Mechanical Condition Monitoring
Cambay Power Services offers real-time mechanical condition monitoring to keep your critical machinery running smoothly. Our diagnostics help reduce downtime, extend equipment life, and improve operational efficiency.
Installation and Commissioning
We develop and implement custom predictive maintenance programs tailored to your plant’s specific equipment and risk profile. These programs combine multiple condition monitoring techniques—vibration analysis, oil analysis, thermography, and ultrasound—to detect early signs of failure. By shifting from reactive to predictive strategies, we help extend asset life, reduce maintenance costs, and minimize unplanned downtime.
Vibration Measurement and Analysis
Our advanced vibration analysis services detect abnormalities such as imbalance, misalignment, looseness, and bearing wear in rotating machinery. Using real-time and periodic monitoring tools, we provide insights into equipment health and performance. Detailed analysis helps in early fault detection, improving machine uptime and reducing catastrophic breakdowns.
Transient Analysis of Critical Machines (Turbines, Compressors)
Transient analysis captures data during startup, shutdown, and other non-steady-state operations of critical machines like turbines and compressors. These conditions often reveal issues not seen during normal operation. We analyze the dynamic response of machinery to identify resonance, thermal effects, and system instability, ensuring safe and optimized performance under varying load conditions.
Lubrication Management
Proper lubrication is essential to machinery reliability. Our lubrication management services involve oil quality analysis, wear particle detection, and contamination control. We provide guidance on lubricant selection, storage, and re-lubrication intervals. With our systematic approach, you can reduce friction-related failures, improve energy efficiency, and enhance equipment life.
Thermography
Infrared thermography provides a non-invasive way to monitor heat patterns in mechanical systems. We use thermal cameras to detect friction, misalignment, bearing issues, and overheating components. Early identification of thermal anomalies helps prevent failures, improve safety, and plan targeted maintenance without disrupting operations.
Motor Current Analysis
Motor Current Signature Analysis (MCSA) is a powerful tool to detect internal motor faults such as rotor bar issues, winding faults, and electrical unbalance. By analyzing current waveforms under load, we assess both electrical and mechanical conditions of motors. This technique helps prevent failures and extends motor lifespan without the need for disassembly.
Laser Alignment
Misaligned machinery leads to increased wear, vibration, and energy consumption. Our precision laser alignment services ensure accurate shaft alignment in rotating equipment like pumps, motors, and fans. Using state-of-the-art laser tools, we achieve sub-millimeter accuracy, reducing mechanical stress and extending equipment lifespan.
Condition Monitoring of Static Equipment
Static equipment such as tanks, pressure vessels, and pipelines require regular condition assessments. We use advanced non-destructive testing (NDT) methods including ultrasonic thickness testing, visual inspection, and corrosion mapping. These assessments help ensure structural integrity, safety, and regulatory compliance for long-life performance.
Valve Pass Monitoring
Internal valve leakage or valve passing can go undetected and lead to significant energy loss and process inefficiencies. Our valve pass monitoring uses acoustic and ultrasonic methods to detect leaks in control and isolation valves during operation. Early identification allows for timely repairs and better process control.
Ultrasound-Based Continuous Monitoring System
Our ultrasound-based monitoring systems provide real-time insights into mechanical condition and fluid leaks. These systems detect early signs of bearing degradation, cavitation, steam trap failure, and air leaks. Installed sensors transmit continuous data, enabling preventive maintenance actions well before failure occurs.
Tank Testing for Tightness
Tank tightness testing is critical for preventing hazardous leaks and ensuring environmental compliance. We use pressure, vacuum, and tracer gas methods to detect any leakage or structural weakness in aboveground and underground storage tanks. Our testing ensures regulatory compliance and long-term asset integrity.
Compressed Air Leak Detection
Compressed air systems often lose up to 30% of air through leaks, increasing operational costs. We perform ultrasonic leak detection to locate even the smallest leaks in compressed air, gas, and vacuum systems. Timely repairs based on our findings help improve energy efficiency and lower utility expenses.
Continuous Monitoring Systems
Our continuous monitoring systems offer 24/7 surveillance of critical mechanical assets. Equipped with wireless or wired sensors, these systems measure vibration, temperature, acoustic signals, and more. Real-time alerts and trend data support predictive maintenance decisions and reduce risk of unplanned failures.
Root Cause Analysis (RCA)
When failures occur, simply fixing the symptoms isn’t enough. We conduct thorough Root Cause Analysis (RCA) using industry-recognized methodologies such as Fishbone Diagram, 5 Whys, and Fault Tree Analysis. Our insights help eliminate the true source of failures, improve system reliability, and prevent recurrence.
Operational Deflection Shape (ODS) Analysis
ODS analysis visualizes how machines and structures behave under operational loads. We measure and model deflections to identify excessive vibrations, looseness, or resonance conditions. This technique is especially useful for diagnosing complex machinery issues and validating corrective actions post-maintenance.
Turbine Monitoring & Protection
Our turbine monitoring solutions offer complete surveillance of operational health, including vibration, speed, temperature, and critical clearances. Integrated protection systems provide alarms and automatic shutdowns in case of anomalies. This ensures safe and uninterrupted operation of high-value rotating equipment.
Portable Ultrasound & Vibration Sensors & Solutions
We provide easy-to-use portable sensors that allow maintenance teams to perform quick, on-the-spot diagnostics. These tools measure ultrasonic signals and vibration levels to detect bearing issues, leaks, or imbalance. Ideal for route-based maintenance, they support real-time decision-making and improve field productivity.