics and health monitoring of equipment and processes.
On 26 of April, 2001 he successfully defended a doctor thesis entitled "Development of the theory, technology and monitoring system equipment for units of petrochemical complex" in Bauman’s Moscow State University.
Solution of the country’s energy supply is closely connected with safe operation of equipment unit of petrochemical continuous production and, first of all, petrochemical complexes (PCC). High concentration of machinery units in PCC: pumps, compressors, air-coolers, smoke exhausters, etc. with single powers vary from dozens of kWt to a few MWt, hidden nature of malfunction appearance and development, poor observability of unit defects, which can lead to sudden failures – often were reasons of production malfunctions and emergencies followed by big financial losses and environmental pollutions.
Recently, State Technical & Mining Inspectorate of Russia began to increase the supervision on the equipment state using modern methods and automatic means of monitoring, adequately reflecting high speed rates of all the processes in the “supervision-control-stability-supervision” loop.
That requires the development of new approaches to the creation of automatic diagnostics and monitoring systems (DMS), providing minimal cost of automatic diagnostics, delivery and issue of diagnostic prescriptions on the unit state control to the personnel and execution control. The existing regulatory system and vibration operational standards do not correspond to automatic DMS requirements and do not provide safe petro-chemical unit operation. The technology of usage of automatic SDM as stationary industrial system also requires further developments.
Therefore, completing such an important national economic task – to provide safe money-saving operation of machinery units and continuous productions, raises a problem of developing of theory, technology and equipment of real-time monitoring systems for petrochemical complex unit, considering human factor.
He is an author of more than 100 papers in the field of technical diagnostics and condition monitoring of machinery.
In 2007 he defended a thesis, entitled "The organizational and economic mechanism of equipment operation management (on the example of the oil processing enterprises".
Alexey Vladimirovich Kostyukov
First Deputy Director General - Technical Director, member of the board of directors, head of metrological service, head of Independent Organization of Personnel Certification, Candidate of Technical Sciences, the specialist of the III-rd level in vibration analysis, acoustic emission, visual and measuring control.
He is an author of more than 120 papers in the field of machinery condition monitoring.
In 2006 he defended a thesis, entitled "Control and monitoring of centrifugal pump unit by means of vibration parameter trends".
Boychenko Sergey Nikolaevich
Deputy Director general on Science Issues of DYNAMICS SPC, Candidate of Technical Science, Russian Federation Government prize-winner, 3-level specialist in vibration analysis, acoustic emission, visual control and control by measurement.
He is an author of more than 80 papers in the field of machinery condition monitoring.
In 2006 he defended a thesis, entitled "Centrifugal pump-unit state control and monitoring of technical state by means of vibration spectral features".
Scientific-methodical and normative-technical provision of real-time equipment state monitoring
Kostyukov V.N., The Automated Control Systems for Safe-Money-Saving Real-Time Maintenance of refinery and petrochemical plants equipment (The ACS SMSRTM™ COMPACS®)" (monograph) / V.N. Kostyukov, S.N. Boychenko, Al.V. Kostyukov. - Moscow: Mashinostroenie, 1999. - 163 p.
Kostyukov V.N., Increase of operational efficiency of the enterprise on the basis of real-time monitoring (monograph) / V.N. Kostyukov, An.V. Kostyukov. - Moscow: Mashinostroenie, 2009. - 192 p.
Kostyukov V.N., Fundamentals of machinery vibroacoustic analysis and monitoring: tutorial / V.N. Kostyukov, A. P. Naumenko. - Omsk: OmSTU, 2011. - 360 p.
Kostyukov V.N., Fundamentals of machinery vibroacoustic analysis and monitoring: tutorial / V.N. Kostyukov, A. P. Naumenko; Ministry of Education and Science of Russian Federation, Omsk State Technical University; DYNAMICS SPC. — 2nd edit., with amendments. — Novosibirsk: SB RAS publishing, 2014, 378 p.
SА-03-001-05. Centrifugal pump and compressor units in hazardous industrial facilities. Operating standards for vibration / V.N. Kostyukov (and others), DYNAMICS SPC, Rostechexpertise, approved by the Federal Service of Ecological, Technical and Nuclear Supervision of the Russian Federation, a letter from the 1st of February. - Moscow: Compressor and Chemical Equipment Publishing, 2005. - 24 p. (Series 03. Regulative documents of intersectoral application concerning industrial safety and protection of a subsoil).
SA 03-002-05. Systems for monitoring of units on hazardous production sites. General technical requirements / V.N. Kostyukov (and others), DYNAMICS SPC, Rostechexpertise, approved by the Federal Service of Ecological, Technical and Nuclear Supervision of the Russian Federation, a letter from the 1st of February. - Moscow: Compressor and Chemical Equipment Publishing, 2005. - 42 p. (Series 03. Regulative documents of intersectoral application concerning industrial safety and protection of a subsoil).
STO 03-002-08. Monitoring of hazardous production facilities. Management procedures / V.N. Kostyukov (and others), DYNAMICS SPC. - Moscow: Scientific-and-Industrial Union "RISCOM", 2008. - 37 p. (Series 03. Regulative documents of intersectoral application concerning industrial safety and protection of a subsoil).
STO 03-003-08. Monitoring of hazardous production facilities. Terms and definitions / V.N. Kostyukov(and others), DYNAMICS SPC. - Moscow: Scientific-and-Industrial Union "RISCOM", 2008. - 24 p. - (Series 03. Regulative documents of intersectoral application concerning industrial safety and protection of a subsoil).
STO 03-004-08. Monitoring of hazardous production facilities. Application procedures / V.N. Kostyukov (and others), DYNAMICS SPC. - Moscow: Scientific-and-Industrial Union "RISCOM", 2008. - 14 p. - (Series 03. Regulative documents of intersectoral application concerning industrial safety and protection of a subsoil).
GOST R 53563-2009. Condition monitoring and diagnostics of machines. Monitoring the condition of the equipment hazardous. Order organization. - Introduced on 01/01/2011. - Moscow: "Standardinform", 2010. – 5 p.
GOST R 53564-2009. Condition monitoring and diagnostics of machines. Monitoring the condition of the equipment hazardous. Requirements for monitoring. - Introduced on 01/01/2011. - Moscow: "Standardinform", 2010. – 20 p.
GOST R 53565-2009. Condition monitoring and diagnostics of machines. Monitoring the condition of the equipment hazardous. Vibration centrifugal pump and compressor units. - Introduced on 01/01/2011. - Moscow: "Standardinform", 2010. – 8 p.
STO 03-007-11. Stationary piston compressor units of hazardous production facilities. Vibration operation regulations / V.N. Kostyukov, A. P. Naumenko; DYNAMICS SPC, Scientific-and-Industrial Union "RISCOM". – Moscow: Compressor and Chemical Equipment Publishing, 2012. – 18 p. - (Series 03. Regulative documents of intersectoral application concerning industrial safety and protection of a subsoil).
STO 03-001-12. Piston compressors of the oil processing, petrochemical and chemical companies. Operation, technical supervision, audit, rejection and repair / V. N. Kostyukov, A. P. Naumenko [and oth.]; VNIKTIneftekhimoborudovaniye. – Volgograd, 2013. – 242 p.
GOST 32106-2013. Condition monitoring and diagnostics of machines. Hazardous equipment monitoring. Vibration generated by rotodynamic pump and compressor units. - Introduced on 01.11.2014. - Moscow: "Standardinform", 2014. - 8 p.
GOST R 56233-2014. Condition monitoring and diagnostics of machines. Hazardous equipment monitoring. Vibration generated by land-based reciprocating compressors. - Introduced on 01.12.2015. - Moscow: "Standardinform", 2015. - 20 p.
Quality management system certification
Voluntary certification of DYNAMICS SPC quality management system has been carried out in 2001, in order to prove its compliance with the requirements of international standard ISO 9001:1994, which confirmed high level of products and services quality management.
In 2004, 2007, 2010, 2013, 2016 and 2018 the DYNAMICS SPC recertified the quality management system to meet the requirements of international standard ISO 9001 in GOST R certification system, considering designing, development, production, mounting and maintenance:
automatic systems of monitoring, diagnostics, and equipment safe money-saving operation control;
testing equipment for metrological maintenance of production and operation of diagnostic systems and equipment;
industrial security expertise according the accreditation area;
personnel qualifying evaluation according to the accreditation field.
Resolution of the Russian State Technical & Mining Inspectorate Commission considering possibility and reasonability of the COMPACS® systems application
In 2003 the system of a complex real-time state monitoring of machinery and static equipment, as well as comprehensive systems of continuous and periodic monitoring of petrochemical complexes on the basis of the automatic safe money-saving control systems COMPACS® had passed аn all-round tests and had been accepted by Russian State Technical & Mining Inspectorate Commission. The commission recommended wide implementation of the COMPACS® systems on petrochemical and oil-refining enterprises across the country. Particularly, the conclusion states:
1. The implementation of the system for comprehensive petrochemical complex equipment state monitoring COMPACS® provides rapid decrease of sudden failures of all the unit equipment diagnosed and increases its safety by means of timely twenty-four-hour notification of personnel on the place, time and reasons of failures.
2. High reliability, low cost and simple operation of the system mark it out from its foreign counterparts.
3. Wide implementation of the systems for comprehensive petrochemical complex equipment state monitoring COMPACS® on Russian enterprises will allow condition-monitored operation and repair of both pump-and-compressor and process equipment, giving bigger economic and ecologic effect, which, according to the commission is necessary.
4. The commission recommends:
1) design organization making projects of reconstruction and building of process units and enterprises to add to the projects usage of real-time comprehensive machinery and process equipment state monitoring systems;
2) chemical, petrochemical and oil-refining enterprises to equip operating, reconstructing and commissioning powers with systems mentioned;
3) developer and producer of comprehensive monitoring systems - DYNAMICS SPC - in joint with institutions interested to prepare a regulative document for determination of stated requirements implementation order and recommendations on the enterprises controlled by the Russian State Technical & Mining Inspectorate.
The world's first standards in the field of state monitoring
In April, 2006, a council of experts in normative-technical documentation from Scientific-and-Industrial Union "RISCOM", examined standards of Association of Russian Technical Expertise "Systems for monitoring of units on hazardous production sites. General technical requirements" and "Centrifugal pump and compressor units in hazardous industrial facilities. Operating standards for vibration", recommended them for their adoption as standards of Scientific-and-Industrial Union "RISCOM".
In autumn 2007, continuing the development of monitoring methodology, specialists of DYNAMICS SPC and SIU "RISCOM" developed and in winter 2008 approved as standards of Scientific-and-Industrial Union "RISCOM" the following standards:
Monitoring of hazardous production facilities. Terms and definitions (STO 03-003-08);
Monitoring of hazardous production facilities. Management procedures (STO 03-002-08);
Monitoring of hazardous production facilities. Application procedures (STO 03-004-08).
Standards GOST R 53563-2009, GOST R 53564-2009, GOST R 53565-2009
In 2008 and 2009 initiative work on promotion state monitoring metrology to the national level has been continued. The result of this work is adoption on 15th of December 2009(by the order of Federal Agency on Technical Regulating and Metrology) and implementation on first of January 2011 of the following standards:
GOST R 53563-2009: Condition monitoring and diagnostics of machines. Hazardous equipment monitoring. Organizational procedures.
Standard is aimed at drawing up the rules and procedures of development, implementation and operation of comprehensive monitoring systems and providing of safe and reliable money-saving operation of hazardous production facilities, as well as to determine the main logistical principles of construction and realization of comprehensive monitoring systems, categories of equipment, liable to monitoring, including risk analysis matrix, equipment state evaluation, monitoring system types, equipment safety monitoring service requirements.
On the basis of this and other standards from the "Monitoring the condition of the equipment hazardous" series, an owner of hazardous equipment can develop enterprise regulations for state monitoring implementation, considering the work specification and design features of the equipment, allowing to switch over to equipment condition-monitored operation.
GOST R 53564-2009: Condition monitoring and diagnostics of machines. Hazardous equipment monitoring. Requirements for monitoring systems.
The standard establishes a classification and general technical requirements to the comprehensive monitoring systems, designed for the hazardous equipment state estimation and resources forecasting, in real time scale and without shutdowns, disassembling or decommissioning.
The standard determines equipment hazard rating and establish the requirements for usage of precise state monitoring systems for precise equipment types. The document also describes system design principles, requirements for sensors and equipment checkability, requirements for personnel, including requirements for the database, metrological and designing requirements.
GOST R 53565-2009: Condition monitoring and diagnostics of machines. Hazardous equipment monitoring. Vibration generated by rotodynamic pump and compressor units.
The standard spreads on centrifugal and screw pump and compressor units with electric motor and/or steam turbine drive units with reducers or multipliers, as well as fans, smoke exhausters, air blowers and air-cooling devices with capacity more than 2 kW and basic rotation frequency from 120 to 15000 min-1 and establishes management of vibration state evaluation during operation and commissioning tests. The standard is designed for usage in joint with GOST ISO 10816-3.
The document also contains the general requirement to machinery unit monitoring systems, sensor mounting conditions, standardized parameters, unit state evaluation criteria. In the standard for the first time in the world the basic vibration parameters values were mentioned in the part of joint usage of velocity, speed and motion parameters and speed rates of their changes for hazardous production facilities vibration state evaluation.
Standards are developed by DYNAMICS SPC together with Scientific-and-Industrial Union "Risk Management, Industrial Safety, Control and Monitoring" (RISCOM), Association of experts in hazardous anthropogenic objects (Rostechexpertise), Association of Russian petroleum processors and petrochemical industry workers ("АPP"), Non-profit organization "Research-and-development center of engineering systems" (NPO "RDC CD").
SТО 03-007-11 and SТО 03-001-12 standards
In 2011 and 2013 DYNAMICS SPC group of authors took part in development of SIU "RISKOM" and "VNIKTINeftekhimoborudovanie", JSC standards:
Standard SТО 03-007-11: Condition monitoring of hazardous production facilities. Stationary piston compressor units of hazardous production: operating vibration standards
Standard is developed on the basis of Russian State Technical & Mining Inspectorate Commission Conclusion considering commissioning tests of hazardous production facilities comprehensive monitoring systems. The commission was created according to the Direction № Р-20, of State Technical & Mining Inspectorate Chief Deputy from 02 of December, 2003, which contains long-term experience of creation and implementation of comprehensive machinery and technological equipment real-time state monitoring systems of hazardous plants of different industries.
It is recommended to be used in expert, engineering organizations and industrial enterprises as a manual for choosing and implementing of the vibration parameters system for state monitoring of piston compressor units aimed at anthropogenic accident prevention and providing safe money-saving condition-monitored equipment operation.
Standard SТО 03-001-12: Piston compressors of the oil processing, petrochemical and chemical companies. Operation, technical supervision, audit, rejection and repair
The standard reveals the requirements of safe operation of piston compressors, methods, volumes and time of revision of their details and assemblies, criteria of penalization due to wear, defects, vibration condition, operation life end, shows the data on quality assessment of the repair conducted and technical documentation created.
The standard is made for the specialists in operation, revision, repair and technical diagnostics of piston compressors. The standard is developed in replacement for "The main specifications of piston compressors repair", 1985.
Standards GOST 32106-2013 and GOST R 56233-2014
In 2013 and 2014 the following standards were developed and approved with the assistance of DYNAMICS SPC:
GOST 32106-2013. Condition monitoring and diagnostics of machines. Hazardous equipment monitoring. Vibration generated by rotodynamic pump and compressor units.
The standard applies to rotodynamic and screw pump and compressor units, driven by electric motors and/or steam turbines with gearboxes or multipliers, as well as to fans, exhausters, blowers and air cooling units with a capacity of more than 2 kW and a nominal rotation frequency from 120 to 15000 min-1 and sets guidance on assessment of their vibration state during operation and acceptance tests after mounting and repair.
This Standard is intended for usage in conjunction with GOST ISO 10816-3. This standard complements GOST ISO 10816-3 with regard to joint use of acceleration, velocity, displacement parameters as well as rates of their changes for assessment of the hazardous equipment vibration state.
GOST R 56233-2014. Condition monitoring and diagnostics of machines. Hazardous equipment monitoring. Vibration generated by land-based reciprocating compressors.
The standard applies to the stationary piston compressors for Т2-Т6 explosive gas groups according to the classification  as well as for the stationary piston compressors using the harmful gases, 1–2 class of hazard according to GOST 12.1.007. Also, the standard sets guidance on the assessment of their vibration state during operation and acceptance tests after mounting and repair.
The standard does not apply to refrigerating and oxygen compressors, to the compressors that used to handle the radioactive gases and gases of an acetylene series as well as to the gas-engine compressors.
In accordance with the standard recommendations, the assessment of the equipment vibration state is based on the joint measurements of the displacement, velocity and acceleration of the unit casing as well as compressor mechanism or the compressor case in the direction of the vibration vector maximum.
The vibration measurements in the range from 2 to 3000 Hz are used for an assessment of the vibration state. For the in-depth study to find out the fault condition or the diagnostics, the carrying out of the vibration measurement in the range up to 10000 Hz and higher is recommended.
The standard's requirements may be used in conjunction with recommendation for assessments of vibration state of the general-purpose stationary piston compressors, including the assessment of the monitored vibration parameter value changes criteria.
The developing and wide implementation of the COMPACS® systems
In the end of 20th century the COMPACS® systems came out of the boarders of oil-processing, oil-producing and petrochemical industries of national economy and successfully implemented in mining and metallurgical sectors, municipal engineering, mechanical engineering and railway transport. Beside the usual customers from oil and gas industry: Gasprom, Gaspromneft, Sibur, Lukoil, Rosneft, TNK-BP, refineries from Ukraine and Kazakhstan, the systems began actively implemented at Russian Railways; in mining-and-ore industry at Silvinit, Uralkali, OJSC "ALROSA" enterprises; in metallurgical sector – at Vyksa Steel Works, OJSC "Magnitogorsk Iron and Steel Works"; in the port industries – at "RPK Vysotsk LUKOIL-II"; in mechanical engineering – at OJSC "K. Marx’" PEMZ (Ukraine), EPK (Samara), "Volgogradneftemash" JSC; in power industry – at Reftynsk District Power Plant (Sverdlovsk Oblast).
Since 2003 began the implementation of the system for columnar-capacitive equipment state monitoring COMPACS®-AE.
In 2005 the first export contract considering the COMPACS® systems shipment to Bulgaria was signed, since that time we annually supply systems, carry out maintenance works and services at near and far abroad. More than 12 branches of national economy successfully uses developed and implemented systems and methods of safe money-saving operation of equipment and processes.
Development of the COMPACS®-EXPRESS-TR3 comprehensive system for diagnostics of EMU-trains sections
In 2005 the comprehensive system for diagnostics of EMU-trains sections COMPACS®-EXPRESS-TR3 was for the first time implemented at the Ramenskoye depot of Moscow Railways.
The COMPACS®-EXPRESS-TR3 system is designed for an efficient comprehensive evaluation of the state and repair quality of sections of electric multiple unit trains ER2, ER2R, ER2Т, ED4, ED4М(К), EM2, EM4 with operating repair ТR-3.
The system configures depending on the types of trains, repaired in a depot. The system includes seven sub-systems:
sub-system for wheel-motor unit vibration analysis;
for automatic evaluation of break equipment state evaluation;
for control circuit diagnostics;
for auxiliary circuit diagnostics;
for power circuit diagnostics;
for electric circuit isolation state diagnostics;
for pantograph power and time characteristic diagnostics in operating altitude range with lifts and drops.
The development of the On-board system for electric multiple-unit trains equipment health monitoring COMPACS®-EXPRESS-3
In 2007-2010 the on-board electric multiple-unit train equipment real-time condition monitoring system COMPACS®-EXPRESS-3 has been developed and implemented at the Moscow Railways.
The COMPACS®-EXPRESS-3 system is designed for health monitoring of EMU-train (wheel-motor unit and axle equipment, compressed-air braking system, electric circuits, etc.) during operation with transmission of the data on train condition both to the driver cabin and to the Compacs-Net® diagnostic network for quick preparation for purposeful condition-monitored repair and maintenance of electric trains.
The on-board electric multiple-unit train equipment real-time condition monitoring system COMPACS®-EXPRESS-3 allows timely detection of electric and mechanic malfunction initiation and development, including malfunctions of wheel-motor units and trailer wheelsets, pneumatic equipment, electric units, supplementary machinery and traction electric engines.
The system carries out real-time EMU-train condition parameter measurements, as well as automatic analysis and issues data on malfunctions detected on a on-board computer display, located in a driver’s cabin.
Development of the ACS SMSRTM™ EMU COMPACS®
In 2012 the ACS SMSRTM™ EMU COMPACS® - the Automated Control Systems for Safe-Money-Saving Real-Time Maintenance of Electric Multiple Units Equipment (EMU) has been developed and for the first time implemented at the Moscow and Oktyabrskaya Railroads.
The ACS SMSRTM™ EMU COMPACS® includes the Compacs-Net® diagnostic network, which contains all data on the train equipment condition gathered from the on-board monitoring system COMPACS®-EXPRESS-3, the COMPACS®-EXPRESS-TR3 comprehensive system for diagnostics of electric sections, the COMPACS®-EXPRESS systems for repair quality diagnostics of wheel-motor units and EMU-train units and the COMPACS®-Agregat system.
The automatic diagnostics and monitoring of EMU-train condition in general, as well as its electric sections ready-fitted and all the equipment included allows to observe MDRS technical readiness and implementation practice of the personnel in real time, and, consequently, control MDRS operation during the operating life.
The EMU-train operation technology, realized in the ACS SMSRTM™ EMU COMPACS® provides considerable decrease of expenses and losses, due to timely and purposeful maintenance and MDRS equipment repair during the operating life by means of real-time health monitoring.
Implementation of the COMPACS® systems in mechanical engineering
Since 2012 the unique systems COMPACS®-RPP-AE and the COMPACS®-RPG has been implemented at the leading enterprises.
The COMPACS®-RPP-AE system for vibration analysis of rolling bearing
The COMPACS®-RPP-AE system is a modification of the computer monitoring system COMPACS® and serves for objective evaluation of technical state of rolling bearings and detection of defects, influencing their recourse according to the vibration and acoustic emission parameters.
Bearing condition is evaluated in 4 frequency diapasons considering the results of digital processing of acoustic emission sensors signal and issuing on the display in the form of colored pictograms and numerical values of vibration and acoustic emission parameters. The system meet the requirements of GOST 520-2002, GOST 52545.1-2006, ISO 15242-1:2004.
The COMPACS®-RPP-AE system advantages:
internal defect origin diagnostic on acoustic emission parameters;
wider measurement range of RMS vibration parameters (vibration acceleration: 0,03-500 m/s2; velocity: 0,01-50 mm/s);
lower level of drive noises;
bearings diagnostics can be done in all the vibration categories: Sh-Sh9;
wider diapason of spindle rotation frequency: 30-3000 rev/min;
wider diapason of loadings: 0-2000 N;
system kitting with extra sensors of temperature, vibration, acoustic emission and motion;
temperature and drive assemblies vibration control;
usage of high-precision assemblies and special equipment.
The COMPACS®-RPG: System of hydraulic testing control and pump units diagnostics
The COMPACS®-RPG system is a modification of the COMPACS® computer monitoring system and designed for hydraulic testing control and pump units diagnostics during operation, production and/or after repair and testing of the parameter correspondence between pump units and regulatory documentation.
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 bearing temperature, bearing body vibration, temperature and liquid level in the tank, temperature and useful current of the vacuum pump, consumption current, power consumption, line voltage and frequency, supply and head pressure. During the test, the force-feed, energy, cavitation and vibration features of a pump unit are automatically calculated.
The COMPACS®-RPG system advantages:
high efficiency: two computers are used;
control of three test areas is carried out both automatically and manually;
the system diagnoses a big range of pumps (with engine capacity from 4 to 400 kW) with the same sensors having the extended measure rating (without reinstallation);
the system measuring part meets the 1st class requirements of the GOST 6134-2007 "Rotodynamic pumps. Testing methods";
all the measuring means possess verification certificates;
implementation of vibration diagnostic, heat, electric, parametric and other non-destructive control methods;
automatic shutdown of pump units in case of malfunction found in the unit or stand itself;
objective test data issuing in order to control the quality of the produced goods.
The Compacs®-micro™ personal system for automatic vibration analysis
In 2015, a new personal system for automatic vibration analysis Compacs®-micro™ with a vibration analyzer 8710 was developed.
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®-AE static equipment monitoring system
In 2015, a new COMPACS®-AE system was developed. It is a part of the COMPACS® comprehensive computer monitoring system, which can be used separately and developed for the continuous monitoring and health evaluation of hazardous production facilities, such as coke drums, reactors, pipelines and other static equipment without decommissioning. The monitoring is carried out by vibration parameters, acoustic emission (AE), temperature, pressure, mode of deformation and other states, revealing crack formation and deviation in technological process.
The system allows to control condition in the technological mode, identify the presence, location and acoustic emission sources category. The system visualizes health of the column-capacitive equipment and pipelines on the display by location areas. In case of the defect occurrence and development, the system indicates its location, type, grow rates and the hazardous level. The personnel has an opportunity to take timely actions, plan repairs and prevent accidents. There is no need to examine the whole vessel or pipeline surface during the repair, it is enough to examine the places, indicated by the system.
DYNAMICS SPC today
In July 2015 the DYNAMICS SPC board of directors was created. Vladimir Kostyukov was assigned its chairman. The position of the Director General was appointed Andrey Kostyukov, and the position of the First Deputy - Technical Director was appointed Alexey Kostyukov.
In July 2017 the Chairman of the Board of directors of DYNAMICS SPC, Scientific Adviser - Chief Designer, Russian Federation Government Award-winner, full member of the Russian Engineering Academy, member of the International Academy of Social Sciences, Doctor of Technical Science, Professor, Hero of Labour, Vladimir Nikolaevich Kostyukov has passed away in the age of 67.
During the 46 years of work in the field of vibration acoustic analysis and monitoring, 760 automated diagnostic complexes, systems and devices were implemented in different spheres of national economy. This equipment provides an efficient evaluation of the condition on different levels of equipment operation life - during the development and finishing of the construction, as well as pilot production, serial production and operation. Novelty of technical solutions is proved by more than 130 patents of the Russian Federation and copyright certificates for inventions, industrial samples and useful models, certificates on official registration of the computer programs and trademarks, including the international patents for industrial samples.
Scientific activity under the leadership of the Chairman of the board of directors of DYNAMICS SPC Vladimir Nikolaevich Kostyukov - the winner of the Russian Federation Government Award, the Doctor of Technical Sciences, professor - is conducted by doctors and candidates of science, highly qualified engineers, graduate students and students. For these years two doctor's and five master's theses has been prepared and defended, there are some more dissertation works are preparing. Annually, the fund of intellectual property and publications steadily grows and replenishes. There is global and continuous process of the applied researches and development.
In spite of the irreparable loss among the DYNAMICS SPC staff, created due to hard work of its founder - Vladimir Nikolaevich Kostyukov - the school of monitoring and diagnostic sciences continues to perform activities on rising Russian authority in highly technologically developed and innovative country. Students of the school are company's core scientific and engineering potentials and by adopting the 25 years of successful experience, they look forward to developing the Technology of safe resource-saving operation of machinery of hazardous production facilities.
Today DYNAMICS SPC is firmly established, and occupies the position of one of the world science and practice leaders in the field of development, production and implementation of comprehensive systems for the equipment health monitoring. The COMPACS® systems provide safe money-saving operation of hundreds productions, carrying out real-time health monitoring of more than 25700 units of more than 2450 types of various equipment. Total annual economic effect from implementation of all the COMPACS® systems in Russia and abroad exceeds 10 billion rubles, and calculation of the net present value (NPV) of investments into our systems shows that cumulative economy from reduction of expenses and losses of a national economy counts more than 200 billion rubles!
The most important priority for our enterprise is possibility of unlimited professional growth of the employees provided with continuous scientific researches in various branches of knowledge, development of new types of production, program and technical means on the basis of the last scientific achievements proved by practice. In our organization the paramount attention was always paid to development of the human capital. We stand on the principles of the growth of our employees’ mental and creative skills.
The fundamental principle of social policy of the Center is positive and constructive reaction of all the personnel to environmental changes which is provided with continuous training, study and professional development of all the employees without exception and the majority of our partners, and also with an objective evaluation of a contribution into the common business made by each person on ensuring economically effective money-saving safety and productivity of industrial productions on the basis of real-time health monitoring. It is possible to claim unambiguously that the staff of the Center is the one team, which motto is:
"Through reliability and quality to money-saving safety, effective production and prosperous society!"