Our Precision Process

A standardized, data-driven methodology aligned to ISO standards to maximize rotating machinery lifespan.

Proactive Diagnostics, Step-by-Step

We don't guess—we measure. From initial sensor setups to post-intervention verification, our processes are designed to target bearing distress, alignment deviations, and dynamic mass unbalance.

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1. Onsite Inspection & Equipment Scoping

Phase 1: Discovery

We visit your industrial facility to audit critical rotating equipment under real operating environments. During this process, our certified engineers map machine layouts, collect technical plate values, identify foundation rigidity problems, and locate immediate electrical safety challenges.

Core Tasks Conducted

  • Foundation structural structural resonance check.
  • Review of machine maintenance journals and bearing logs.
  • Initial visual inspection of shaft couplings and belt systems.

Key Deliverable

  • Site scoping audit report outlining diagnostic sensor locations and diagnostic path.
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2. Vibration Signature & Thermal Mapping

Phase 2: Diagnostic Data

Our technicians capture raw operating vibration data using accelerometers placed on radial and axial bearing caps. Simultaneously, infrared thermography is executed across terminal boards, electrical panels, and bearing housings to register hot spots caused by lubrication starvation or friction.

Hardware Used

  • Dual-Channel FFT Spectrum Vibration Analyzers.
  • High-resolution infrared thermal imaging cameras.
  • Calibrated magnetic-mount piezoceramic sensors.

Target Fault Profiles

  • Outer/Inner race bearing fatigue (BPFI/BPFO).
  • Rotor eccentric unbalance signals.
  • Soft foot foundation misalignment.
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3. Spectral Analysis & Root Cause Reporting

Phase 3: Deep Analysis

We convert gathered wave formats into Fast Fourier Transform (FFT) graphs. Analyzing amplitude-frequency spikes reveals precisely what forces are wearing out your machine’s internal mechanical seals and bearing shells. This analysis completely eliminates troubleshooting guesswork.

Analytical Metrics

  • Phase angle variation mapping.
  • Frequency spectral peak tracking (1X, 2X, 3X RPM).
  • Time-waveform impact tracing for cracked teeth.

Action Report

  • Comprehensive ISO 10816 machinery severity rating, localized root cause, and corrective action recommendations.
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4. Onsite Corrective Interventions

Phase 4: Intervention

Once defects are targeted, we carry out precise corrections. If unbalance is found, we complete in-situ multi-plane dynamic balancing. If parallel misalignment is found, we complete laser alignment using precise shims to bring systems within co-axial tolerances.

Corrective Methods

  • In-situ single & dual-plane fan balancing with test weights.
  • Laser shaft alignment accurate to within 0.01mm.
  • Replacement of failing bearings using hydraulic pullers.

Compliance & Standards

  • Rotor Balancing strictly adhering to ISO 1940 standard.
  • Precise machine torque specifications on foundation bolts.
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5. Post-Intervention Baseline Verification

Phase 5: Verification

We restart the machine and run another signature analysis sweep to verify that vibration and heat signatures fall well within optimal zone guidelines. We archive these results to establish a healthy operating signature baseline for future comparisons.

Quality Checks

  • Confirm overall vibration levels fall within ISO Class I-IV "Good" zones.
  • Check and document post-intervention bearing running temperatures.

Close-out Assets

  • Documented comparison report showing before and after vibration signatures.
  • Archived baseline profile for future diagnostic tracking.
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Why We Align with ISO Standards

Adhering to internationally recognized standards like ISO 10816 (vibration assessment) and ISO 1940 (rotor balance grades) guarantees that our repairs are structurally durable, safe, and built to stand up to grueling shifts in mining, manufacturing, and energy generation.

ISO 10816

Machinery condition severity evaluation criteria.

ISO 1940

Rigid rotor balance quality grades and tolerances.

Precision Limit

Laser adjustments engineered down to 0.01 mm.