Condition Monitoring (CM) is the process of monitoring a certain aspect of the condition of a piece of machinery, such that a significant change is indicative of a developing failure. CM allows maintenance to be scheduled or other actions to be taken to avoid the consequences of a full failure before the failure occurs. 

Condition Monitoring from Allied Reliability means that our experts select the correct combination of technologies, sensors and software to monitor your high-value equipment. We manage the CM system to identify component defects and recommend proactive maintenance to prevent unplanned downtime.

 

Analytics for Condition Monitoring

OIL ANALYSIS

Often referred to as the life blood of equipment, oil can provide a great deal of information on the condition of equipment, as well as serve as a leading indicator of what the condition of the machine could be if action is not taken. Is there contamination? Has the chemistry of the oil been compromised? Is there wear debris present? 

OIL ANALYSIS DETECTS COMMON FAILURE MODES:

  • Incorrect Lubricant Use/Selection
  • Over Extended Oil Drains
  • Component Fatigue
  • Sliding Wear
  • Abrasive Wear
  • External Contamination
  • Poor Handling/Sampling Practices
  • Inadequate Contamination Control Measures

VIBRATION ANALYSIS

Vibration Analysis is the most frequently deployed technology on the market today and can be an important tool to deploy in your journey to Excellence in Maintenance and Reliability. All rotating equipment vibrates to some degree, but as components reach the end of their product life, they begin to vibrate more dramatically and in distinct ways. Ongoing monitoring of equipment allows these signs to be identified well before the damage becomes an expensive problem.

VIBRATION ANALYSIS DETECTS COMMON FAILURE MODES:

  • Gear wear
  • Cavitation
  • Imbalance
  • Misalignment
  • Cracked or broken gear teeth
  • Chain looseness
  • Rolling element bearing defects
  • Resonance
  • Bent shaft
  • Bearing issues
  • Structural looseness
  • Sheave run-out
  • Many electrical problems
  • Fluid and airflow problems

INFRARED THERMOGRAPHY

Commonly used for both mechanical and electrical applications, Infrared (IR) Thermography is one of the most diverse and widely accepted condition monitoring technologies on the market today. In electrical systems, there are several causes of thermal anomalies. Electrical resistance converts electrical energy to thermal energy. These situations and others lead to higher temperatures and wasted electrical power. Thermography plays an integral role in evaluating and identifying energy efficiency opportunities. Integrating Thermography into routine energy audits such as Heat Loss Surveys, Piping Insulation Surveys, Building Envelope, and Steam System Analysis will enable your energy management team to identify defects leading to increased energy consumption.

INFRARED ANALYSIS DETECTS:

  • Bearing and Couplings Defects
  • Seals Issues
  • Barrier System Failures
  • Alignment Issues
  • Heat Dissipation
  • Lubrication Issues
  • High Resistance Connections
  • Faulty Fuse Clips
  • Loose Connections
  • Faulty Transformer Bushings
  • Heat Exchanger Issues
  • Boiler Inefficiencies
  • Steam Trap Failures
  • Refractory Degradation
  • Insulation Failures
  • Building Envelope Defects

ULTRASOUND Analysis

Ultrasound is high frequency sound waves above 20 kilohertz (kHz) and up to 300 kHz. Commonly used for leak detection and mechanical and electrical inspections, Ultrasound is one of the more flexible condition monitoring technologies on the market. Although Ultrasound testing provides many benefits, there are two primary areas that generate the greatest value to a plant: air leak detection and electrical applications. For electrical applications, safety is always a concern. Ultrasound can be used as a safety precaution for identifying failure modes such as Arcing, Tracking and Corona.

ULTRASOUND ANALYSIS DETECTS COMMON FAILURE MODES:

  • Compressed gas leaks
  • Heat exchangers
  • Boilers and condensers
  • Tanks and pipes
  • Valves and steam traps
  • Arcing, tracking, corona
  • Switchgear
  • Transformers
  • Bearing faults
  • Gear problems
  • Circuit breakers
  • Coupling defects

MOTOR CIRCUIT ANALYSIS

Motor Circuit Analysis (MCA) is the most powerful condition monitoring technology for evaluating the health of your electrical motor. In the hands of a capable analyst, offline (static) and online (dynamic) testing helps a company effectively ensure that their new or repaired motors meet standards, evaluate and define the integrity of their motor's insulation system, identify and locate power related issues and load problems, define rotor bar issues, and measure distortion. MCA can help companies improve equipment reliability, increase production capacity, and effectively provide information leading to increased energy efficiency.

MCA DETECTS COMMON FAILURE MODES:

  • Current Imbalance and Loading Issues
  • Power Quality Disturbances (Harmonics, Voltage Imbalance, Power Factor Anomalies)
  • Circuitry and Motor Insulation Breakdown/Degradation
  • Rotor Damage (Loss of Torque, Loss of HP)
  • Loose Motor Foundation (Soft Foot, Sprung Foot)
  • Eccentricity in Rotors (Motor, Sheaves, Fans)
  • Belt Defects
  • Vane/Blade Pass
  • Gearing Defect (Broken Tooth, Backlash, Looseness)

ADVANCED DIAGNOSTICS SERVICES

Advanced diagnostics techniques are available from Allied. An experienced and Certified Analyst or Subject Matter Expert is available for organizations looking to utilize Advanced Diagnostic Services for solving structure-related problems.

MOTION AMPLIFICATION

Allied's motion amplification service uses high-speed cameras to measure equipment movement.

Motion amplification allows Allied professionals to assess critical manufacturing processes and structural components that affect plant reliability. This technology detects subtle motion and amplifies it to a level visible with the naked eye - creating millions of measurement locations in an instant. The data is displayed in a Vibragram, depicting a specific vibration frequency and an intuitive motion-amplified video to illustrate all frequencies at once.

OPERATING DEFLECTION SHAPE TESTING

With Operating Deflection Shape (ODS) testing, a visual representation of machine motion is captured to aid in the root cause identification of repetitive problems or complex vibration issues.

IMPACT TESTING

Impact testing utilizes run up or coast down activities to identify natural frequency content for resonance considerations.

PHASE ANALYSIS

Allied uses phase analysis to identify and address/confirm failure modes such as looseness, misalignment, and bent shafts.

EXPERIMENTAL MODAL ANALYSIS

Experimental modal analysis is used to help identify and resolve both structural and equipment resonance concerns.