Diagnostic Analysis

Machinery and tools with rotating parts, gears and bearings can be monitoring using vibration analysis. Diagnostic analysis is becoming a much more simple process with modern vibration analysis systems and temperature measurement.

The oldest and probably simplest way to check for potential problems was using the eye. Maintenance engineers could visually inspect machinery for faults. However, was complex machinery this method was not always accurate. Even tiny cracks or a slightly misaligned bearing may not be spotted. Modern measurement technology can be in operation while processes are running, ensuring no downtime to stop and visually inspect.

Machinery will be initially measured at a time when it is known to be working correctly, giving a baseline measurement. With vibration analysis of machinery any deviations from the baseline will highlight a potential fault and give machine operators time to find the fault and fix it before a machine fails. The problem may be general wear and tear from moving parts or a misalignment.

Vibration analysis is most often done using Frequency Analysis, which monitors the frequency levels in machinery vibrations. From baseline measurements the frequency of certain parts of a machine will be known and any changes can help find a fault very quickly. Sometimes even the smallest noticeable change in frequency can help prevent machine failure weeks before it happens.

Using temperature analysis can also be used to detect potential failure of machinery. Rotating shafts, bearings and other similar moving parts will have a baseline operating temperature and changes could be a sign of potential problems. Condition monitoring of high-speed bearings, fluid couplings and conveyor rollers can be done using temperature analysis.

Degradation of electrical components and connections can also be monitored using temperature analysis.

Gas meters can be used to monitor machinery and pipes for leaks. Numerous gases can be measured in working environments and any increase in background levels will warn against potential leaks. Gas leaks can be dangerous as well as environmentally unfriendly so any problems can be found quickly and repaired.

Flow meters can be used in pipelines to monitor correct flow rates in both liquids and gases. With gas flow meters a change in pressure or temperature may be a sign of a problem within a system or pipeline. Liquid flow meters can detect changes in density and flow rate, signalling a potential problem or blockage.