Coming Soon
Data, Trends & Analytics
The Power of Data & 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, Ultrasonic Scanning and Tri-Axial Vibration analysis which will provide a detailed and complete analysis of the condition of Equipment. 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. Being an experienced Electrician, hand tools are always present.
- Multiple Technology State-of-the-Art Test Equipment all contained in 1 Mobile Test Rig. Unique Methodology developed which uses multiple technologies (Thermal, Ultrasonic, Vibration) within 1-Survey to support comprehensive Predictive Maintenance Programs
- Engineering Services from a Company with decades of experience with Critical Processes and Electrical/Mechanical Equipment. Experience working with stakeholders (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.
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).
The Tools/Instruments/Technologies & Software have changed considerably from 40 years ago and are state-of-the-art.
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
Next Level Service: Comprehensive Testing in 1-Survey
FIELD SURVEY CHECKLIST
Thorough & Quality Field Analysis using Multiple Technologies in 1-Survey
Our Knowledge Base
Next Level Service with a Portable Test Rig
Next Level Service with a Portable Test Rig
Next Level Service with a Portable Test Rig
The development and field application of our Mobile Test Rig is a major component of providing our Next Level Service. The portable Rig combines several technologies which can be interchanged quickly and on-demand while conducting the survey. Our Engineer will rotate between Thermal, Ultrasonic, Vibration and Power Quality technologies
The development and field application of our Mobile Test Rig is a major component of providing our Next Level Service. The portable Rig combines several technologies which can be interchanged quickly and on-demand while conducting the survey. Our Engineer will rotate between Thermal, Ultrasonic, Vibration and Power Quality technologies efficiently to get to the Root Cause of a detected anomaly. The measured data is readily stored on a laptop and will then support any required immediate action and future reporting, including the analysis of trends.
This Testing Methodology was developed and successfully employed in a Critical and Continuous Process responsible for melting Titanium at high-volumes. Interruptions in the process meant significant monetary losses: product quality, down-time, Safety, on-time delivery. Melting Titanium at high-volumes requires several electrical and mechanical systems to operate reliably and simultaneously. Mechanical systems such as vacuum, compressed air/gas, high-flow water-cooling, hydraulic, and their components (motors, pumps, flow valves, heat-exchangers). Electrical Systems including HV DC power supplies, high-current AC systems, motor generator and battery emergency support, aerial pole-line & distribution, VF drive and process control PLCs, and their individual components (oil/dry transformers, metal-clad switchgear, fuses/breakers, rectifiers and inductors/capacitors, regulators and surge arrestors). These systems and components were concentrated in a small area surrounding the physical process. This created the ideal environment to employ a Mobile Test Rig equipped with multiple technologies. Alternating between the testing technologies was an ideal solution to support Predictive Maintenance and equipment Reliability in an intense electrical and mechanical manufacturing process.
Trouble-Shooting Problems
Next Level Service with a Portable Test Rig
Next Level Service with a Portable Test Rig
One of the many services Kunst offers includes making Emergency Service Calls to support clients’ Continuous Operations in the event of an Unplanned Outage. We offer +40 years of experience in trouble-shooting electrical & mechanical systems with a goal to get your Continuous (24-7) Manufacturing Operation back on-line.
Intermittent pro
One of the many services Kunst offers includes making Emergency Service Calls to support clients’ Continuous Operations in the event of an Unplanned Outage. We offer +40 years of experience in trouble-shooting electrical & mechanical systems with a goal to get your Continuous (24-7) Manufacturing Operation back on-line.
Intermittent problems are very challenging to identify and can present costly interruptions to a continuous process. They often involve the failure of a weak-link that may not identify the root cause right away. Sometimes mechanical issues can be visually confirmed and quickly resolved. Electrical-related issues can be much more difficult since they aren’t always visible and therefore require another approach to finding the issue. An example is when the root cause problem creates voltage or current anomalies which damage other connected components.
Consider these methods to make troubleshooting more effective:
- Engage the support staff & gather observations & facts (past & present) leading up to the failure
- Recurring events and recent changes to the system should be identified
- Confirm facts with measurements using test instruments and updated drawings
- Use a steady & methodical troubleshooting approach to zero-in on the location of the fault
- Be careful of replacing components that aren’t part of the Root Cause as this may create additional equipment failures and Safety Risks
Unplanned outages which occur on off-peak times (late shifts, weekends, Holidays) are especially challenging due to limited support resources (mechanics, electricians, engineers). 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 available resources. This further emphasizes the importance of using effective Trouble-Shooting techniques.
Finally, it is very important to evaluate the availability of spares, drawings, tools and training after the Root Cause has been identified and corrected. These items should be included in the Corrective Actions following the process being back on-line. This is always an essential element of the Final Report provided by Kunst. Sometimes it’s also an opportunity to assemble a Continuous Improvement Initiative/Team which includes the Stakeholders of the Process.
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 equipment they support. Critical Processes often include expensive Emergency Power Systems to support 24/7 operation. The risks and costs of the failure of the Emergency Power System is significant: Production, Product Quality, Equipment/Personnel Saf
Maintenance of Emergency Power/Energy Systems is equally important as Maintenance of the equipment they support. Critical Processes often include expensive Emergency Power Systems to support 24/7 operation. The risks and costs of the failure of the Emergency Power System is significant: Production, Product Quality, Equipment/Personnel Safety, Environmental Excursions, On-Time-Delivery- all suffer.
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). Routine service by the OEM is extremely important for the equipment Warranties, insurance requirements and for hardware upgrades.
Also, it is imperative for the Owner to perform Full-Load Testing with the Goal to ensure the expensive Emergency Power System will support the Process Equipment under real-situation conditions (middle of the night, weekends, peak demand times).
Testing Emergency Systems during "normal conditions" is NOT meaningful or effective. Testing MUST be performed to consider situations out of the Customers' control (Utility network is lightly/heavily loaded creating voltage & gas pressure abnormalities).
Since the condition of the Utility System will vary then Testing of the Emergency Power System must include these non-ideal Test Conditions:
· Lightly loaded Utility System (off-peak testing will not include impact of other local customers effecting the voltage or gas pressure)
· Customer Production Demand & Internal Processes operating at <50% and at +75%
Our experience has supported the design, installation, commissioning and maintenance of:
o Water cooling systems & heat exchange
o Computer data equipment Power Supplies and their cooling requirements
o Start-up of large motors banks +50 HP and voltage dip situations for :
o Liquid mixing systems
o Hydraulic systems
o Pressurized gas/vacuum systems
In summary, effective Maintenance and Testing of Emergency Power Systems for Critical Processes should have 2 components:
1. Routine testing of the individual Emergency System Equipment by the OEM
2. System Testing performed at heavy process demand during peak Utility conditions (safe and controlled situations must be considered)
Power Quality & Harmonics
Testing Emergency Power/Energy Systems
Testing Emergency Power/Energy Systems
coming soon!
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