Non Destructive Testing (NDT)
Commercial & Industrial Solutions & Services
NDT Services Group
The NDT Services Group is a wholly owned subsidiary of Kenshaw, that provides independent, non-destructive testing and condition monitoring services. We pride ourselves on customer service for reliable plant and equipment which maximises profits and minimises downtime for clients.
Our technicians are highly skilled and experienced across a wide range of industries from mining, utilities, infrastructure, processing, military and transport.
The condition monitoring technologies and services that we offer include: Vibration Analysis, Dynamic Balancing, Thermal Imaging, Oil Analysis, Laser Alignment, Electric Motor Testing, Ultrasonic Testing and Customer Support.
With the advances in computer aided and enhanced test equipment, electrical condition monitoring is now widely accepted as a beneficial technology to complement existing condition monitoring techniques such as vibration analysis, infra-red thermography scans and oil analysis.
The use of a combination of proven and reliable condition monitoring techniques enables the motor or generator owner to confidently move from a time based maintenance regime to a condition based maintenance regime. A condition based maintenance program allows for the efficient use of site resources and offers significant financial benefits.
The use of a combination of proven and reliable condition monitoring techniques enables the motor or generator owner to confidently move from a time based maintenance regime to a condition based maintenance regime.
A condition based maintenance program allows for the efficient use of site resources and offers significant financial benefits.
No single test can identify all potential fault mechanisms.
The following tests are utilised by NDT Services Group to determine the condition of electrical rotating assets and to identify potential failure mechanisms:
- Symmetry – Resistance / Inductance
- Insulation Resistance
- DC Hipot – Step Voltage
- Polarisation Index
- On-line and Off-line Partial Discharge
- Dielectric Dissipation Factor
- AC and DC Voltage Drop
- Current Spectrum Analysis
- Instantaneous Power Analysis
- Current In-rush
Reports with all test results, detailed analysis and recommendatioins are issued for every motor.
Why conduct Oil Analysis?
Oil analysis can detect:
- Fuel dilution of lubrication oil
- Dirt contamination in the oil
- Antifreeze in the oil
- Excessive bearing wear
- Misapplication of lubricants
Some wear is normal, but abnormal levels of a particular material can give an early warning of impending problems and possibly prevent a major breakdown.
Sampling and analysing on a regular basis establishes a baseline of normal wear and can help indicate when abnormal wear or contamination is occurring. Oil analysis works like this. Oil that has been inside any moving mechanical apparatus for a period of time reflects the exact condition of that assembly. Oil is in contact with engine or mechanical components as wear metallic trace particles enter the oil. These particles are so small they remain in suspension. Many products of the combustion process also will become trapped in the circulating oil.
The oil becomes a working history of the machine.
Particles caused by normal wear and operation will mix with the oil. Any externally caused contamination also enters the oil. By identifying and measuring these impurities, you get an indication of the rate of wear and of any excessive contamination. An oil analysis also will suggest methods to reduce accelerated wear and contamination.
The typical oil analysis tests for the presence of a number of different materials to determine sources of wear, find dirt and other contamination, and even check for the use of appropriate lubricants.
With the implementation of a routine vibration analysis program the following benefits are possible:
- Identification of issues prior to expensive plant downtime and loss of production
- Positive prioritisation of required maintenance to maximise maintenance efforts and resources
- Reduction of damage to secondary and ancillary equipment
- Improved plant reliability and production
Reports list the condition of the plant surveyed in a clear and easy to understand format. Plant requiring corrective actions have a detailed fault analysis and description with required recommendations.
Grease and oil sampling, on-site balancing, motor diagnostics, laser alignment and thermography services are offered by NDT to complement vibration analysis programs.
Early identification of serious problems is possible.
Positive identification of the following problems can be achieved with vibration analysis:
- Rotating component imbalance
- Mechanical looseness
- Bearing defects
- Gear mesh problems / defects
- Misalignment of components
- Lubrication issues
- Pump cavitation
- Electric motor problems
Reports are delivered promptly so identified problems can be actioned prior to costly failures.
A non destructive and non intrusive preventative maintenance tool.
With increasing demand to cut costs and remain competitive, many companies are expanding their maintenance programs to include predictive and proactive technologies such as infrared thermography.
Recent years have seen an increase in the acceptance and use of infrared thermography for preventative and predictive maintenance. While early applications were confined primarily to electrical and structural situations, today's industrial environment has resulted in NDT Services Group constantly finding new and diverse applications for thermal imaging.
Detailed full colour reports detailing IR and visual images, fault severity, fault description and recommendations are issued for every survey. These reports are utilised by maintenance personnel to action identified problems and by insurance companies for compliance audits.
Infrared scans identifies problems not seen by the human eye.
Infrared scans are the fastest way to identify heat generating faults in your facility.
Common uses for this technology include identification of problems in:
- Electrical assets such as switchboards, cables and motors
- Rotating component failures in gearbox assemblies and conveyors
- Furnace and heat plant inefficiencies due to failing refractory / insulation
- Production problems such as blockages and incorrect levels
Using laser alignment systems, our technicians provide a comprehensive shaft alignment measurement service for your rotating assets. Whether you have complex drive trains, vertical machines, or any number of simple pump and motor sets to align, in standard or hazardous environments, NDT Services Group can provide a cost effective, professional service for your company.
The laser alignment systems utilised by NDT Services Group are calibrated to applicable standards which enable both accurate and repeatable measurements.
Detailed reports are provided that clearly show, both graphically and numerically, the original and final alignment condition of the drive train components.
Plant reliability starts with accurate alignment.
When misaligned, the loading of the drive components dramatically increases due to the rotational reaction forces.
This increased loading can lead to:
- Premature bearing and seal failures
- Advanced coupling and shaft wear
- High bearing temperatures
- Lubrication problems
- Excessive vibration
- Damage to component mountings
- Increased power consumption
All alignments have a report documenting before and after measurements.
On-site balancing operations allow production to commence immediately after balance correction limiting costly downtime.
The benefits of on-site dynamic balancing are:
- Reduction in downtime, no disassembly and removal of components off site
- Can be carried out during short planned outages effectively
- Extends the service life of bearings, seals and machine components
- Product quality maintained with increased productivity
Typical equipment / components that are balanced on site include:
- Pulleys and rollers
- Pump impellors
- Blowers and fans
- Large rotors
We come to your facility and carry out balancing on your assets.
Typical industries utilising our on-site balancing services are:
- Cement Plants
- Pulp and Paper Mills
- Power Utilities
- Water Utilities
- Steel Mills
- Materials Handling Operations
- Manufacturing Sector
With concerns regarding access and arc flash exposure, thermal imaging is becoming increasingly difficult on some high voltage installations. Ultrasonics coupled with TEV measurements allows for non intrusive assessment of high voltage installations in a safe and accurate manner prior to an in service failure.
All high voltage assets will have some level of partial discharge occurring either internally or on the surface of the insulation. TEV readings taken, can be quantified to determine the severity of any internal discharge problems and any required investigations or maintenance strategies.
Ultrasonic inspection of the assets allows for easy identification of surface tracking that may lead to erosion of insulation and the deposit of potentially conductive surface contamination.
Ultarsonic and TEV detection have become the technology of choice for safe unobtrusive High Voltage electrical inspections.
Typical applications include:
- Transmission and distribution lines
- Substation inspections / audits
All audits have a detailed report documenting the found state and recommended actions.
Magnetic Particle Testing
Dye Penetrant Testing
Magnetic Particle & Dye Penetrant
At NDT Services Group we recognise that the reliability of Crack Testing depends on repeatability and acceptance levels. When safeguarding structural integrity, our technicians and engineers work together to select the correct NDT method and Australian standard to enable reliable results to be produced.
A full colour report detailing visual images, fault severity, fault description and recommendations are issued for every survey. These reports are utilised by maintenance personnel to action identified problems. If required, sample reports for this service offering are available upon request.
Types of Crack Testing include:
- Magnetic Particle Testing to AS1172
- Dye Penetrant Testing using fluorescent penetrant to AS 2062
- Dye Penetrant Testing using visible penetrant to AS 2062
NDT Services Group is a NATA certified Crack Testing provider.