Kunst Engineering & Consulting, L.L.C.
Just Added:
- Fluke Power Quality Analyzer 1735
- Older Equipment: Coupling Testing Technologies (IR, U-Sonic Vibration)
Coming Soon
Data, Trends & Analytics
The Power of Knowledge to make Decisions and Take Action
Kunst Engineering & Consulting, L.L.C.
Our APPROACH
Traditional Testing Companies employ Technicians who are skilled at using their test equipment.
Kunst uses a different and unique approach. A knowledgeable and experienced Prof. Engineer will conduct comprehensive Testing of your Electrical and Mechanical Equipment.
In one Survey we perform Thermal Imaging and Ultrasonic Scanning which will provide a detailed and complete analysis of the condition of the Equipment (Vibration Analysis is also available). When State-of-the-Art Testing Equipment is combined with an Engineer of +35 years of experience (Design, Engineering, Installation and Maintenance of Industrial Processes) the result is our NEXT LEVEL SERVICE.
Our NEXT LEVEL SERVICE
Our Next Level Service includes 3 major components
- The Engineer performing the Survey has Knowledge & Experience of Electrical/Mechanical Equipment & Process Systems, well beyond traditional Testing Companies and their Technicians.
- State-of-the-Art Testing Equipment all contained in 1 Mobile Test Rig.
- Engineering Services from a Company with decades of experience with Critical Processes and Electrical/Mechanical Equipment (Utilities, Contractors, Insurance Companies)
Fore-seeing problems before they happen: that’s where we excel.
Our support and experience is reinforced by a Master Electrician turned Professional Engineer with long-term success in High-Technology Manufacturing Environments.
Next Level Service: Comprehensive Testing in 1-Survey
Utilizing State-of-the-Art Equipment to Perform Our Surveys
The Test Rig
UE System UltraProbe 10,000
FLIR T640/T865
Our Test Rig is compact, mobile and is based upon decades of experience. It was used successfully to perform Surveys of an intense 365/24 Operation: vacuum, gas, compressed air, water cooling and DC and AC power supplies, all within very close proximity.
This collection/assembly/ of Test Instruments allows Kunst to achieve our Primary Go
Our Test Rig is compact, mobile and is based upon decades of experience. It was used successfully to perform Surveys of an intense 365/24 Operation: vacuum, gas, compressed air, water cooling and DC and AC power supplies, all within very close proximity.
This collection/assembly/ of Test Instruments allows Kunst to achieve our Primary Goal: To perform a detailed and efficient analysis of the condition of Electrical/Mechanical Equipment. This helps/allows our Customer’s to make informed decisions based upon Data.
The Rig includes State-of-the-art Test Instruments:
- FLIR T640 Thermal Imager
- UE Systems Ultraprobe 10000 Detector
- Fluke 810 Tri-Axial Vibration Analyzer
- Fluke 199B Scope Meter and Fluke 1775 Power Analyzer for short- and long-term electrical load analysis
- Portable Laptop loaded with software supporting for the Test Equipment
- Also loaded with the Customer’s previous Survey Data for rapid on-site evaluation
- Hand-tools to provide quick accessibility (suction cups, insulated tools, PPE)
- Markers, magnetic labels, wax pens used to identify equipment for the Base-line and follow-on Surveys
This is a full complement of Test Equipment. Our Test Rig continues to grow to meet Customer’s specific testing needs. We strive to be prepared to perform an in-depth and efficient Survey as another way to help our Customers maintain their Maintenance Budget.
FLIR T640/T865
UE System UltraProbe 10,000
FLIR T640/T865
"The high-performance FLIR T640 helps you find hidden signs of electrical resistance, mechanical wear, and other heat-related problems. Offering the rich detail of MSX®, the enhanced resolution FLIR UltraMax®, and temperature calibration to 2000°C, the 307,200 (640 x 480) pixel T640 has the superior image quality and clarity needed to di
"The high-performance FLIR T640 helps you find hidden signs of electrical resistance, mechanical wear, and other heat-related problems. Offering the rich detail of MSX®, the enhanced resolution FLIR UltraMax®, and temperature calibration to 2000°C, the 307,200 (640 x 480) pixel T640 has the superior image quality and clarity needed to diagnose problems quickly, so you start on repairs immediately. Keep things operating safely and head off expensive downtime with this flexible, dependable thermal imaging camera." From FLIR
UE System UltraProbe 10,000
UE System UltraProbe 10,000
Fluke 1735 Power Quality Analyzer
"The Ultraprobe 10,000 is an advanced ultrasonic instrument that can be used for all ultrasound applications. Ideally suited for condition monitoring of bearings and electrical inspections. This instrument brings ultrasound technology to a new level by allowing inspectors to record and analyze sound samples, and store and manage data. Wi
"The Ultraprobe 10,000 is an advanced ultrasonic instrument that can be used for all ultrasound applications. Ideally suited for condition monitoring of bearings and electrical inspections. This instrument brings ultrasound technology to a new level by allowing inspectors to record and analyze sound samples, and store and manage data. With an intuitive, built-in touch screen, this single hand-held tool can easily test and report on every aspect" From UE Systems
Fluke 1735 Power Quality Analyzer
Fluke 1735 Power Quality Analyzer
Fluke 1735 Power Quality Analyzer
The Fluke Power Quality Analyzer provides long-term (+2 weeks) recording of electrical or mechanical sensors. This information provides detailed and instantaneous insight into unseen events and identifies system Risks (abnormalities, variations) and making improvements with DATA!
With this tool (and my other tools) I will CATCH YOU (hidden
The Fluke Power Quality Analyzer provides long-term (+2 weeks) recording of electrical or mechanical sensors. This information provides detailed and instantaneous insight into unseen events and identifies system Risks (abnormalities, variations) and making improvements with DATA!
With this tool (and my other tools) I will CATCH YOU (hidden problem), the exact time and severity of the problem. You are being recorded and I don't need to be present.
The Tools/Instruments I use are the best I know available. 40 years ago as an Apprentice Electrician working for I learned the value in having the best tools, despite the expense.
Fluke 810 Vibration Analyzer
Fluke 1735 Power Quality Analyzer
Fluke 810 Vibration Analyzer
"On-board identification and location of the most common mechanical faults (bearings, misalignment, unbalance, looseness) focus maintenance efforts on root cause, reducing unplanned downtime. Overall vibration level allows you to quickly assess overall machine health directly from the diagnosis screen." From Fluke
The 810 uses Patented Tr-
"On-board identification and location of the most common mechanical faults (bearings, misalignment, unbalance, looseness) focus maintenance efforts on root cause, reducing unplanned downtime. Overall vibration level allows you to quickly assess overall machine health directly from the diagnosis screen." From Fluke
The 810 uses Patented Tr-Axial Sensor Technology, not available in other Vibration Analyzers. Perfect application for: motors, fans, blowers, belts and chain drives, gearboxes, couplings, centrifugal pumps, piston pumps, sliding vane pumps, propeller pumps, screw pumps, rotary thread/gear/lobe pumps, piston compressors, centrifugal compressors, screw compressors, closed coupled machines
CONTINUOUS IMPROVEMENT
CONTINUOUS IMPROVEMENT:
Kunst Engineering offers decades of Experience and Knowledge of the application of Continuous Improvement for Manufacturing Environments. We support our Customers so they maintain their competitive advantage. Our Support will help:
- Improve the Reliability of the Process
- Support & Provide the Maintenance & Engineering Teams with Data and Solutions
- Control Energy Costs with Long-Term Analysis and Solutions
-Assist in implementing Improvements by offering our Knowledge & Experience
The Process of Serving our Customer
Our Knowledge Base
Combining Technologies: Predictive Maintenance Advantage for Older Equipment
Combining Technologies: Predictive Maintenance Advantage for Older Equipment
Combining Technologies: Predictive Maintenance Advantage for Older Equipment
Specializing in the maintenance of older electrical and mechanical equipment means having the required experience, knowledge and test equipment. Newer equipment, if engineered and installed properly, will require minimal maintenance.
Older equipment may be subjected to the harsh outdoor environment: thermal expansion/contraction, humidit
Specializing in the maintenance of older electrical and mechanical equipment means having the required experience, knowledge and test equipment. Newer equipment, if engineered and installed properly, will require minimal maintenance.
Older equipment may be subjected to the harsh outdoor environment: thermal expansion/contraction, humidity, airborne contaminates. Many indoor processes and their equipment also experience these conditions, especially in industrial manufacturing.
Our Next Level Service includes a Mobile Test Rig which couples several technologies on-demand, while conducting our surveys. Our Engineer will switch between thermal, ultra-sonic, vibration, and power quality technologies efficiently to get to the Root Cause of a detected anomaly. This data will then support any required immediate action and is stored for future reporting and analyzing trends.
A proper/effective analysis requires sizeable load conditions (+60% full load). Thermal imaging will detect conditions of heat which are created by friction or resistance to current flow (hot motor bearing, corroded contact in a breaker, poor motor terminal/lead connection). However, even at high plant load conditions thermal imaging will not permit detection behind metal enclosures.
Then we rely on ultra-sonic testing to compliment a thermal scan. Ultra-sonic can detect conditions of electrical partial discharge which tend to be low level and non-heat emitting. These low energy level discharges include Corona, Tracking, intermittent Arcing and Treeing. An added level of safety is then achieved if a partial discharge is detected BEFORE opening a metal enclosure. This prevents a dangerous Arc Flash condition which occurs when a rush of incoming air suddenly ionizes the air inside the cabinet to create a sudden and extreme flash.
Ultra-sonic technology will detect sound waves which are airborne and structure borne. A simple swapping of plug-in modules allows the instrument to switch between these test methods. An air sensor is replaced with a contact stethoscope or a corded magnet. Misalignment in motor drives, bearing anomalies and fluid/gas leaks have unique structure born and airborne wave patterns which allow for precise analysis and repair. Ultra-sonic can also detect changes in the sound wave during lubrication. Thus, a situation of over-lubrication, very common failure mode in bearings, can be observed with Ultra-sonic technology.
Infra-Red and the Fluke power analyzer is another great partnership. IR scan detects excessive heat in a specific leg of a three-phase apparatus. The Fluke analyzer can determine source of the heat is not imbalance but excessive resistance in breaker contacts or motor terminals.
One last comment regarding older equipment and processes. Many critical and continuous processes have redundant equipment. The redundancy ensures critical parts of the process (water cooling, hydraulic, vacuum/pressure) maintain operation in the event a parallel motor/pump fails. Our expertise and experience realize the benefits of using comparison testing scans to understand which of 3 identical motors/pumps has an abnormal condition and why. This is a very efficient and effective analysis tool offered by an experience Design Engineer and not a Technician.
Trouble-Shooting Problems
Combining Technologies: Predictive Maintenance Advantage for Older Equipment
Combining Technologies: Predictive Maintenance Advantage for Older Equipment
Critical or Continuous Manufacturing Operations rely upon equipment with special requirements. Complex Electrical and Mechanical Systems involve around-the-clock attention and maintenance. The more complicated the Operation, the more essential the Maintenance.
You learn a lot when your Operation experiences an unplanned outage at 01:00 on
Critical or Continuous Manufacturing Operations rely upon equipment with special requirements. Complex Electrical and Mechanical Systems involve around-the-clock attention and maintenance. The more complicated the Operation, the more essential the Maintenance.
You learn a lot when your Operation experiences an unplanned outage at 01:00 on a Sunday morning. In-house resources (mechanics, electricians, engineers) are scarce. The costs (Production, Quality, Equipment, Safety…) associated with the outage will exceed the costs of a similar outage occurring during the weekday since the outage will likely last longer due to the lack of resources available.
There are always surprises encountered when trouble-shooting an electrical or mechanical equipment problem. After 40+ years of experience I have learned the value of applying a slow, steady disciplined approach to trouble-shooting Two valuable reasons for a methodical approach: you will usually find and correct the issue quicker than just jumping around, and rushing and haste may put personal Safety at risk.
Some Tips and Tools of the Trade for Effective Troubleshooting:
· Gather the facts: discuss and engage the support staff
o Re-occurring event? Anything odd happen before the fault?
o Have there been any recent changes to the system?
o Confirm facts with measurements
· Your best friends are drawings/documents and proper test instruments/tools
· Stick to a methodical agreed-upon troubleshooting approach of drilling-down on the issue (verify upstream equipment/systems are operating properly then slowly work down-stream towards the issue)
· Don’t jump to conclusions without supporting data
Intermittent Problems are the worse. They often involve the failure of a weak-link but does not directly help identify the root cause. Can’t tell you how many times in the past (and more in the future) we have made the comment “I wish it would just fail” out of frustration. Sometimes Mechanical issues can be visually confirmed and quickly resolved. Electrical issues can be much more challenging. They typically aren’t immediately visible and this further supports the advantage of a methodical trouble-shooting approach and testing plan.
One of the many services Kunst offers includes making Emergency Service Calls to support getting your Operation back on-line. Our Customer can be sure of our support until the issue is resolved AND we will also provide a Report with recommendations for improvements and additional resources to prevent recurrence of the issue.
Testing Emergency Power/Energy Systems
Testing Emergency Power/Energy Systems
Testing Emergency Power/Energy Systems
Maintenance of Emergency Power/Energy Systems is equally important as Maintenance of the Systems and Equipment they support. Critical Processes often include expensive Emergency Support Systems. The Risks and Costs of loss of energy include: loss of Production, Product Quality, Equipment/Personnel Safety, environmental Excursions, On-Time
Maintenance of Emergency Power/Energy Systems is equally important as Maintenance of the Systems and Equipment they support. Critical Processes often include expensive Emergency Support Systems. The Risks and Costs of loss of energy include: loss of Production, Product Quality, Equipment/Personnel Safety, environmental Excursions, On-Time-Delivery among many other costs.
Process Owners should always have the Support Systems routinely serviced by the OEM (diesel/gas generator, transfer switches, Uninterruptible Power Supplies, battery banks, electrically/mechanically buffered/isolated systems, etc). This is extremely important for the equipment Warranties, insurance requirements and to ensure necessary upgrades are completed.
Also, it is imperative for the Owner to perform Full-Load Testing with the Goal to ensure the expensive Back-up/Support System Equip will support the Process Equipment under real-situation conditions (middle of the night, weekends, peak demand times).
I have often witnessed Emergency Systems fail to start and support the Process because the Back-up System was always Load-Tested during ideal conditions. This type of test is not thorough since the Utility Provider is lightly loaded and the Utility System parameters (voltage, gas pressure) are different. The condition of the Utility System will vary (soft or stiff electrical or gas pressure source)
Some examples of non-ideal Emergency System Test Conditions:
· Lightly loaded Utility System. A testing at night or the weekend will not include impact of other local customers bringing down the voltage or gas pressure
· Other internal Processes not Operational or operating <50%
Some systems which I have successfully designed, installed and maintained/tested:
o Water cooling systems/pumps
o Computer data equipment and their air conditioning
o Sequential Start-up of larger motors +50 HP under voltage dip situations
o Liquid mixing systems
o Hydraulic systems
o Pressurized gas/vacuum systems
In summary, effective Maintenance and Testing of Emergency Back-up Systems for Critical Processes should have 2 components:
1. Routine testing of the individual Emergency Equipment performed by the OEM
2. Full System Testing done with simulation of full load at Peak/demanding Utility times (when Production can be safely interrupted if the Tests fail)
Power Quality & Harmonics
Testing Emergency Power/Energy Systems
Testing Emergency Power/Energy Systems
coming soon!