What, why, and How of Condition Monitoring

Condition monitoring is the process of monitoring a parameter of condition in machinery (vibration, temperature, oil condition, etc.) to identify a significant change that is indicative of a developing fault. It is a major component of predictive maintenance. This market includes hardware, software, and services.

Based on the findings of the aforementioned market research and study, it's now opportune to elevate existing condition monitoring programs by integrating appropriate procedures, tools, and techniques. This involves amalgamating big data, established asset strategy models, and diagnostics capabilities to prepare for embracing new technologies like AI/ML-based IIOT solutions, enabling advanced automated machine health predictions and actionable insights.

The AIVA Team, boasting a collective experience of 50 years in machine condition monitoring, is adept at assisting our clients in optimizing their current programs. We accomplish this by comprehensively understanding their software systems configuration, structuring meticulous data analysis, and seamlessly integrating asset condition data and process data. Furthermore, we offer guidance in implementing AI/ML-based IIOT Asset Predictive Analytics solutions, aligning with the trajectory of the Fourth Industrial Revolution (Industry 4.0).

Vibration Analysis and Data Diagnostics Services

Vibration analysis technology is a proven method used to assess the condition of machinery and equipment by analyzing their vibration patterns. It involves monitoring and analyzing the vibrations produced by various components of machinery, such as motors, pumps, gears, and bearings. By measuring and interpreting these vibrations, engineers and technicians can identify abnormalities, detect potential faults or failures, and determine the overall health and performance of the equipment.

Vibration analysis technology typically involves the use of specialized sensors or accelerometers to measure vibrations at different points on the equipment. These sensors generate data that is then analyzed using software tools to identify patterns, frequencies, and amplitudes of vibrations. By comparing these patterns against established baselines or known signatures of normal operation, abnormal conditions or potential issues can be detected.

Vibration analysis is a meticulous process aimed at identifying anomalies and monitoring deviations from the established vibration signature of a system. The vibration of any object in motion manifests through variations in amplitude, intensity, and frequency. These variations can be indicative of underlying physical phenomena, enabling us to leverage vibration data to glean insights into equipment health. Vibration analysis serves several purposes.

• Detecting and addressing developing problems to prolong machine lifespan.
• Identifying and monitoring chronic issues that may exacerbate over time and cannot be rectified.
• Establishing acceptance testing criteria to ensure the proper conduct of installations and repairs.

Benefits of Vibration Analysis

Early Detection of Machinery Issues: Vibration analysis enables early detection of potential machinery problems such as misalignment, imbalance, bearing defects, and looseness. By identifying these issues at an early stage, maintenance can be scheduled proactively, preventing costly breakdowns and production losses.

Improved Equipment Reliability: Regular vibration analysis helps ensure that machinery operates within acceptable vibration limits. By maintaining optimal operating conditions, equipment reliability is improved, leading to increased uptime and productivity.

Enhanced Safety: Monitoring vibrations allows for the detection of abnormal conditions that may pose safety risks to personnel or the surrounding environment. By addressing these issues promptly, the likelihood of accidents or injuries is reduced.

Increased Equipment Lifespan: By identifying and addressing potential issues early, vibration analysis helps to extend the lifespan of machinery and components. This reduces the need for premature replacements and prolongs the overall life cycle of equipment.

Cost Savings: Proactive maintenance based on vibration analysis results in cost savings compared to reactive maintenance practices. By preventing unexpected breakdowns and minimizing downtime, organizations can reduce repair costs, avoid production losses, and optimize maintenance budgets.

Improved Product Quality: Machinery operating with excessive vibrations can lead to product defects or variations. By maintaining optimal machinery conditions through vibration analysis, product quality can be improved, and consistent manufacturing processes can be ensured.

Energy Efficiency: Monitoring and optimizing vibration levels can help identify inefficiencies in machinery operation, leading to energy savings. By reducing unnecessary vibrations and improving equipment performance, energy consumption can be minimized.

We are proud to have the most esteemed Vibration Analysis experts on our team. Led by an ISO Level-III Vibration Analyst certified by Mobius Institute – our Vibration Analysis services at AIVA TECH SOLUTIONS PRIVATE LIMITED are unparalleled.

Laser Shaft Alignment

Shaft alignment refers to the process of aligning the rotational centers of two or more shafts so that they are collinear when the machines are operating under normal conditions. Proper shaft alignment is determined not solely by the total indicator reading (TIR) of the coupling hubs or shafts, but rather by ensuring the correct centers of rotation of the shaft supporting members, such as machine bearings.

Types of Misalignments

• Parallel or Offset Misalignment: This occurs when the rotational axes of two shafts are parallel but not collinear, resulting in a lateral offset between the shafts.
• Angular Misalignment: Angular misalignment happens when the rotational axes of two shafts intersect but are not collinear, causing an angle between the shafts.
• Combined Misalignment: Combined misalignment involves a combination of both parallel and angular misalignments, where the shafts are both laterally offset and angled relative to each other.

At AIVA TECH SOLUTIONS PRIVATE LIMITED, we offer comprehensive Laser Shaft Alignment solutions tailored to meet the needs of various industries. Utilizing a range of cutting-edge laser alignment equipment such as Easy laser, Optalign, Rotalign, and fixture laser, we provide precise alignment services for rotating machinery. Whether it's ensuring optimal performance, reducing energy consumption, reducing wear and tear, or preventing unexpected breakdowns, our laser shaft alignment solutions are designed to maximize efficiency and reliability across diverse industrial applications.

We provide Shaft Alignment, Flatness Alignment, and Bore Alignment services to a diverse range of industries, including:

• Power Generation: Alignment of turbine shafts and casings.
• Metal and Non-Metallic Industries: Alignment of gearboxes, blowers, pumps, fans, compressors, and mills, among others.
• Offshore: Motor shaft alignment and generator alignment.
• Manufacturing: Pump and motor alignment, as well as machine train alignment.
• Process Industries: Alignment of kilns and pump alignment.
• Oil & Gas: Alternator shaft alignment and machine base alignment.

Our expertise and advanced alignment techniques ensure precise alignment, contributing to the efficiency, reliability, and longevity of equipment across these industries.

Benefits with Laser Shaft Alignment

In-Situ Dynamic Balancing

Single/Dual Plane Balancing

Multiplane Balancing

Expertise in In-Situ Dynamic Balancing:

We possess extensive knowledge and a dedicated drive to deliver exceptional service. We always strive to exceed expectations and ensure the highest quality of service possible.

Tailor-Made Reporting:

AIVA TECH SOLUTIONS PRIVATE LIMITED offers customized reporting for every client. Each part of the report can be modified to meet your specific needs and requirements. We take pride in our comprehensive balancing reports and are confident that you will be satisfied with our reporting standards.

Benefits of In-Situ Dynamic Balancing:

Reduced Vibrations: In-situ dynamic balancing helps to minimize vibrations in rotating machinery by ensuring that the mass distribution is evenly distributed. This leads to smoother operation and reduces wear and tear on components.

Extended Equipment Lifespan: By reducing vibrations, in-situ dynamic balancing helps to prevent premature wear and failure of bearings, shafts, and other critical components. This extends the lifespan of the equipment and reduces the frequency of repairs and replacements.

Improved Product Quality: Machinery operating with excessive vibrations can lead to product defects or variations. In-situ dynamic balancing ensures that machinery operates within acceptable vibration limits, resulting in improved product quality and consistency.

Enhanced Safety: Excessive vibrations in rotating machinery can pose safety risks to personnel and the surrounding environment. In-situ dynamic balancing helps to mitigate these risks by reducing vibrations to safe levels, thereby improving overall workplace safety.

Optimized Performance: Balanced machinery operates more efficiently, leading to improved performance and productivity. In-situ dynamic balancing ensures that machinery operates at its optimal level, resulting in higher throughput and reduced energy consumption.

Cost Savings: By preventing premature wear and failure of components, in-situ dynamic balancing reduces the need for costly repairs and replacements. Additionally, improved efficiency and productivity lead to cost savings through reduced downtime and energy consumption.

Minimized Downtime: In-situ dynamic balancing can be performed without the need to shut down or disassemble the equipment, minimizing downtime and disruption to production schedules. This allows for maintenance activities to be carried out more efficiently and effectively.

Overall, in-situ dynamic balancing is a valuable maintenance technique that helps to ensure the reliability, safety, and efficiency of rotating machinery in various industrial applications.

Infrared Thermography

How Infrared Thermography Works

All electrical and mechanical equipment emit heat, known as thermal radiation. Infrared video cameras, sensitive to this thermal radiation, detect and measure temperature variances between surfaces. These cameras then convert this information into an image visible to the human eye, displaying a heat signature.

Typical applications of Infrared Thermography include

• Electrical Surveys: Inspection of electrical panels, distribution boards, transformers, HV switchgear, etc.
• Mechanical Surveys: Assessment of motors, fans, pumps, gearboxes, conveyors, etc.
• Refractory: Examination of boilers, incinerators, thermal oxidizers, freezers, etc.
• Process: Monitoring of production processes.
• Buildings: Detection of heat loss, water leaks, etc.

Ultrasound

Benefits of Ultrasound Technology

On-Board Analysis of Electrical inspection

Motor Current Signature Analysis (MCSA)

An Electrical Motor Winding Test is performed to detect any electrical failures far in advance of an electrical breakdown ‐ giving you the power to confirm faults and take preventative action.

Cost effective, non‐destructive testing of:

• Motors (AC & DC)
• Generators
• Transformers

Conducted onsite, by specialist Condition Monitoring engineers, Monition’s Electric Motor Test & comprehensive report gives you the power to: ‐

• Detect problems in motors ahead of failure.
• Conduct Quality acceptance testing of new or rewound motors.
• Confirm winding faults before removing motors from service.
• Performing on‐site motor testing in industrial environments is normally hazardous.
• to electronic test instruments
• Check the integrity of inventory replacement units.

Infrared Thermography Analysis of Mechanical and Electrical Systems:

Lube Oil Analysis

Benefits of Lube Oil Analysis:

Lube oil analysis plays a crucial role in industries, especially in machinery and equipment maintenance and reliability. Here are some key benefits:

• Early Detection of Issues: Lube oil analysis can detect potential problems early, such as abnormal wear, contamination, and fluid degradation. This early detection allows for proactive maintenance and prevents costly equipment failures and downtime.
• Optimized Equipment Performance: By monitoring the condition of lubricants, industries can ensure that equipment operates at optimal levels. Proper lubrication extends equipment life, reduces energy consumption, and enhances overall performance.
• Cost Savings: Regular lube oil analysis helps in extending oil change intervals without compromising equipment health. This leads to cost savings by reducing the frequency of oil changes, disposal costs, and the need for replacement parts.
• Preventive Maintenance Planning: The data gathered from lube oil analysis enables maintenance teams to plan preventive maintenance schedules effectively. They can schedule repairs or component replacements based on actual equipment condition, reducing unplanned downtime and improving reliability.
• Improved Equipment Reliability: Monitoring lubricant condition helps in maintaining equipment reliability. Clean and properly lubricated machinery is less prone to failures, breakdowns, and premature wear, ensuring smooth operations and productivity.
• Environmental Protection: Regular oil analysis ensures that lubricants are within acceptable limits and free from contaminants. This promotes environmental protection by minimizing oil leaks, spills, and pollution risks.
• Condition-Based Maintenance: Lube oil analysis supports a condition-based maintenance approach, where maintenance activities are performed based on the actual condition of equipment rather than fixed schedules. This approach maximizes equipment uptime and reduces maintenance costs.
• Asset Health Monitoring: Lube oil analysis provides insights into overall asset health. Trends in oil properties and contaminants over time help in assessing equipment performance, identifying recurring issues, and making informed maintenance decisions.

Lube oil analysis can identify a range of conditions and issues related to lubricants, machinery, and equipment. Here are some key parameters and conditions that can be identified through lube oil analysis:

Oil Condition:

• Oxidation: Detects the level of oxidation in the oil, which can lead to viscosity changes and decreased lubrication effectiveness.
• Nitration: Measures the presence of nitrogen compounds, indicating potential thermal stress on the oil.
• Sulfation: Indicates the accumulation of sulfur compounds, which can affect oil performance and lead to corrosion.
• Acid Number (AN): Measures the acidity of the oil, which can increase due to degradation or contamination.

Contaminants:

• Water Content: Determines the level of water contamination in the oil, which can lead to corrosion, emulsification, and reduced lubrication properties.
• Particle Count: Identifies the presence of solid particles such as dirt, wear debris, or metal fragments, indicating potential equipment wear or contamination.
• Fuel Dilution: Detects the presence of fuel in the oil, which can occur due to leakage or improper combustion, affecting oil viscosity and lubrication properties.
• Coolant Contamination: Detects the presence of coolant or antifreeze in the oil, indicating potential leaks or issues with cooling systems.

Wear and Condition Monitoring:

• Wear Metals: Identifies the concentration of wear metals such as iron, copper, aluminum, and others, indicating wear rates and potential component failures.
• Additive Depletion: Monitors the depletion of additives in the oil, such as anti-wear additives, detergents, and dispersants, affecting lubrication performance.
• Viscosity: Measures the viscosity of the oil, which can change due to contamination, thermal stress, or degradation, impacting lubrication effectiveness.

Fluid Properties

• Total Base Number (TBN): Measures the reserve alkalinity of the oil, indicating its ability to neutralize acids and extend oil life.
• Total Acid Number (TAN): Measures the acidity of the oil, which can increase due to oxidation, contamination, or degradation.
• Flash Point: Determines the temperature at which the oil vapor ignites, indicating its flammability and potential for thermal breakdown.

Equipment Health

• Wear Patterns: Analysis of wear particle morphology and size distribution can provide insights into the type of wear, severity, and potential sources within the equipment.
• Condition Trends: Monitoring changes in oil properties and contaminants over time helps in identifying trends, predicting failures, and planning maintenance activities.

Annual Reliability and Condition Monitoring Contracts (AMC’s)

• Annual reliability and condition monitoring projects play a crucial role in ensuring the efficiency, safety, and longevity of industrial assets and infrastructure. These projects involve systematically assessing the condition of machinery, equipment, and facilities to detect potential issues early, prevent breakdowns, and optimize performance. The importance and benefits of such projects are manifold:
• Preventive Maintenance: Regular monitoring allows for the identification of potential issues before they escalate into costly failures. By addressing these issues proactively, companies can schedule preventive maintenance, reducing downtime and avoiding unplanned shutdowns.
• Cost Savings: Investing in reliability and condition monitoring projects can lead to significant cost savings in the long run. By detecting and addressing problems early, companies can avoid expensive repairs, minimize production losses due to downtime, and extend the lifespan of their assets.
• Improved Safety: Monitoring equipment and infrastructure for potential faults or malfunctions enhances workplace safety. By identifying safety hazards in advance, companies can take corrective actions to mitigate risks and ensure a safer working environment for employees.
• Optimized Performance: Regular monitoring enables companies to identify opportunities for optimizing equipment performance. By analyzing data collected through condition monitoring, companies can fine-tune operational parameters, improve efficiency, and maximize productivity.
• Enhanced Asset Management: Reliability and condition monitoring projects provide valuable insights into the health and performance of assets over time. This information helps companies make informed decisions about asset maintenance, repair, and replacement, leading to better asset management strategies and allocation of resources.
• Compliance and Regulatory Requirements: Many industries are subject to regulations and standards governing equipment safety and reliability. Implementing reliable condition monitoring practices helps companies demonstrate compliance with these requirements, reducing the risk of fines, penalties, and legal liabilities.
• Predictive Maintenance: Advanced condition monitoring techniques, such as predictive analytics and machine learning, enable companies to predict equipment failures with greater accuracy. By leveraging predictive maintenance strategies, companies can schedule maintenance activities based on actual asset condition, further minimizing downtime and maximizing uptime.
• Data-Driven Decision Making: Reliability and condition monitoring projects generate a wealth of data about equipment performance and health. By analyzing this data, companies can identify trends, patterns, and root causes of issues, enabling data-driven decision-making and continuous improvement initiatives.
• Competitive Advantage: Companies that invest in reliability and condition monitoring gain a competitive advantage by reducing operational risks, improving efficiency, and enhancing overall performance. This can lead to increased customer satisfaction, market differentiation, and business growth.