Static Equipment Monitoring – Cracks and Leaks Prediction
The Real-Time Diagnostic COMPACS® System
Book a MeetingThe COMPACS® system detects and pinpoints emerging cracks and leakages with over 97% accuracy. The defect can be localized within a 10 cm × 10 cm area. Once a defect is identified, the system provides clear prescriptions on preventive actions to avoid equipment failure and extend its lifespan.
The Monitor Mode – Fixed Equipment State At Your Fingerprints
The Monitor Mode offers comprehensive insights into the state of fixed equipment through a user-friendly interface. It displays diagnostic indicators, health status, estimated residual lifespan, total operating hours, and startup time. Its key advantage lies in delivering accurate, data-driven predictive prescriptions to facilitate timely maintenance decisions based on static equipment monitoring. Learn more about the Monitor Mode
Preventing Failures In Static Equipment
The static equipment monitoring system helps to prevent not only failures but also unnecessary maintenance. It provides actionable guidance in plain language, such as “Slow Down Operation” or “Switch to Lower Mode.” Therefore, operators don’t need expertise in signal interpretation to respond effectively.
For maximum efficiency, the system is ideally located in the Control Room, where operators are available around the clock. This ensures an immediate response to any diagnostic prescription. Simultaneously, maintenance teams and management have complete access to the data for planning and oversight.
Types of Static Equipment Monitored by The COMPACS® System
The COMPACS® system efficiently monitors the state of static equipment, especially in the oil and gas, petrochemical, and mining sectors. It operates in real-time, delivering continuous diagnostics to identify early signs of defects or degradation, thus helping to ensure the safe, efficient, and uninterrupted operation of critical infrastructure.
A Pipeline
A Heat Exchanger
A Tank
A Vessel
A Regenerator
A Coke Drum
A Tower
Defects Detected at the Earliest Stage
The COMPACS® system detects defects in static equipment as soon as they begin to appear. It operates in real time and provides early warnings before issues escalate or cause damage. This helps prevent accidents and unplanned repairs. Here is the list of the defects:
CRACKING PROCESSES
passive AE source
active AE source
critically active AE source
catastrophically active AE source
catastrophic rise in pulse energy
catastrophic rise in pulse number
PROCESS MODE VIOLATIONS
unacceptable linear body strain
unacceptable rate of linear body strain
unacceptable local deformation
unacceptable rate of local deformation
overheating
unacceptable temperature drop
ACCOMPANYING DEFECTS
leak
corrosion, erosion
tube bundle contamination
Let’s Talk – Schedule a Meeting
Explore how real-time fixed equipment monitoring with AI-driven prescriptions can enhance equipment uptime, reduce maintenance costs, and increase operational reliability.
The COMPACS® System Modes Explained
Analysis Mode
Analysis Mode allows subject matter experts (SMEs) to conduct thorough manual signal analysis. It helps identify the root causes of defects by providing access to detailed diagnostic data and signal patterns, thereby supporting accurate decision-making and advanced troubleshooting.
Trend Mode
Trend Mode enables signal analysis experts to track changes in equipment state over time. It helps diagnose malfunctions, detect early signs of potential failures, and trace the root causes of gradual equipment degradation.
System Mode
System Mode provides real-time self-diagnostics to ensure the COMPACS® system operates reliably. If a malfunction occurs, it quickly identifies the faulty component, minimizing response time and system downtime.
Oscilloscope Mode
Oscilloscope Mode enables manual adjustments of real-time measurement settings and fine-tuning of the COMPACS® system’s configuration. It gives experts complete control over signal parameters during setup and diagnostics.
Report Mode
Report Mode provides access to both automatically generated and on-demand reports. It helps users collect, review, and share key data on equipment state, diagnostics, and maintenance actions for informed decision-making and documentation.
Editing and Creating Processing Programs
The mode enables users to create and modify algorithms for calculating diagnostic indicators. This allows for customization of diagnostic logic to address specific equipment monitoring needs.
Everything You Need to Know About Static Equipment Monitoring
Static Equipment Monitoring System Implementation On A Turnkey Basis
Design
Manufacture
Supply
Commissioning
Training
Service
If the customer chooses to begin with a Pilot Project, our team will provide hands-on support for six months. During this time, we focus on enhancing equipment state, boosting operational reliability, and maximizing unit uptime.
Once the Pilot Project results are successfully validated, we propose transitioning to a long-term system-as-a-service (SaaS) agreement. This partnership includes complete deployment of our solution across the site and offers flexible terms of 3, 5, or 10 years.
At the end of the SaaS term, we will establish a dedicated support center at or near the facility. This guarantees that customers have ongoing access to our advanced digital diagnostics and reliability services—quickly, locally, and on demand.
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