Condition Monitoring

& Advanced Maintenance

Techniques

Testing, measurement, monitoring and diagnostic services for rotating & static equipment.

In process industries like Oil & Gas, Chemical and Power, it’s vital to enhance performance and ensure reliability. Maintaining rotating equipment is an important driver for performance. In order to assess the condition of rotating equipment, our team of Diagnostic engineers offers condition monitoring and a broad range of measurements on rotating equipment such as pumps, compressors, electro-motors, turbines and generators.

Our Diagnostic Services

SES is focused on developing a portfolio of services comprising this suite of condition monitoring, available to the domestic industrial market and also aims to service the region through specific training modules for capacity building and competency development.

The benefits of our Machine Diagnostic Services:

  • We assess the condition of your pump and take any necessary measures to reduce the risk of downtime
  • We can plan maintenance more efficiently, so ensuring that your maintenance costs are manageable
  • We can prevent production downtime
  • We can achieve an optimum service life

Our engineers have a wealth of experience in the field of condition monitoring. We are pleased to offer the following supports:

  • Database setup.
  • Training.
  • Asset criticality assessment.
  • Site condition monitoring surveys.
  • Troubleshooting and general consultancy.
  • Diagnostics to assess the condition of critical equipment.
  • Case-by-case diagnostics, for example for troubleshooting or end-of-warranty inspections.
  • Diagnostics before main equipment overhaul to define the scope, and after overhaul to evaluate the repair works.
  • Diagnostics as part of a condition-based maintenance program.

Through our strategic partnerships, we are also able to offer thermal analysis and oil analysis services to customers who wish to employ a variety of predictive maintenance techniques.

What We Offer?

We ensure the long term reliability and safety of your equipment by detecting faults at an early stage and limiting the likelihood of future breakdowns and incidents through a complete package of advanced services:

Vibration Analysis

Vibration Monitoring and Analysis is the most utilized form of PdM in rotating equipment for assets such as pumps, turbines, motors, gearboxes, fans and compressors, making it an integral service offering of our PdM portfolio.

With a team of certified Vibration Analysts dedicated to equipment service of these advanced technologies, we offer periodic vibration monitoring analysis services on a contractual basis. We also offer related consultancy based advisory support.

Vibration Analysis is the foundation of all Predictive Maintenance Programs. It is a nondestructive testing technique that is utilized to monitor and trend particular rotating equipment. In addition to condition monitoring, this technology allows us to determine problematic issues such as:

  • Bearing degradation.
  • Unbalanced components.
  • Structural support issues.
  • Rotational problems.
  • Alignment concerns.
  • Resonance.
  • Electrical problems.
  • Unbalanced components.
  • Structural support issues.
  • Rotational problems.

We can arrive at your site to perform a detailed vibration analysis on one machine or on all the equipment in your plant! We utilize state of the art measurement equipment and years of experience to provide the best service possible to our customers. Most importantly, the professional who collects the data will be the same professional that performs the analysis, issues a report on the findings and recommends any improvements.

If a severe defect or a safety issue is identified while we are on-site, you will be notified of the problem prior to our personnel leaving the site. If the problem is imbalance or misalignment, your SES service professional is capable of correcting the problem. This is just another way we provide the superior service capabilities you need to help keep your plant up and running at peak efficiency.

SES is providing consultation and on-site support for various vibration analysis services including:

Routine Condition Monitoring:

It is well documented that a predictive maintenance program which establishes equipment condition and allows for maintenance to be scheduled accordingly can save companies up to millions of dollars annually in maintenance costs and expensive unscheduled down time. Bearing vibration can be identified in early stages of failure when a monthly vibration program is in place. The key to success and the challenge is not the potential of savings or the ability of the program to provide good predictive data, but in the conversion of information into action. SES is focused on providing comprehensive reports that are structured to allow front line personnel to quickly understand the results of the analysis and how best to utilize the information in the form of action

Rotating equipment diagnostics:

This is a situation in which a perceived or known defect is present and facility maintenance personnel require additional resources to determine the best course of action. Various analytical tests are typically required to determine the root source of the vibration or reoccurring equipment failure. The ability to test and determine the presence of resonance, unbalance, poor lubrication, incorrect engineering applications and verify calibration of on-board monitoring equipment is required.

Acceptance Testing:

In critical equipment repairs and installations an acceptance test is typically required by the customer. This can be in the form of testing motors at vendors’ shop or testing the unit as whole in place under normal loaded conditions. Many test requirements require a certified ANST Level lll Analyst to review the data and supervise the test procedure. Test standards can be set by the customer, API standard reference, or Government standards.

Infrared Thermography

IR-Thermography employs equipment and methodologies geared towards detecting infrared energy emitted from objects, convert it to temperature, and displays image of temperature distribution. This is a critical tool used for reliable inspection of rotating equipment, refractory vessels and electrical systems. Amongst its many insightful results, relative comparison of distribution of surface temperature can be made over a wide area as well as temperature can be measured easily for moving assets or volatile equipment which requires far proximity of interaction.

SES provides infrared inspection services using latest technology. Infrared technology provides an excellent complement to vibration analysis in reliability applications as well as electrical applications and is a great addition to any predictive maintenance program. Our technical team are well trained and are qualified to provide infrared services in most applications. Our infrared digital cameras detect abnormal thermal patterns and are beneficial at identifying the source of defects.

Typical Infrared Inspection services:

Power Transmission Line Inspections

They prevent high voltage failures which can result in fire and facility power interruptions. Electrical power line failures are one of the leading causes of fires in the field. Many customers choose to implement an infrared inspection program on a quarterly or even annually basis to monitor all energized lines and catch potential defects when they begin.

Electrical Switch Gear Inspections

They save companies thousands of dollars in providing a predictive maintenance tool for repairs prior to failure. The reason many insurance companies provide a reduction in rates based on the implementation of a good infrared inspection program is because of the proven benefits to minimizing lost production and maintenance costs. By routinely implementing infrared inspection on rotating equipment, defects can typically be monitored for more advanced stages of failure before scheduling repairs.

Mechanical Related Inspections

They are less common, but provide an exceptional compliment to a rotating equipment monitoring and diagnostics. Infrared provides an excellent alternative to monitoring inaccessible equipment such as pillow block bearings in cooling fans, or loose belt and poor sheave conditions. Poor lubrication and excessive load conditions can be easily detected with infrared and corrective action taken prior the evolution of defects in which vibration analysis typically detects these conditions in some applications.

Airborne Ultrasound

SES offers this service on a contractual basis through either advisory consultancy support or equipment sales.

This technique is used primarily for leak detection, mechanical analysis and electrical inspection, these instruments have saved our clients tens of thousands of dollars in premature failure detection, elimination of downtime, increased productivity, and overall replacement costs.

Ultrasound technology is a great supplement to any existing condition monitoring program, but can also be effective on its own as a small scale predictive maintenance tool.

Popular uses of ultrasound include:

  • Monitoring bearings for early signs of wear and poor lubrication issues.
  • Locating steam, air, and water leaks.
  • Identifying pump cavitation.
  • Locating MCC panel faults including arcing and corona.

Monitoring bearings with ultrasound during the lubrication process helps ensure just the right of amount of grease is applied, as levels will drop off sharply once it has enough.  This helps prevent under and over lubrication. This is a great predictive maintenance tool as up to 70% of mechanical failures can be attributed to poor lubrication practices! (“Lubrication for Industry”, Ken Bannister, Industrial Press, 1996).

Integrated Predictive Maintenance Programs

SES team provides customers with service offerings that allow for combining two or more Predictive Maintenance Technologies into a scheduled PdM Program. Some of our customers choose to have us to provide all of their Predictive Maintenance needs.

Laser Alignment

SES provides state-of-the-art precision Laser Alignment Measuring Systems. We also provide full technical support and service necessary for effective implementation of a PdM alignment program.
As known, once alignment is completed, then vibration data can be collected and analyzed to verify the alignment was successful and the unit is running at acceptable levels.

Reverse dial and laser alignment applications are incorporated in conjunction with site inspection for pipe strain, base imperfections and mechanical runout of shaft and couplings to ensure best possible results.

Hot alignment applications are also offered for equipment that experiences significant thermal growth.
Ensuring your equipment is correctly installed with precision alignment stands provides an excellent return on investment.

On-site Balancing

SES provides options for onsite in-place balancing services on turbines, generators, motors, crushers, and a variety of other equipment.
In-place balancing of rotating equipment by using computerized and vector plot techniques allows for a reduction in overall vibration levels to extend equipment run time. Below is a chart of the effective reduction in bearing life extension when machines are balanced to various grades. Due to excessive vibration as a result of imbalance or a combination of various influences (such as imbalance, resonance and misalignment or run-out conditions), balancing and other corrective measures are required to establish an acceptable overall condition on the equipment.  For instance, once the excessive imbalance vibration is reduced to acceptable levels, dampening influences and resonant responses may amplify a residual imbalance that is best addressed with a focus on changing the unit’s natural frequency by installing bracing or dampening.

It is important to establish a target prior to starting the balancing process and to verify a balance condition exists. Some common balance criteria are referred to in manufacturer’s recommended balance criteria, ANSI S2.19-1989 / ISO 1940 balance grades, Machine average baseline + 1 sigma (standard deviation), MIL-STD 167, and API 610.

Following balance work, SES provides a complete comprehensive report showing as found and as left conditions with additional recommendations, if needed, to further reduce vibration and extend equipment life.

New Design.. More Efficiency

We analyze the response and stability of a rotor system by modeling the stiffness and mass of the rotor and its interaction with the bearings and seals. In order to increase turbomachinery life and reduce vibration, we could provide new designs and evaluate rotor stability. We offer condition monitoring and maintenance services on large rotating equipment tailored to your needs through:

  • Vibration diagnostics.
  • Field (rotor) balancing.
  • Resonance frequency tests.
  • Alignment tracking.
  • Performance testing.

Contract Base Predictive Maintenance

As an acknowledged leader in the field of rotating equipment, we are ideally positioned to undertake your maintenance needs. We deliver measurable benefits to your business in a number of ways:

  • Expert staff dedicated to maintaining your equipment.
  • No impact on your head count.
  • Infrastructure savings at your site through the use of our service center facilities.
  • Enhanced performance, efficiency, and reliability through upgrades developed by our skilled specialists.

We tailor maintenance services to individual needs with a focus on contract maintenance and predictive maintenance agreements.

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