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Online systems are used to collect repeatable data more frequently to ensure that any developing faults are spotted on time and not missed.
Our team can assist in configuration, accelerometer installation, wireless sensors, data reduction, alarm threshold set up and parametric set up to ensure that the usefulness of such powerful tools are derived by our clients. If not set up correctly, Online systems can feel like a white elephant project.
We carry out training and knowledge transfer partnership programs to ensure that our clients’ representatives and engineers get adequate knowledge required to understand the important bits of what we do.
We discovered the primary reason a lot of programs fail is due to lack of training and understanding of how our role compliments the jobs of shop floor personnel and all other stakeholders.
Our engineers are skilled in carrying out Pump Performance tests to check if the actual performance of a Pump matches that derived by the manufacturer. Solutions are then proffered to rectify any recorded major deviations from the manufacturer’s Pump curve.
This process is used to determine the remaining plate thickness and the integrity of steel, aluminum and pipe work. Although the process itself is non-destructive, it involves contact with material surfaces.
Periodic surveys can be carried out and trends developed over time to give a reasonable scale of material degradation and how to best to resolve it.
Unbalance in rotating equipment often leads to excessive vibration, causing highly unacceptable noise, looseness, premature bearing & structure failure and catastrophic failure in service if the issue is not corrected. Our engineers use sophisticated technology to confirm imbalance and are able to carry out in-situ balancing to correct the fault.
Misalignment is one of the major contributors to machinery breakdowns and plant downtimes. This is as a result of increased forces placed on bearings, mechanical seals and internal components. Laser Alignment technique gives precision alignment of shafts to within very fine tolerances. Laser Alignment uses laser-based technology to ensure that shafts are coupled properly together along a rotational centerline.
Our engineers can perform shaft alignment of vertically and horizontally mounted machines as well as pulley alignment.
Structural-related issues and resonance can often result to high vibration and prolonged operation of machinery under these conditions leads to fatigue failure. Our specialist engineers can model a unit and proffer solutions using other FMEA tools.
Gaining access to data collection points on some machines during operation can pose safety issues, hence it is essential that such machines are hard-wired with remote accelerometers to make it easier and safer to collect data. In other cases we make use of wireless sensors (IIOT).
Our engineers are trained to hard-wire machines and terminate accelerometer cables to improve safety and maintain quality data.
For high speed turbo-machinery, it is essential to carry out transient data capture (run up and run down) and analysis during commissioning to be able to ascertain the behaviour of the entire unit and proffer applicable recommendations to any abnormal observations. For this purpose precision multi-channel digital acquisition units are used to study the rotor-dynamics of the shaft.
After machinery overhaul during planned periodic plant shutdowns and vessels visits to shipyards, some machines tend to show wide variations in their behavioural characteristics when comparing pre overhaul to post overhaul. This is as a result of various reasons including; use of incorrect spare parts, application of incorrect overhaul procedures, non-compliance to manufacturers’ guidelines; errors during assembly / re-installation; use of unsuitable grease; lack of attention to details; etc.
Our aim is to identify and rectify any faults post-overhaul. Even when issues are discovered, rectifications can sometimes be intrusive thereby leading to potential infant failures with further cost implications and inability for the equipment to meet its OEM status. Hence there is the need to institute a quality control / quality assurance technique for all machines that have undergone any form of maintenance activity. In order to mitigate these types of occurrences, it is pertinent to utilize the relevant Condition Based Maintenance (CBM) techniques to validate any maintenance work carried out in shipyard and work within the scope of assisting our clients to troubleshoot / correct any issues.
Where there is Friction, Impact or Turbulence, Ultrasound technology can be used to listen for high frequency sounds that are not heard in the audible range by human hearing. These high frequency sounds are translated into audible sounds that can be heard by the user of the instrument.
Furthermore these high frequency sounds can be displayed and viewed as decibel levels or even as a spectra. Using this information, it is possible to interpret the conditions of bearings and determine what level of corrective action is to be taken to remedy any developing situation.
We conduct both mechanical and electrical thermography using high resolution thermal imaging technology to identify faulty and overheating components in mechanical rotating components for mechanical thermography. No special requirements and preparations are necessary as this is a safe, non-intrusive technique. For electrical thermography, we follow industry standard safety procedures to identify hot spots in electrical panels and faulty electrical components. Electrical systems can be considered one of the most critical in large office buildings and industrial plants, hence it is beneficial to reduce unplanned outages and downtimes and likelihood of fire-related incidences given that electrical fires account for up to 20% of large scale fire incidents.
Thermography Survey provides an instantaneous cost effective, precise, non-contact analysis of plant & machinery condition to highlight faulty components such as bearings, motors, fuses, relays, steam pipes, drive gears & belts, generators, transformers, fuse connections, switchgear, starters, contactors and any other hardware associated to electrical systems. . The resistance or molecular friction produced within these problem areas is visible in the infrared spectrum captured during thermography surveys.
Lubrication Oil Analysis involves the in-depth analysis of oil samples from machinery to be able to reveal the condition of internal components. Oil Analysis is a useful tool in determining component wear, deterioration of internal seals, fuel dilution, contamination, ingress of dirt, etc. With Tribology, we go even further to decipher friction, wear, lubrication and contact mechanics to be able to proffer advanced solutions to issues concerning lubrication and rotating components like bearings, gear, etc.
Using Oil Analysis as a proactive CM technique makes it possible to trend results of oil samples over a given period thereby aiding in the insight into the operating condition of given machinery. We are also able to quickly detect the onset of internal component wear and plan appropriate actions accordingly.
Our Oil Analysis Tests includes but not limited to: ICP AES (Inductively Coupled Plasma, Atomic Emission Spectroscopy); Viscosity (Kinematic viscosity at 40°C and/or 100°C); PQ & FW (Ferrous Wear Index); Water; TIM (Total Insoluble Matter) (A measure of Soot and oxidation products); Dielectric; TAN (Total Acid Number); TBN (Total Base Number); Particle Size Distribution (Cleanliness of hydraulic systems).
Using Vibration Analysis, we are able to detect early problems in rotating equipment such as Electric Motors, Gearboxes, Industrial Fans & Blowers, Shaft Drives, Compressors, Pumps, Mixers, Driers, Conveyor Drives, Purifiers, Turbines, and almost any type of active rotating machinery.
Using state of the art technologies, we can easily identify faults ranging from poor lubrication, defective bearings, imbalance, misalignment, structural issues, looseness, worn out belts and gear-related problems, etc. This in turn makes it possible for you to plan and take maintenance action prior to the onset of catastrophic failures, ensuring that the uptime of your plant and production are maximized.
Our reputable engineers are well trained and certified with a strong focus on safe working practices in all the industry we currently service. We offer full range of service including; machinery criticality assessment; site visits for professional data collection & analysis; supply of data collector and accessories; periodic routine analysis & world-class reporting and root cause analysis.
By deploying tailor-made solutions that are applicable to the Maritime sector, we can assist our clients to align their Predictive Maintenance goals with specific Class requirements without any conflicts of interest.We can also ensure that vessel operators can operate their machinery safely by performing:
– Warranty and Sea Trials Surveys
– Pre Drydock Surveys
– QA/QC Post Maintenance Validation
– Machinery Life Extension Programs
– Team integration and maintenance culture change
Condition Based Maintenance (CBM), a maintenance strategy that applies Condition Monitoring (CM) techniques to monitor the actual condition of the asset to decide what maintenance needs to be done. CBM dictates that maintenance should only be performed when certain indicators show signs of decreasing performance or upcoming failure, thereby cost effectively maximizing the life of the asset.
We use non-intrusive technology to ensure scheduling and performing of maintenance is based on actual condition of the equipment and hardware and not on a “hard time” given by the OEM.
