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Setting up a Predictive Maintenance System

MDS Machinery Diagnostic Service engineers help you design and implement the Predictive Maintenance system for your specific machinery requirements. Training local plant personnel in initial system setup, use of monitoring and test equipment, and in data acquisition procedures are emphasized. As the experience of plant personnel develops, they can perform an increasing role in the program until it can be maintained without MDS assistance.


  • Development of PDM Cell in an industrial unit
  • Development and Implementation of PDM program
  • Providing necessary instrumentation for all PDM techniques
    • Vibration Monitoring: Most mechanical faults with rotating equipment induce vibration i.e., unbalance, misalignment, looseness caused by poor assembly, deterioration of bearings, wear of gear teeth, etc. Vibration monitoring involves the periodic measurement of machine vibration, usually measured on bearing housings or from the machine supervisor's panel output/data.
      • Vibration monitoring can detect a wide range of failure modes: •Bearing defects •Misalignment •Imbalance •Soft Foot Mounting •Mechanical Looseness •Resonance •Bearing pre-load and incorrect assembly •Gear mesh abnormalities •Journal bearing faults •Belt drive faults •Pump cavitation and process flow problems •Beat frequencies •Single and multi-plane in-situ balancing •Complex machine investigations and problem solving •Turbo-machinery start-up/shutdown and troubleshooting •Machine baselines, acceptance testing and 3rd party witnessing •Failure investigations and warranty issues •Structural and modal analysis investigations •Turbines, Generators, Compressors, Motors, Pumps and couplings •Performance testing Machinery protection •Envirnomental motoring ( NOX, SOX, CO2, SpM(PM 10, PM 2.5) etc.
      • Visual Monitoring
      • Noise Monitoring
      • Bearing Condition Monitoring (Shock Pulse/ Kurtosis)
      • Hot-spot Monitoring: This non-destructive method uses an infrared camera to detect thermal patterns and measure operating temperatures. It’s useful for detecting loose or improperly terminated electrical connections, overloading, defective contacts, phase imbalances and other electrical problems. In mechanical applications, it’s useful for detecting overheated bearings; misalignment in belts, sheaves and couplings; faulty steam traps; and other anomalies that exhibit a thermal change as components degrade.
      • Motor Check Monitoring:- Motor current signature analysis (MCSA) has proven to be a highly valuable predictive maintenance tool. Although it is a relatively young, rarely utilized technology, it is rapidly gaining acceptance in industry today. Mechanical faults related to belts, couplers, alignment and more are easily found through the use of a demodulated current spectrum. MCSA is simply the process by which motor current readings are recorded and analyzed in the frequency domain. It has been effective in locating rotor faults and air gap problems in motors.
      • Wear Debris Monitoring- Monitor wear debris contamination by detecting the particle size, shape, and elemental composition. The process is to detect size and shape of each particle, identify particle chemistry, pinpoint exact component failure and use trending to monitor wear.
      • Structural Integrity Monitoring [Modal Analysis & Operation Deflection Shape (ODS) Analysis]
      • Transformer Monitoring: Transformer failures can occur due to various causes. Transformer in-service interruptions and failures usually result from dielectric breakdown, winding distortion caused by short-circuit withstand, winding and magnetic circuit hot spot, electrical disturbances, deterioration of insulation, lightning, inadequate maintenance, loose connections, overloading, failure of accessories such as OLTCs, bushings, etc.. The important aspects of condition monitoring of transformers are :- i)Thermal Modelling, ii)Dissolved Gas Analysis, iii)Frequency Response Analysis and iv)Partial Discharge Analysis.
      • Water Chemistry Monitoring :- • Temperature; • Dissolved Oxygen ;• Total Alkalinity ; • Total Hardness ; • pH ; • Turbidity
      • Performanace Monitoring
    • Envirnomental Monitoring ( SOX, NOX, CO2, SpM 10& 2.5 etc )
  • Continuous Support to executives
  • Training of executives