Rotating Equipment Monitoring and Failure Prediction
The Real-Time Diagnostic COMPACS® System
Book a MeetingThe COMPACS system detects almost all defects in rotating equipment with an accuracy of over 97%. After defect detection, the system issues prescriptions on what should be done to prevent failure and extend equipment lifespan.
The Monitor Mode – Equipment State At Your Fingerprints
The Monitor Mode provides valuable insights into the equipment state. The user-friendly interface displays diagnostic signs, machine health indicators, predicted residual lifespan, machine running hours, and start time. The main feature of the Monitor Mode is precise and accurate predictive analytics prescriptions. Learn more about the Monitor Mode
Preventing Failures
The machinery monitoring system provides the operator with guidance on how to prevent not only failure but even redundant maintenance. It issues prescriptions in a human language (e.g. Check Bearing, Check Lubrication, etc.), so the operator doesn’t have to be an expert in signal analysis.
The best way to use the system is to locate it in the Control Room because operators are available 24/7. Once the system issues a prescription, the operator can act immediately. The maintenance team and management also have access to this information.
Types of Rotating Equipment the COMPACS System Monitors
The system is capable of monitoring any type of rotating equipment, especially in oil and gas, petrochemical, and mining industries.
Here are a few examples of machinery that the system can monitor in real-time.
A Blower
A Fin Fan
A Centrifugal Compressor
A Reciprocating Compressor
A Gear Box
A Pump
Defects The System Detects at the Earliest Stage
Here is the list of defects that the system identifies in real-time at the emergence before they degrade the equipment
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
TEMPERATURE
- overheating
- uneven heating
- intolerable gradients
HYDRO-GAS-DYNAMICS
- cavitation
- hydraulic impact
- air break
MACHINE TRAIN
- shaft misalignment
- rotating mass imbalance
- lubrication problems
- loosened fastening to the base and attached structures
- gear faults
MACHINE
- fastening problems
- rotor imbalance
- impeller faults
- shaft cut
- intolerable rotor runout
- intolerable axial thrust
- coupling fault
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
CYLINDER PISTON GROUP
- ring wear
- liner wear
- part loosening
- lack of lubrication
- condensate flow-in (hydraulic impact)
- process upset
ELECTRICAL EQUIPMENT
- defects in cells, contactor, transformer, etc.
- insulator contamination
- partial discharge in insulation
- stator iron sparking
- contact sparking
- corona discharge
SLIDER-CRANK MECHANISM
- babbitt wear
- part loosening
- lack of lubrication
- increased rod-slider clearance
MAIN BEARING
- babbitt wear
- looseness
- lack of lubrication
ROD
- gland wear
- bent rod
- broken rod
MACHINE TRAIN
- loosening of body components
- rotating mass imbalance
Let’s Talk: Book a Meeting Today
Discover how real-time machinery monitoring with AI-prescriptions can enhance uptime and reduce maintenance costs.
Real-time Residual Lifespan Assessment
Utilizing physics-based AI, the system calculates equipment’s residual lifespans.
Thus, operators know not only what should be done to prevent failure but also how much time they have to take action.
Operating Modes of The COMPACS System
Analysis Mode
Analysis Mode allows SMEs to conduct comprehensive manual signal analysis and identify the root cause of defects
Trend Mode
This mode enables signal analysis experts to diagnose malfunctions, identify potential failures, and track the root causes of equipment degradation.
System Mode
This mode offers real-time self-diagnosis and ensures the system operates reliably, quickly identifying the fault node in the event of a failure
Oscilloscope Mode
Enables manual adjustment of the real-time measurements and configuration of the COMPACS system
Report Mode
Enables a variety of automatically generated and on-demand reports, allowing users to collect and share valuable data on equipment status and maintenance activities
Editing and Creating Processing Programs
The mode facilitates the creation and editing of algorithms for calculating diagnostic signs
All You Need to Know About Rotating Equipment Monitoring
System Implementation On A Turnkey Basis
Design
Manufacture
Supply
Commissioning
Training
Service
Should the customer choose to initiate cooperation through a Pilot project, our team will offer hands-on assistance for a six-month engagement period aimed at enhancing equipment state, operational reliability, and overall uptime of the Unit.
Following the successful validation of the Pilot Project outcomes, we will invite the customer to transition into a long-term system-as-a-service (SaaS) partnership that offers flexible terms of 3, 5, or 10 years, along with the full-scale deployment of our solution across the entire site.
Moreover, after the conclusion of a SaaS agreement, we will establish a dedicated support hub within or near the facility, enabling the client to access our high-standard digital diagnostics and reliability services on demand and without delay.
Ready to Reduce Downtime and Maintenance Costs by 6-8 Times?
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