Infrared thermography, thermal imaging, thermographic imaging or thermal video are all types of infrared imaging. Thermographic cameras detect the infrared radiation and produce images, known as thermograms, which depict variations in temperature in ferrous and non-ferrous materials. Thermal inspection is an excellent tool for checking abnormally hot or cold areas on a component, maintenance of electrical and mechanical systems, areas of corrosion thinning on plant carrying hot gas or liquid, checking for fouling or internal plugging of piping systems, checking the quality of refractory linings, leak detection, composition changes and condition monitoring of laminates and others The portable nature of this method of Non Destructive Testing allows large areas to be compared in real time. It can be used as a preventative maintenance tool to determine the onset of probable failure. It can measure and observe areas where that maybe inaccessible to other methods.
Our team members are Certified Thermographers from Infrared Training Centre, Sweden.
Perfect Test House performs onsite thermographic inspection
Recommendation for the given Thermogram: As the working Temperature is 103.5°C and the rise is above 20.0°C. Therefore, we recommend checking of Yellow wire strand and wire for a bad connection. Advantages of Thermography:
• Ability to perform inspections by keeping user out of danger when scanning electrical systems is under load
• Minimizes unscheduled downtime by detecting the faults well before failure
• Monitors tank and vessel levels from far distance • Ability to watch remote locations effectively.
Condition Monitoring- Condition monitoring (or, colloquially, CM) is the process of monitoring a parameter of condition in machinery (vibration, temperature etc.), in order to identify a significant change which is indicative of a developing fault. It is a major component of predictive maintenance. The use of condition monitoring allows maintenance to be scheduled, or other actions to be taken to prevent failure and avoid its consequences. Condition monitoring has a unique benefit in that conditions that would shorten normal lifespan can be addressed before they develop into a major failure. Condition monitoring techniques are normally used on rotating equipment and other pumps, electric motors, internal combustion engines, presses etc. while periodic inspection using non-destructive testing techniques and fit for service (FFS) evaluation are used for stationary plant equipment such as steam boilers, piping and heat exchangers. These services help in you in following way to Switch towards Predictive Mode more is the increase in Over Equipment Effectiveness (OEE%) Our Asset Life Improvement Package can give you Return On Investment as low is 15-30 days.
Key Benefits:
Machine Condition Monitoring (Level 1):
Machine condition monitoring calls for measurement of suitable vibration characteristic overall and diagnostic values, which allow the general vibration condition of the machine to be estimated. The trend development of these characteristic values points out condition deterioration, i.e. damage progression. This type of vibration measurement is characterized as ‘Level 1’. It allows monitoring of many aggregates without imposing high demands in terms of equipment and manpower.
Parameters :
Machine Condition Diagnosis (Level 2):
Characteristic overall value (Level 1) measurements, however, are insufficient for precise localization of defects, as this requires closer analysis of the machine spectrum. Most types of damage can be detected by their characteristic frequencies or typical pattern of frequencies. ‘Level 2’ vibration diagnosis normally requires measurement of vibration signals using an FFT vibration analyzer by trained personnel who are experienced in interpreting vibration spectra. We will be happy to evaluate your machine conditions.
Signal Analysis:
Compressed Air / Gas/ Steam Trap Leak Detection Surveys with cost analysis
Compressed Air Leak Survey Leaks are a significant source of wasted energy in a compressed air system, often wasting as much as 20-40% of the compressor’s output.
Power Quality Is:
ALPHACORE TECHNOLOGIES is an established Non-Destructive testing (NDT) business providing customers with inspection and reporting services. Markets covered include FMCG, aviation, power generation, oil and gas, construction, rail, motorsport, land based aero derivatives and gas, construction, rail, motorsport, land based aero derivatives and other industrial applications. ALPHACORE TECHNOLOGIES can arrange inspections including;
NDT is used in a variety of applications including:
Section 1.0 – General Description of Services:
Perfect Test House shall provide engineering services, maintenance assessment services and safety evaluation services for sites. These services shall be performed in accordance with the prescribed set of standards and criteria as described in Sections 2 through 5 of this Scope of Work. This section also specifies the required format for site reports.
Perfect Test House shall participate in the following project meetings:
Part 1.1 Project Conference Calls
Part 1.2 Site Assessment Kickoff Meeting
Part 1.3 Site Closing Meeting
Section 2.0 – Engineering Services
Perfect Test House shall provide the following Engineering Services for all Ammonia refrigeration systems on a respective Site
Part 2.1 Calculation of Ammonia Inventory
Part 2.2 Evaluation of Technical Information
Part 2.3 Future Engineering Services
Section 3 – Planned Maintenance Evaluatio.
Perfect Test House shall evaluate the existing site Planned Maintenance (PM) program for ammonia refrigeration assets against the criteria in Checklist. The site must provide documented evidence of each component PM in order to be credited.
Section 4 – Independent Mechanical Integrity (MI) Validation.
Perfect Test House shall perform a mechanical integrity validation in accordance with referenced Standard Maintenance Procedures including non-destructive testing (NDT) using non destructive measurements. Perfect Test House shall submit specific tests for performing the assessment. Perfect Test House shall perform this work within 10 working days of initial assessment.Priorities shall be set based on initial visual assessments.
Part 4.1 Piping System Assessment
Part 4.2 Vessel and HEX Assessment
Section 5 – Ammonia Refrigeration System Safety Evaluation
Perfect Test House shall perform a Safety Evaluation of each refrigeration system on site. For effort efficiency, be completed in conjunction with Section 4 Mechanical Integrity validation. Deficiencies shall be identified.
Section 6 – Project Documentation and Site Assessment Reports
Perfect Test House shall insure that the quotation, all correspondence, documentation and final reports are submitted in accordance with the following criteria:
Part 6.1 Project Schedule
Parts 6.2 Site Assessment Report
ADDITIONALLY:-
AMMONIA PPM WILL BE MEASURED IN ALL AREAS HAVING AMMONIA REFREGRATION SYSTEMS
VALUES WILL BE REPORTED ALONG WITH ALARMS IF ANY
Field Balancing by balancing machines under operating conditions, we reduce unallowably high vibration loads by performing 1-plane, 2-plane or multiple plane balancing. The purpose of balancing a machine under operating conditions is to reduce vibrations, strain, bearing forces and shaft deformation to acceptable levels. Using VIBXPERT, PERFECT TEST HOUSE service and diagnosis specialists are able to detect and quickly eliminate imbalance even under difficult conditions. The balancing results are automatically compared to the evaluation criteria for the balance condition of rotating, rigid bodies as stipulated in the DIN ISO 1940 standard.
Manufacturing Defects
Installation Errors
Imbalance from Operation
Imbalance from Repairs
Accidents are unpredictable. You can’t really say when a switch goes haywire leading to a fire breaking out in a closed chamber. It is crucial to be prepared beforehand. Citing the same, timely fire safety audit is indispensable for every organization.
A sudden breakout can lead to severe loss of life as well as property. Fire and electric safety audit is one of the vital steps for ensuring if the fire safety standards of occupancy are at par. Not only does it help the owners identify the areas for improvement but also allows them to come up with an action plan to tackle the situation.
Who Are We?
Alphacore Technologies is a professional provider of value added solutions such as energy, fire and safety audit for plants & equipment. We help conducting Industrial Safety Audit for High Rise Buildings as per National Building Code of India, 2005, The Indian Electricity Rules, 1956 and other relevant safety standards.
The results and outcome of our energy safety audit help the organizations identify impending hazards and further undertake corrective & preventive actions. In addition to fire safety audit, we also specialize in warehouse audit, energy safety audit, warehouse safety audit and electrical safety audit. Our fire audit helps you prepare emergency plans for fire safety through effective methods such as conducting mock drills.
Why Choose Us?
When it comes to energy, fire and safety audit, Perfect Test is a renowned name. We are a well-known energy safety company in India.
Having been a renowned fire safety company in India for quite a few years now, we have a team of experienced professionals who ensure that nothing skips notice. We are a professional provider of electrical safety audit services for various large scale plants and organizations as well.
In process industries, fire breakouts due to electrical reasons are very probable, especially in industries that handle inflammable chemicals.
In service industries such as information technology, telecommunications, business interruption losses due to electrical hazards (fire in the server room, damage of expensive communication equipment, loss of data, fire in cable gallery, etc.) could be substantial.
Having served a wide clientele consisting of national as well as international clients, we know what works and what doesn’t. The fire audit is conducted as per the IS (Indian standard) guidelines, and IE (Indian electricity) rules, thus making sure that you are in safe hands. We have our infallible fire and safety audit checklist coupled with a state-of-the-art thermal imaging camera often used in thermography, that helps us make sure nothing skips our notice.
In case you are the owner of a warehouse, you know how tough, time and energy consuming a warehouse audit can be. However, no longer do you need to worry about the safety quotient of your warehouse!
We provide expert warehouse safety audit services for small and large scale warehouses. Not only do we review current safety measures to find gaps but also help you develop systems and processes to address issues, if any.
Why Is A Fire Safety Audit Essential?
Every air conditioning system leaks whether it is one ounce per year or one ounce every thousand years. The leaks are caused by cracks, bubbles, impurities, and other flaws in the brazing, joining, or manufacturing process. While they may not be detectable, they are leaks nonetheless and will eventually become detectable given enough time. The pressure, heat, and vibration from normal day-to-day operation is what causes them to become a problem.
Remote Visual Inspection or Remote Digital Video Inspection, also known as RVI or RDVI, is a form of visual inspection which uses visual aids including video technology to allow an inspector to look at objects and materials from a distance because the objects are inaccessible or are in dangerous environments. [1] RVI is also a specialty branch of non-destructive testing (NDT)
Purposes
Technologies include, but not limited to, rigid or flexible borescopes, video scopes, fiberscopes, push cameras, pan/tilt/zoom cameras and robotic crawlers. Remote are commonly used where distance, angle of view and limited lighting may impair direct visual examination or where access is limited by time, financial constraints or atmospheric hazards.
RVI/RDVI is commonly used as a predictive maintenance or regularly scheduled maintenance tool to assess the “health” and operability of fixed and portable assets. RVI/RDVI enables greater inspection coverage, inspection repeatability and data comparison.
The “remote” portion of RVI/RDVI refers to the characterization of the operator not entering the inspection area due to physical size constraints or potential safety issues related to the inspection environment.
Oil debris analysis is the investigation of wear particles and contaminates in grease or oil lubricant. Investigating and analyzing these particles help develop a clear picture of the type of wear or contamination occurring within a system. Information obtained from oil debris analysis can lend insight into a system well beyond just describing the condition of the lubricant. The minimization of downtime and unexpected failures, and an increase in uptime can be achieved into a system well beyond just describing the condition of the lubricant. The minimization of downtime and unexpected failures, and an increase in uptime can be achieved.
Oil debris analysis is a proactive and predictive technique. Industrial maintenance departments are constantly evaluating their systems and looking for areas where reliability can improve. Improved reliability means an increase in Mean Time Between Failure (MTBF). The best way to increase MTBF is to eliminate the failure’s root cause. Oil debris wear analysis helps determine some key elements in assessing root cause analysis. Oil debris analysis gives an observation or proof that a certain type of wear has occurred or is under development. In addition to determining the root causes of a particular problem, maintenance personnel can receive advanced notice of upcoming machine issues by using technology such as wear debris analysis. This is referred to as predictive maintenance.
Remote diagnostics is the act of diagnosing a given symptom, issue or problem from a distance. Instead of the subject being co-located with the person or system doing the diagnostics, with remote diagnostics the subjects can be separated by physical distance. When limiting to systems, a general accepted definition is: “To improve reliability of vital or capital-intensive installations and reduce the maintenance costs by avoiding unplanned maintenance, by monitoring the condition of the system remotely.”
Process elements for remote diagnostics
Shaft Alignment: At the point of power transfer from one shaft to another, the axes of rotation of both shafts should be collinear when the machine is running under normal conditions
Introduction:
– Misalignment results in higher electrical power consumption.
– Coupling misalignment decreases bearings life cycle.
– Coupling misalignment decreases seals life cycle.
– Misalignment influences the normal machine and coupling temperature
Geometrical Alignment: Reliability Starts with Precision Alignment.
Bore alignment applications include:
Flatness applications include:
Flatness:
Flatness measurement is one of the key measurements for determining the uniformity of a surface. A surface is perfectly flat when all points on the surface lie in the same plane. This is only theoretically possible, therefore the first element to determine is the flatness tolerance, within which all measured points on a surface will lie.
Level Inclination and Plumbness:
Level, inclination and plumbness are key parameters of rotating machine performance. The levelness of machine foundations is of particular importance to avoid the deformation of the base and housing due to the transmission of vibration through the various components down to the foundation. In most cases, flatness and level measurements are practiced together. Plumbness measurements include vertical shafts and surfaces. A typical application is the measurement of the vertical shaft of hydro turbines.
Level, inclination and plumbness applications include:
Monitoring of Machines Positional changes:
Monitoring machine positional changes during operation helps understand and control environmental factors that may affect your machine operating conditions. The biggest contributing factor for lowering the operating costs of rotating machinery is to align the machine using the real coupling target values. However, target values recommended by manufacturers do not always reflect the real thermal growth compensation values. Our real-time and continuous monitoring systems help to exactly determine the actual absolute and relative positional changes between coupled machines during run-up and coast-down.
Perpendicularity and Parallelism:
Parallelism and perpendicularity applications are very common industrial applications to improve machine geometry and production quality. Both measurements can be performed at the commissioning of the machine or after a few years, to check if the machine is still running within specifications.
Parallelism applications include:
Straightness:
Improved machine geometry help increase product quality, machine lifecycle and reduce downtimes. Straightness is one of the most common geometric applications in industrial environments. What is right on one axis might be bent on another. To check how straight a line is, both x and y axes must be measured.
Straightness applications include:
Characteristic overall value (Level 1) measurements, however, are insufficient for precise localization of defects, as this requires closer analysis of the machine spectrum. Most types of damage can be detected by their characteristic frequencies or typical pattern of frequencies. ‘Level 2’ vibration diagnosis normally requires measurement of vibration signals using an FFT vibration analyser by trained personnel who are experienced in interpreting vibration spectra. We will be happy to evaluate your machine conditions.
Critical Building Vibration from construction projects is caused by ground motion from general equipment operations, but is often highest during pile driving activities. Although construction vibrations are sometimes noticeable outdoors, they are mainly observed indoors. While it is conceivable for ground motion from construction projects to cause building damage, construction vibrations rarely cause even minor cosmetic damage to buildings. The primary concern is that the vibration can be intrusive and annoying to building occupants.
Why building vibration monitoring matters:
Vibrations even of a low magnitude can cause disruption to the local environment. Vibration monitoring is crucial to establishing the effects of vibrations from sources such as construction work to avoid long-term damage to surrounding structures. New construction works in built up urban areas or those which are adjacent to sensitive buildings will often specify vibration limits as part of a contract, to help to provide peace of mind and ensure the safety of buildings in the vicinity.
Motor current signature analysis has proven to be a highly valuable predictive maintenance tool. Although it is a relatively young, rarely utilized technology, it is rapidly gaining acceptance in industry today. Mechanical faults related to belts, couplers, alignment and more are easily found through the use of a demodulated current spectrum. MOTOR CURRENT SIGNATURE ANALYSIS is simply the process by which motor current readings are recorded and analyzed in the frequency domain. It has been around since 1985 and proven itself well over the years in locating rotor faults and air gap problems in motors.
FAULTS THAT CAN BE DETECTED WITH MOTOR CURRENT SIGNATURE ANALYSIS
The major faults of electrical machines can broadly be classified by the following
Human ears perceive certain modulations of the atmospheric pressure as sound. Such modulations result from a propagated vibration of an elastic medium or superposition of such vibrations. These vibrations cause an alteration in pressure, stress, particle displacement, or particle velocity of the medium. Sound propagates through the medium as a wave.
In the absence of acoustic energy in a particular space, air molecules move about in a random thermal motion. There occur frequent collisions amongst the molecules without loss of energy. The net result is an equilibrium condition with characteristic absolute temperature and pressure. On introduction of a vibrating surface, the molecules gain additional momentum by momentum transfer, and the disturbance propagates into the space with a velocity essentially equal to the thermal speed of individual molecules.
If the vibrating surface is a pulsating sphere, the sound waves spread out spherically with a wave of single frequency. The disturbance caused by the vibrating surface spreads through the medium by momentum transfer. The disturbance induces displacement of the individual particles of the medium. The particles attain velocities in the direction of propagation. These bring changes in absolute pressure and temperature. Human ears or microphones detect this pressure change as sound. Whenever the sound is irritating, annoying, unpleasant and unwanted, it is called noise.
Effects of Noise
Excessive exposure to noise has numerous direct and indirect effects on safety and hygiene. It directly affects our sensation of hearing, disrupts sleeping, and causes masking of speech. Otologists link industrial noise as a source of numerous problems of the ear, such as noise-induced hearing loss, permanent hearing impairment, acoustic trauma, sensorineural hearing loss, tinnitus etc. Exposure to high noise levels can indirectly affect human psychology and physiology, resulting in adverse effects on general performances. A number of ailments have a causal relationship with noise exposure.
It is possible for engineers to face situations where for reasons of a lack of time or resources they need support from external sources in order to carry out certain aspects of their work.
It might be that a project must be completed by a specific deadline or that there are measurement requirements that can’t be dealt with in house. In such cases Perfect Test House are able to offer support in the form of a measurement service making use of the performance of our flowmeters and the knowledge of our engineers.
Infrared Thermography is the ONLY diagnostic technology that lets you instantly visualize and verify thermal performance. Nearly everything that uses or transmits power gets hot before it fails. Cost effective power management is critical to maintaining the reliability of your electrical and mechanical systems. ALPHACORE Technologies’ infrared program shows you thermal problems, quantifies them with precise non-contact temperature measurement, and documents them within a report. Finding and fixing a poor electrical connection or mechanical fault before a component fails can save you the much greater costs associated with manufacturing downtime, production losses, power outages, fires, and catastrophic failures.
CBM_IR_660W
ALPHACORE Technologies will become an invaluable resource to assure that your equipment uptime is at its optimum and comply with insurance needs. Our extensively trained thermographs can spot trouble before it becomes a major problem associated with costly down time. Couple Infrared Imaging with route based vibration analysis to enhance both operations providing a greater level of confidence in all phases of your maintenance and production operations.
Ultrasonic Surveys can be very beneficial to your company by locating expensive air and gas leaks. Compressed air is one of the most expensive utilities commonly supplied throughout most facilities. If ignored, this distribution system can develop numerous leaks, which will result in an increase of air usage. This increase in air usage will create an increase in power consumption and wear to your compressor systems. Why add another compressor when in most cases by locating and correcting leaks you can significantly reduce your usage? Ultrasonic sensing equipment allows for the survey to be conducted during normal production when all systems are in use so there is no need to wait until an outage or when equipment is shutdown.
ALPHACORE Technologies offers trained / certified ultrasonic analysts to conduct an Ultrasonic survey at your facility. The air (or gas) leak survey will consist of the following: locate the leak, label leak with hanging tag, take digital photo of leak location, and estimate leak rate. A written report will be delivered consisting of: leak locations, digital picture, estimated priority, and estimated total leak rate.
As one of the largest predictive service companies in the country, we have an analyst near you for immediate service. We are available 24 hours a day.
Dynamic Balancing and Precision Maintenance Practices are becoming essential tools necessary to achieve success in the increasingly competitive world industrial market. Excessive imbalance of rotating equipment adversely affects quality, productivity, wear, operator fatigue, and power consumption. It affects all rotating components… fans, couplings, spindles and more!
Your equipment can be conditioned for optimum life expectancy with Precision Maintenance Practices. ALPHACORE Technologies offers precision balancing of your equipment, in-place and at speed, with minimal impact to production. We will correct the imbalance on your machinery without the need for costly tear down and removal. Our analysts are experienced with single and dual plane balancing techniques, using precision portable equipment. You will receive a detailed report analyzing the vibration signature of your equipment with comprehensive before and after balance results.
As one of the largest vibration service companies in the country, we have an analyst near you for immediate service. We are available 24 hours a day for emergency service.
In-situ Dynamic Balancing
Field Balancing by balancing machines under operating conditions, we reduce unallowably high vibration loads by performing 1-plane, 2-plane or multiple plane balancing. The purpose of balancing a machine under operating conditions is to reduce vibrations, strain, bearing forces and shaft deformation to acceptable levels. Using VIBXPERT, PERFECT TEST HOUSE service and diagnosis specialists are able to detect and quickly eliminate imbalance even under difficult conditions. The balancing results are automatically compared to the evaluation criteria for the balance condition of rotating, rigid bodies as stipulated in the DIN ISO 1940 standard.
Manufacturing Defects
Installation Errors
Imbalance from Operation
Imbalance from Repairs
Condition Based Monitoring Program Audit
Just like an older car, an internal CBM Program periodically needs a tune-up. ALPHACORE Technologies has over 30 years’ experience conducting multiple technology CBM programs in all types of industrial environments. We understand what it takes to make a program succeed and because we are always evaluating new technology, we can provide that insight to our clients. Contact us about our CBM Program Audits.
No matter what hardware/software you may be using, we are well versed in all the major systems on the market today. We focus on your plant, your people, and your program! We evaluate all aspects of your company’s internal CBM efforts including technology deployment, personnel training/competency levels, and communication of results.
ALPHACORE Technologies can provide the support and experience your internal plants CBM efforts needs in order to maximize its potential.