DYNAMICS Scientific Production Center USA, Inc.

801 Travis St
2025
Houston,  TX  77002

United States
http://www.usadynamics.com
  • Booth: 5102

We provide Safe Resource - saving Operation and Maintenance of Machinery at Refineries and Petrochemical Facilities installing the Real-Time Diagnostic COMPACS System. The system monitors a lifespan of rotating and fixed equipment that gets Accident Free Operation, Longest Possible Uptime, Shortest Possible Turnaround, and Reasonable Maintenance Cost. To install now call +1 832 664 1700


 Press Releases

  • Safe and sustainable operation is a key factor for the profitability of every processing business, such as a petroleum refinery. The US petroleum refiners have a chance to increase their profit of at least 20% by using contemporary cutting-edge digital technology which provides safe resource-saving operation and maintenance of machinery. To be able to provide safe, reliable and effective operation, the personnel of the refinery must have precise, focused, and timely information on machinery health (“Make The Future Visible”, n.d.). By making machinery health visible, using the unbiased AI prescriptions in real-time becomes a reality, which leads to effective reliability management which dramatically reduces losses that come from: incidents and unplanned shutdowns due to machinery breakdowns, short uptime and extended turnaround outage, overestimated maintenance costs.

    Any petroleum refinery is a hazardous processing plant that constantly experiences incidents due to machinery breakdown.  According to F. Buder, CEO at Pruftechnik:

    Avoiding failures that impact production is time-sensitive and critical, and yet there were 2,200 unscheduled shutdowns in the US alone between 2009 and 2013, an average of 1.3 incidents a day, costing roughly $20 billion per year, according to Deloitte Insights. It’s no wonder that 54% of owners said their spending should be on predictive maintenance (Petrochemical Update, 2018).

    According to another trustworthy source (“HPI Market Data”, 2018a), the US refining industry comprises 135 refineries with a total capacity of approximately 18.6 million barrels of crude oil per day. Almost every incident came with a shutdown that led to refinery losses in the average amount of $36.4 million dollars ($20 billion dollars divided by 2,200 unscheduled shutdowns and divided by 4 years). Moreover, following the statistics above, an average refinery encounters around 4 incidents annually. By installing the AI system which transforms sudden defect in machinery into the gradual ones, refiners can avoid most of the incidents and corresponding losses. Even if the AI system prevents only 75% of the incidents and shutdowns, the total annual savings at one average refinery can be to $110 million dollars.

    The AI system can bring more additional value if it provides extended uptime and decreases turnaround’s outage. According to the lobby interviews during 2018 AFPM Annual meeting which was held in New Orleans, LA, it was pointed out that the average gross margin in US petroleum refining in 2017 was $17 dollars per barrel. Also, it was mentioned that an average annual availability rate of refinery uptime was revealed as 91.2%. This information means that in 2017 an average refinery lost as much as $76 million dollars (365 days in a year multiplied by the difference between 100% and 91.2% of availability rate, then multiplied by $17 gross margin per barrel, then multiplied by the average specific capacity of US refinery, 140,000 barrels a day). Knowing machinery health and eliminating destructive forces at the early stages of machinery degradation extended uptime twice and cut turnaround’s outage by 10-15 days, which totally brings over $50 million dollars of additional profit annually.

    Last but not least, the source of transparency-driven value is overestimated maintenance costs. “US refiners increased planned maintenance spending by an estimated 38.5% to $1.26 billion dollars in 2018… (“HPI Market Data”, 2018b).” This means that an average US refinery spends over $9 million dollars on the maintenance annually. It’s well-known that the later a defect is identified, the greater the costs and losses become. By using AI system and identifying defects timely, refiners can reduce the maintenance costs up to 40% (“HPI Market Data”, 2018b), which is approximately $4 million dollars annually.

    Finally, by summarizing all value sources mentioned above, the total amount of additional profit that comes from the AI system implementation at an average US refinery could be as much as $164 million dollars annually. The estimated AI system’s lifespan is at least 10 years, which allows the refinery to aspire the total net additional income in the amount of 1.6 billion dollars.

    References

    HydrocarbonProcessing.com. (2018a). HPI Market Data 2019. p.48.

    HydrocarbonProcessing.com. (2018b). HPI Market Data 2019. p.82.

    Make The Future Visible. (n.d.). Retrieved from http://www.usadynamics.com/

    Petrochemical Update. (2018, November). North American Downstream Market Outlook and Insights 2019. p.67.
  • The reliability theory has been developing almost 70 years, and all the time people attempt to find out an instance when equipment should fail to be able to prevent its breakdown. Since the middle of 50’s last century, a lot of instruments have been developed: vibration pens, portable analyzers, protection, and condition monitoring systems. Notwithstanding, even if all these instruments are in use, the probability of failure hasn’t been reducing dramatically because of several reasons. Nowadays, some AI systems promise to solve this problem, however, their developers meet either poor and insufficient data or wrong data which is almost or completely not related with a lifespan of a certain piece of equipment. As result, statistics-based algorithms don’t work relevant to the assignment, and their assessment of the probability of failure is seldom more than 50-60%. So, to be able to provide an accurate diagnosis of machinery health, the algorithms of AI should be developed on physics-based rules of degradation. Scientific researches are first, and AI is second. In this connection, there are three topics will be considered in this report: nature of errors of degradation process recognition, the system with physics-based AI, cases of facility’s operation under real-time diagnostics of machinery’s lifespan.
  • Safe Resource-saving Operation and Maintenance of Machinery

    (Andrey Kostyukov – President of DYNAMICS SPC USA, Inc.)

    Why is it called disruptive? If you implement this Technology at your refinery, several usual actions will have no further purpose, however let's be consistent... The main causes of unexpected costs and losses in downstream are well-known. There are accidents and fires caused by equipment failures, downtime of refinery units due to equipment breakdowns, and extended turnaround duration as the exact information about the damage to equipment is unknown. The maintenance expenses are significant as well because of both planned and unexpected maintenance's orders due to sudden breakdowns.

    Within the last 70 years, the reliability strategies have repeatedly changed from Preventive Maintenance (PM) to Reliability-Centered Maintenance (RCM). All of them are based on a probability assessment of the failure instance. However, the probability assessment does not include the possibility of eliminating any of the failure sources mentioned above. There are two main cases occur either with PM or RCM approach: the equipment is removed from operation before or after some critical time point.

    The total amount of expenditures due to breakdowns directly depends on early failure detection and the efficiency of personnel actions under conditions of various velocities of machinery resource's losses. Consequently, the frequency of diagnostics is the basic factor that will decrease the number of unplanned expenses and losses, as well as increase the reliability and safety of the refinery operation.

    Even if you determine and identify the failure in its early stage you also need to localize its impact on expenditures before the critical time point passes. Therefore, we have developed the Technology of Safe Resource-saving Operation and Maintenance of Machinery. Today Dynamics offers the SROMM-Technology, which significantly cuts the duration of equipment health improvement at each stage of decision making. Implementation of the SROMM-Technology means that you start using the following on a regular basis: management of the objective real-time information about machinery health, efficiency of machinery operation modes, quality and timeliness of fulfilled maintenance actions, and efficiency of root cause reliability analysis at the refinery.

    Using the real-time machinery health information, you can determine a failure, its cause, what should be done to prevent expenses, what type of actions were done or were not done, and who is or was responsible for those actions. This objective information provides the trust basis between all plant personnel, including management, reliability, maintenance, and operations staff of the refinery. It provides the possibility of moving the responsibility for your safety processes from top-management to the plant operator's level. The main advantage of the technology is that personnel become the real team because of extremely high visibility and trust in each other. Due to the elimination of asymmetric information, personnel achieves safe and reliable refining, maximum possible uptime, short as possible turnaround times, efficient maintenance costs, and significant reductions in power consumption.

    The critical element of the SROMM-Technology is the Real-Time Diagnostic COMPACS System which provides everyone at the refinery with objective information on machinery health and the nearest urgent actions required to prevent specific failures. The system considerably cuts the machinery diagnostics interval and makes its duration less than the failure development time. Using AI prescriptions makes it possible to eliminate destructive forces and prevent almost any failures without a significant cost. It provides very fast feedback to the involved personnel and management about the efficiency of the completed actions. It also provides visibility into the efficiency of every involved employee without any restrictions regarding their position in the refinery hierarchy.

    As operation staff receives AI prescriptions they must immediately initiate the nearest urgent actions to increase the lifetime of a diagnosed machine. The unit’s maintenance budget should be used in case the maintenance actions were done efficiently, according to current machinery health assessed by the COMPACS system. The same requirement should be assigned for commissioning of new or repaired equipment. When a machine is operated under "action required" or "unacceptable" states for a long time, or it has been repaired too many times, the reliability team should analyze the COMPACS system data.   They should provide the root cause reliability analysis and provide recommendations to eliminate the found causes. Our original software can be used for automatic analysis of reliability as well as mechanical readiness.

    If the prescriptions issued by the COMPACS system are fulfilled accurately and on time, you see normal charts of maintenance actions below. You can see both typical distributions of repairs which were done in the workshops, and quantity of maintenance actions which were done to machinery in operation. Usually, in six months the quantity of operational maintenance actions doubles, but at the same time, the quantity of costly repairs significantly drops. And finally, if you significantly drop the general level of all machinery vibration at the unit, according to our customers’ feedback, you achieve the considerable - not less than 7% - the reduction of total power consumption in the unit.

    To achieve these significant and valuable outcomes with the technology, we have developed unique AI algorithms for machine failure detection. We have decreased the diagnostics error rate of the COMPACS System from the usual 30-40% to an unbelievable 1%. It provides almost a total elimination of all detectable failures. It is best to select machines to be equipped with the system. Using the COMPACS-NET plant diagnostic network the information from the systems should be collected and presented to all levels of refinery management at the same time. This provides visibility of machinery health and efficiency as well as machinery operation and maintenance.

    In conclusion, the outcome of the SROMM-Technology implemented at the Aromatics Unit of Omsk Refinery, where it made a huge positive impact on the overall unit performance. According to our customers’ published testimonials, the economic benefit of the COMPACS System and the Technology of Safe Resource-Saving Operation and Maintenance of Machinery is not less than 10 US dollar per 1 US dollar of investments. The typical payback period of investment is less than 6 months, but sometimes it is less than one month.


 Products

  • The SROMM-Technology
    The Technology of Safe Resource-saving Operation and Maintenance of Machinery delivers benefits using unbiased information about machinery health, and urgent actions which are taken to prevent failures. Everyone joins a team to support reliability....

  • The SROMM technology creates trust between operators, maintenance team, and management of a refinery. It leads to the accident-free operation, the longest possible uptime, the shortest possible turnaround, and reasonable maintenance cost.

    Firstly, operators become responsible for reliability. To be able to influence on machinery lifespan, they change processing modes. They focus on timely maintenance and root cause failure analysis of equipment failures. Operators add safety, extend uptime, in other words, create additional value in operation.

    Secondly, the maintenance team receives timely information on actions that must be performed to extend a lifespan of equipment. They organize the shortest possible turnaround and achieve reasonable maintenance cost because of immediate unbiased feedback on their actions with equipment.

    Finally, management obtains unbiased information about operation and maintenance actions and supports both to fulfill urgent actions towards reliability paramount.
  • The COMPACS system for fixed equipment
    The system is designed for real-time health monitoring of fixed equipment such as coke drums, tanks, vessels, reactors, pipes, heat exchangers, etc. The system identifies crack’s begetting and its locations, stress-strain states, leakages, etc....

  • The COMPACS system has embedded artificial intelligence which collects data and analyses different parameters of vibration, acoustic emission signals, as well as temperature, pressure, stress-strain state, and other features. The purpose is to identify and to locate cracks, to detect operational deviations which lead to certain malfunctions.

    The advantages of the COMPACS system

    • Monitoring of equipment’s health during operation;
    • Monitoring any structures and materials during operation and service;
    • Monitoring all the parameters for lifespan calculation and assessment.

    Not only does the COMPACS system allow to detect and record emerging defects, but also to classify them by hazard with reducing costs. Moreover, the data from each sensor are combined into the whole, and the system gives the overall information about the equipment health. In addition, the system can use unique fiber-optic transducers that measure the surface temperature of vessels and pipelines, and X-Y axes deformation.

  • The COMPACS system for rotating equipment
    The COMPACS system has embedded artificial intelligence which analyzes vibration and uses other non-destructive testing methods to detect defects and warn personnel when the earliest stage of machinery degradation happens....

  • The COMPACS system provides real-time monitoring of machinery health. It allows creating honest and strong cooperation between management, reliability department, operation, and maintenance team. The Artificial Intelligence diagnoses and predicts almost all malfunctions and defects of compressors, pumps, coolers, motors, and gears with the probability of 97-98%. Furthermore, the system suggests prescriptions to eliminate destructive forces and to stop a defect’s development.

    The COMPACS system allows to:

    - totally eliminate accidents, fires, and breakdowns due to machinery failures.

    - eliminate unplanned downtime;

    - decrease turnaround time showing exactly where the problem is and what the problem should be solved;

    - dramatically reduce both repair’s quantity and its complexity moving from workshop repairs to onsite maintenance actions;

    - decrease the overall vibration level that reduces the energy consumption of the unit up to 7%.