This document discusses predictive maintenance technologies including infrared thermal imaging, ultrasound detection, and vibration measurements. It provides examples of how each technology can be used to detect issues in mechanical, electrical, hydraulic applications and lists specific problems that can be identified, such as bearing issues, leaks, misalignments. Advantages of these non-intrusive technologies include improved safety, reliability and cost savings through reduced downtime and energy use.

1. SVL SINGAPORE SERVICES
RAJAGOPALAN. J
Integrating Infrared with Ultrasound and Vibrations
analysis applications for Marine and Off shore
Industry

2. Predictive Maintenance is the use Non-intrusive
Technologies of Infrared Thermal Imaging, Ultrasound
Detection & Vibration measurements.
Thermal Imaging: With the Thermal Signature, we
can see the Infrared Radiation which we can not
see otherwise
Ultrasound: With Ultrasound machine, we can hear
the High Frequency sound which we can not hear
otherwise
Vibration survey: Vibration signature shows the
physical movement of the machine indicating the
health condition of the same

3. What is infrared?
Advantages:
•Condition analysis of varied Mechanical, Electrical
& Hydraulic applications
•Non-intrusive testing & safe to implement
•Improved Safety & Reliability
•Energy savings and ultimately cost saving

4. What is
Ultrasound?
Human range (16Hz to 18KHz)
Industry Applied range (20KHz to 100KHz) is Heterodyned for
Audible Human range

5. Above baseline 20 dB
Levels of Severity
With ultra sound

6. Mechanical Inspection
Bearing condition
Rubbing condition
Cavitations
Gear boxes & Gears
Pumps & Motors
Lack of Lubrication
Electrical inspection
Tracking
Arcing
Corona
Transformers
Insulators
Relays
Bus bars
Leak Detection/Energy audits
Compressed air
Compressed gases
Vacuum leaks
Condenser tubes
Hatch covers
Boilers Heat exchangers
Valves
Steam Traps

7. Soft foot
Misalignment
Mechanical Looseness
Greasing problems
Some problems that can be detected with
Ultrasound, Infrared & Vibration
Making Motor Ready for Service
Pull the grease tube & verify grease
Carry out Run out test
Carry out Amp draw test
Bench Vibration test

8. COUPLINGS AND SHAFTS ALIGNMENT
 Couplings inspection is difficult in normal operation.
 This is how misalignment looks like I Infrared.
 Note the Heat on the Motor Inboard Bearing and the coupling Rubber
 This Machine will not last long under obvious misalignment

9. Increase machine Reliability
with
Infrared Technology
This could be catastrophic failure on a VLCC can
cause fire in main switch board

10. The thermal image and related Digital image of
Marine pump installation. In digital profile the
pump and motor showing Good. In thermal image
the motor is in trouble and drawing 10% excess
amperes . The motor will burn if the action is not
taken immediately.
This photo is taken in a
leading company tanker
vessel and displaying as
example.
A TYPICAL MOTOR / PUMP PROBLEM -
EXAMPLE

11. A 250 kw motor inert gas fan in a vlcc
operating with drive end bearing
temperature of 93.3*c is going to cause
damage to motor due to misalignment
and overloading

12. • steam traps stuck (open)
position:
- waste of energy and
damage to atmosphere
condenser.($$$)
- excess steam in system
- create back pressure
back pressure can
cause other steam
traps to malfunction
• steam trap stuck in shut
(closed) position:
- water hammer
- line clog and corrode
- possible rupture
cause and effect of
failed steam traps
Failed steam trap
Normal trap
Failed trap

13. The partially
blocked pipe is
an example of
surface
temperature
effects in a pipe
line

14. Sample evaporator
liquid refrigerant
inlet and expanded
gas outlet at the
return headers for
each coil
Both above
compressors
connected to this
defective evaporator
coils. Loss of energy
with 2 compressors
running with
minimum climate
control effect

15. Main air compressor high pressure
suction valves one valve is leaking
badly other valve is chocked with
carbon trouble- energy loss/ damage
to valves, carbonisation in inter and
after coolers and reduced efficiency

16. The Gear box drive end bearing
showing 85.4*C where the Lube oil
temperature at the cooler inlet
48*c indicating trouble at the
bearing condition.
Marine Propulsion Gear box showing
high bearing temperatures

17. Turbocharger lagging to be improved, Areas above 220 Deg C
shown. SOLAS non-compliance

18. A diesel
generator
alternator
showing high
temperatures
can cause
damages loss
of alternator
life due to
excess
temperatures

19. Main start Air
compressor onboard
running very hot with
LP discharge inlet to
inter cooler about
194.2*C reduce the
efficiency, long running
hours and damage to
many components like
valves, coking in inter
after coolers etc.,

20. Leaking Boiler Relief valve
This is not only dangerous but very costly in Steam
production. This must be corrected at the
earliest opportunity.

21. Pumps and
hydraulics
A blocked filter top side
hot oil flowing, bottom
side cooler and showing
no oil flow(blockage)
through filter.
A good filter IN A
CRANE HYDRAUIC
SYSTEM

22. Very effective on Slow
Speed Applications
Types of testing performed
Comparison
Historical Trending
Spectrum Analysis
Bearing
Inspection
Increase your Equipment
Reliability
with
Ultrasound Technology

23. Compressor Valve
Good n Bad
Good
Valve
Bad
Valve

24. Arc Flash Conditions
Corona
Destructive dielectric breakdown that
results in a fault in the insulator.
Only occurs at 1000V or higher, and is
undetectable by infrared inspection.
The main concern in low voltage
systems
Tracking
Arcing

25. High Voltage Components are
well enclosed, making for poor
or sometimes impossible infrared
inspection
Transformers & Power
Supplies
Good Transformer
Loose Transformer
Good Power Supply
Shorting Supply
FFT (dB vs frequency)
Time Series (dB vs seconds)

26. Good Bearing
Suspect Bearing
Receiving
Lubrication
3 min. Post
Lubrication
Bearing Testing

27. Workshop air leak
Meat Room Door
leak
Leakage testing

28. The ISO standards for the machinery
vibration values limits

30. THE FFT spectrum
guidelines for defects
analysis with amplitude on
Y-axis and frequency on X
axis

31. Aux engine Alternator side Vibration analysis

33. Sound profile of the Aft Bow thruster gear box bearing heated up
to 102.8*C on the outer surface.

34. Instruments in use

35. FUTURE PLANS

36. SVL SINGAPORE SERVICES
Office – 65-63001526
Mobile – 65-98637870
e-mail – raja@svlsingapore.com
e-mail --Personal- swmera@gmail.com