CONDITION MONITORING

 Vibration analysis measures the mechanical oscillations of rotating assets to detect early-stage faults such as imbalance, misalignment, looseness, bearing wear, and gear defects. Using spectrum analysis (FFT), time waveform analysis, and trending, our specialists provide a deep understanding of asset condition. 

 Application 

  Identifying hidden issues before they escalate enables proactive maintenance, reduces unexpected shutdowns, improves operational safety, and significantly extends machinery life. 

 Detects :  

  Imbalance, misalignment, looseness, bearing faults, gear mesh issues, etc. 

 Oil analysis checks lubricant condition to evaluate the internal health of machines. It reveals wear, contamination, and chemical changes in the oil that help detect issues before they lead to failure. 

 Application 

 Used to support preventive maintenance by tracking wear trends, oil cleanliness, and fluid breakdown. Helps reduce downtime, extend part life, and optimize oil change intervals. 

 Detects :  

 Wear particles, oil contamination, oxidation, water ingress, additive loss, and signs of metal fatigue. 

 Ultrasound inspection picks up high-frequency sounds caused by air leaks, electrical discharge, and mechanical friction in machines. It’s used to catch problems early — before they cause failures — and supports other condition monitoring methods. 

 Application 

 Helps reduce air loss, spot lubrication problems, and detect hidden electrical issues before they escalate. It also supports reliability programs by giving early warning signs. 

 Detects :  

  Air and gas leaks, weak lubrication, internal leakage, electrical arcing, and abnormal friction or impact. 

 Rotordynamics analyzes the behavior of high-speed shafts — predicting critical speeds, unbalance responses, and resonance risks using simulation and testing. It helps identify instabilities before they cause vibration, damage, or catastrophic failure. 

 Application 

 Ensures safe startup and long-term performance of critical rotating assets. Prevents failures tied to resonance, poor design, or incorrect retrofits — especially in high-value or high-speed machines. 

 Predicts; 

 Critical speeds, whirling zones, vibration instability, and margin to resonance in rotor-bearing systems. 

 Thermal imaging uses infrared cameras to detect abnormal heat in mechanical, electrical, or process systems. It's a fast, non-contact way to find hot spots, poor connections, and insulation faults. 

 Application 

 Identifies abnormal heat patterns in electrical panels, rotating machinery, and insulation systems — enabling early detection of overloads, imbalances, loose connections, bearing wear,  

 Detects :  

 Hot spots, load imbalance, failing insulation, thermal stress, and friction buildup. 

 In-situ balancing is the process of correcting rotor unbalance directly on-site, while the machine is running. It removes the need to dismantle equipment or transport it off-site. Using vibration analysis, phase measurements, and trial weights, the rotor is balanced dynamically under real operating conditions — minimizing vibration without interrupting operations. 

 Application 

 Restores vibration within acceptable limits, extends bearing life, and reduces fatigue on foundations or pipework — especially useful when shutdowns are costly or access is limited. 

 Detects :  

  Mass unbalance — the most common cause of vibration — while the rotor is installed and spinning. Not a fix for bent shafts, soft foot, or misalignment, but can rule them out during diagnostics. 

 Modal and ODS (Operating Deflection Shape) analysis reveal how structures move and vibrate during operation. Modal shows natural frequencies and mode shapes. ODS shows actual movement patterns under running conditions — visualizing how and where the structure flexes, twists, or amplifies vibration. 

 Application 

 Used to prevent resonance, verify design strength, support structural modifications, and avoid failures caused by unexpected vibration behavior. 

 visualizes 

 Real structural behavior under operating or test conditions — including resonance, mode shapes, and areas of amplified motion.. 

 Acceptance testing checks that newly installed, repaired, or commissioned machinery meets ISO/API vibration standards and client performance specs. It confirms that the machine is ready to run — safely, reliably, and within limits. 

 Application 

 Protects your investment, verifies workmanship, prevents warranty issues, and ensures smooth handover from vendor to client. Also used to catch problems early before equipment enters full operation. 

 confirms 

 That vibration and performance fall within ISO/API acceptance thresholds — and flags any out-of-spec behavior before it becomes a dispute. 

 Motion magnification is a video-based technique that visually amplifies tiny machine or structural movements — making invisible vibration problems visible. It helps detect looseness, misalignment, and structural deflection without disassembly. 

 Application 

 Used to speed up diagnosis, reduce manual inspections, and find hidden root causes — without stopping the equipment. 

 Detects :  

 Resonance, looseness, mechanical play, and vibration-related movement that’s hard to see by eye or traditional tools. 

 Laser shaft alignment ensures precise collinearity between connected machine shafts. It reduces mechanical stress, prevents premature bearing and seal failure, and optimizes operational efficiency. 

 Application 

 Decreases energy consumption, lowers repair costs, minimizes machine downtime, and extends equipment service life. 

 corrects :  

 Angular/parallel misalignment between rotating components. 

 MCSA detects electrical and mechanical faults in motors by analyzing current waveforms. It identifies issues like broken rotor bars, eccentricities, stator faults, and power supply anomalies without interrupting machine operation. 

 Application 

 Provides predictive insights into motor health, avoiding costly breakdowns, optimizing energy usage, and enabling better motor lifecycle management. 

 Detects :  

 Broken rotor bars, eccentricity, stator issues, air gap problems, unbalance-related electrical harmonics 

 Technical troubleshooting involves rapid, multi-discipline analysis (vibration, ultrasound, thermography, electrical) to find and fix critical machine or system faults impacting production. 

 Application 

 Restores productivity fast, pinpoints root causes instead of symptoms, and minimizes production losses during unexpected events. 

 applies :  

  Vibration + thermography + ultrasound + electrical checks. 

Sometimes a single tool won’t cut it. In complex cases, we deploy a mix of technologies—vibration, thermography, ultrasound, and electrical diagnostics—to zero in on the real root cause.

Just like a recent case where we traced a hidden failure that basic inspections missed—this integrated approach saved days of downtime and pointed directly to the actual problem