Condition Monitoring Services

Product Details:

“That condition which exists in a rotor when vibratory force or motion is imparted to its bearings as a result of centrifugal forces.”
•Why Balance? All rotating components experience significant quality and performance improvements if balanced. Balancing is the process of minimizing vibration, noise and bearing wear of rotating bodies. It is accomplished by reducing the centrifugal forces by aligning the principal inertia axis with thegeometric axis of rotation through the adding or removing of material. In order to understand the basics of balancing it is necessary to define the following fundamental terms.

•When unbalance has been identified and quantified, the correction is straightforward. Weight has to be either added or removed from the rotating element. The ultimate aim being to reduce the uneven mass distribution so that the centrifugal forces and hence the vibrations induced in the supportingstructures are at an acceptable level.

• Benefits achieved by Dynamic Balancing would be:
??? Minimize vibration, Minimize noise.??? Minimize structural stress.??? Minimize operator fatigue and annoyance.
??? Increase personnel safety.??? Increase machine life & Productivity??? Increase bearing life, Increase product quality.

Product Details:

We are providing effective and rapid assistance to the customers with our instruments and services.

We will be grateful to assist you in all aspects and would like to receive your esteemed query and questions. We insure our immediate, effective more specific support.

Instruments monitor high frequency Acoustic Emissions (AE) signals naturally generated by deterioration in rotating machinery. Our unique way of detecting and processing these signals gives the user condition  related  information in the easiest possible form. These are state of the art Condition Monitoring instruments with extreme sensitivity to developing faults. With thousands of  use in various industries  and countless successes on ball, roller, white metal and journal bearings, this is a proven technology.

All faults commonly encountered in industry, such as unbalance, misalignment, defective mountings, looseness, friction, structural resonance, lubrication defects, bearing defects, gear defects, pump cavitation and more, are detected. Faults are identified in clear and accurate language and displayed with an associated confidence level.

VIBRATION MEASUREMENT AND ANALYSIS SERVICES:
All possible problems of rotating machines can be identified by Vibxpert. Few of them are listed below:

¿¿¿ Unbalance (static, couple, quasi-static).

¿¿¿ Misalignment (angular, parallel, skew).

¿¿¿ Mechanical looseness, structural weakness, soft

foot.

¿¿¿ Bend shaft, Rotor eccentricity.

¿¿¿ Shaft Vibration.

¿¿¿ Resonance, beat vibration.¿¿¿ Gear problems (tooth wear, tooth load,

gear eccentricity, backlash, gear

misalignment, and cracked or broken

tooth.

¿¿¿ Cepstrum analysis.

¿¿¿ Phase Analysis, Cross Phase Analysis.

¿¿¿ Static Shaft Position.

¿¿¿ Mechanical rubbing.

¿¿¿ Problems of belt driven machines.

¿¿¿ Journal bearing defects.

¿¿¿ Antifriction bearing defects (inner race, outer

race, cage, rolling elements).

¿¿¿ Hydrodynamic & Aerodynamic forces (blade of

vane, flow turbulence, cavitation).

¿¿¿ Orbit Analysis.

¿¿¿ Run out Analysis (Shaft Vibration).

¿¿¿ Bump Test.

¿¿¿ Cost down & run Up test.

¿¿¿ Order Analysis.

¿¿¿ Operating Deflection Shape Analysis

(ODS).

¿¿¿ Transient Capture.

 

¿¿¿ Shaft Average centerline Plots.

 

 

Product Details:

- We undertake Dynamic Balancing of Rotary Machines on various capacity Precibalance make, Dynamic balancing machines.
- Balancing capacity is from 0.5 Kgs to 7.5Tons on followingPrecibalance machines.??? Balancing M/c Model HB 5 (Belt Drive)??? Balancing M/c Model HB 1K 40 (Belt Drive)??? Balancing M/c Model H 7.5K (End / Belt Drive)

- With these, we have installed almost all range of machines & we can offer, our balancing facilities depending upon the Clients requirement.

Product Details:

We provide Laser tracker Roll Alignment services.

A new class of automated metrology sensor provides sophisticated in-process measurement, minimizing integration and infrastructure costs. We announce highly-adaptable 3D imager arrays that promise to drive automated industrial manufacturing metrology processes to the next level. The measuring equipment is equipped with dedicated on-board processors.
You can find out easily the misalingment of Rollers and can take the corrective measures.

Additional Information:

• Delivery Time: 10 days

Product Details:

Having correctly aligned machines reduces the risk of breakdowns. Typical problems arising from poor machine alignment are:

 

• LOST PRODUCTION

• LEAKING SEALS

• INCREASED VIBRATION

• HIGHER ENERGY CONSUMPTION

• BEARING FAILURE

• SHAFT BREAKAGE

• COUPLING WEAR

• QUALITY PROBLEMS

There is much to be gained in terms of time and money by adjusting the machines within the prescribed tolerances. Investing in a laser-based measuring system will benefit the company by reducing the cost of spare parts and lost

production. And the working environment is improved at the same time.

Product Details:

Propulsion shaft ( Stern Tube ) alignment is a process that consists of:
• The design and analysis
• The alignment procedure
• Measurements and verification
The terminology and requirements for shafting alignment vary depending on the type of the system analyzed (propulsion, gen-set, etc.), the powertrain size, and the alignment process itself. 

Propulsion Shafting Alignment:
A static condition observed at the bearings supporting the propulsion shafts. To suitably define propulsion shafting alignment, a minimum set of parameters are defined in the design stage and subsequently confirmed acceptable on board: • Bearing vertical offsets • Bearing reactions • Bearing to shaft contact condition (i.e. misalignment angles) • Crankshaft web deflections • Gear mesh misalignment.


Alignment is considered satisfactory when these parameters can be controlled in the static and dynamic condition and maintained within the required limits under all operating conditions of the vessel for all service drafts and service temperatures. A change in the vessel’s draft due to altered loading conditions affects hull girder deflections. This in turn influences bearing offsets, causing a redistribution of the load among the bearings. Achieving a satisfactory alignment design for the loading conditions included in the vessel’s loading manual requires several repeated analyses.
Most modern vessels are state of the art designs, with highly efficient propellers and high-powered main drives with low fuel consumption. Their hull structure is optimized to reduce deadweight and maximize cargo capacity. Unfortunately, most modern ship design improvements can adversely affect propulsion shafting alignment if this is not correctly addressed.

The shaft alignment analysis provides the necessary, accurate and applicable data to support each stage of the actual alignment process.
The alignment procedure is conducted with the required accuracy.
Allowable shaft alignment tolerances are measured in fractions of millimeters, while acceptable hull construction margins are measured in tens of millimeters.  Ideally, a shaft alignment analysis should be performed for maximum allowable alignment tolerances, resulting in acceptable bearing reactions and misalignment angles under all operating conditions of the vessel: loaded, ballast, hot and cold. This implies that hull deflections are initially accounted for in the analysis.

Additional Information:

• Delivery Time: 10-15 Days

Product Details:

When rotating equipment vibrates excessively, it causes stress that reduces component life and has the potential to cause catastrophic failure. Even with the proper predictive maintenance program in place, equipment can become unbalanced. When excessive vibration is present it is often caused by an unbalance. In rotating equipment, unbalance can occur due normal wear and tear, deposit buildup, corrosion, material problems, temperature changes, or deformation. Pioneer Engineering offers dynamic balancing services that help to identify the cause of the unbalance and offer solution to correct the unbalanced equipment.

Determining why there is an unbalance and how to correctly fix the issue is one of our specialties.

Our mechanical engineers will come to your site to begin troubleshooting your machinery. Our state of the art instrumentation, coupled with our extensive field experience, give us the tools we need to not only identify the source of the unbalance, but to also take steps to reduce the excess vibration, helping to safeguard the longevity of bearings, equipment, and the safety of your facility. 

All types of rotating parts can be accurately balanced on our high-precision machines, including rotors, impellers, fans, and shafts.

 

Specialist dynamic balancing with our team  will improve the service life, accuracy, and quality of your machinery. We can identify and correct unbalanced components efficiently.

Product Details:

Transformer oil (also known as insulating oil) is a special type of oil which has excellent electrical insulating properties and is stable at high temperatures. Transformer oil is used in oil-filled electrical power transformers to insulate, stop arcing and corona discharge, and to dissipate the heat of the transformer (i.e. act as a coolant).
Transformer oil is also used to preserve the transformers core and windings - as these are fully immersed inside the oil. Another important property of the insulating oil is its ability to prevent oxidation of the cellulose-made paper insulation. The transformer oil acts as a barrier between the atmospheric oxygen and the cellulose - avoiding direct contact and hence minimizing oxidation. The level of transformer oil is typically measured using a MOG (Magnetic Oil level Guage).
Routine testing of transformer oils and insulating oils on a regular schedule is an accepted industry practice. General and physical tests are suggested twice a year, dissolved gas analysis once a year, and Furan testing every 2 years for transformers in operation at least 5 years.
Transformer oil tests:

Product Details:

Proper alignment is a key component in any rotary kiln processing operation.

Misalignment is one of the most common (and most treatable) causes of rotary kiln damage. Alignment touches all components of the rotary kiln; misalignment will promote wear on all parts. In addition to increased wear, problems have the potential to escalate into major damage and even premature equipment failure.

For this reason, in order to maintain operational efficiency and prolong the life of your rotary kiln, routinely inspecting a kiln to assess alignment should be a part of your regular maintenance program, and any alignment issues addressed promptly. And while the process of aligning a rotary kiln is not new, recent advancements have made alignments more effective than ever.

Rotary kiln alignment methods have come a long way in the recent past. The traditional method of alignment involves hand measuring various points and then using a variety of calculations to determine the adjustments needed. This process is effective, but slow, and ripe with potential for error.

Although this method is still widely used today, new laser tracking systems have taken alignments to a new level, making precision alignment faster and more accurate than ever before possible.

 

Laser tracking systems use laser beams to establish a 3D spatial map of the equipment. In tandem with state-of-the-art software programs, this method of alignment offers precision results in significantly less time with greatly reduced potential for error.

Rotary kilns can fall out of alignment for a number of reasons. Kiln misalignment could be a result of structural issues such as sinking foundations, shifting steel, or processing environment issues such as the amount of humidity or even dust in the air. The myriad of reasons for which a kiln can fall out of alignment can make misalignment difficult to predict. For this reason, regular inspections should be performed by on-site personnel to catch any signs of misalignment at their onset, before they have a chance to escalate. Inspections should also be performed by the original equipment manufacturer at regular intervals, typically on an annual basis. Recording any misalignment issues and how they were treated is best practice and can be useful in helping to predict future alignment issues and treatment methods.

Alignment is also necessary at installation. During installation, care must be taken to account for the hot kiln load; a hot kiln under operational load will behave much differently than a cold, empty kiln. Aligning a cold kiln without taking into account the thermal stresses and operational load of production conditions can result in a misaligned kiln from the start. In addition to alignment at install, kilns should also be realigned after any major components, such as trunnion wheels, have been replaced or resurfaced, as this can cause the kiln to fall out of optimal alignment.

 

Furthermore, if process conditions have changed, the kiln may also require realignment. A change in process conditions can affect the load on the kiln. Because the kiln was designed and aligned for specific operating parameters, a change in conditions will likely require realignment.

There are many signs that can indicate when a kiln is out of alignment. It's important to note that these signs could be indicative of other issues as well, and only a trained professional can determine what the true cause is. Signs that a kiln is out of alignment can include:

 

• • Wear after tire or trunnion surfaces have been recently repaired/resurfaced.
  • Chattering or vibrational noises
  • Excessive wear or damage to the tire/wheel
  • Excessive wear or damage to the thrust roller
  • Excessive wear or damage to the pinion/girth gear

Additional Information:

• Delivery Time: 15-30 days