Instrumentation Maintenance

Lubrication and Fluid Analysis

A good oil analysis program can answer common questions, like:

  • How often should I change my oil?
  • Am I using the right oil for the job?
  • How clean are my high-pressure hydraulic systems?
  • Is that noisy gearbox actually damaged internally?

Our advanced oil package solves these issues by testing the viscosity, checking for water, counting wear metal particles, measuring the Total Acid Number (TAN), and determining fluid cleanliness. All of these parameters can be determined by analyzing only 3 to 4 ounces of lubricant.

Commonly sampled components include diesel engines, critical bearing housings and gearboxes, and hydraulic systems. Our oil analysis programs additionally address a broad spectrum of industrial environments, including CNC machining equipment, water and wastewater plants, and chemical plants.

Thermography

One of the most powerful tools maintenance groups use is thermographic analysis, also called infrared inspection. Thermographic cameras detect radiation in the infrared range of the electromagnetic spectrum and produce images of that emitted energy. Because of this, thermography makes it possible to “visualize” the environment and variations in temperature, regardless of visible illumination. 

FCX’s certified thermographers are NFPA 70E trained, and qualified to perform inspection and analysis on all your power systems:

  • Plant incoming power and distribution lines
  • Substations
  • Motor control centers
  • Transformers
  • Local electrical cabinets
  • Buss systems
  • Motors

Thermography can also be used to troubleshoot or analyze systems where temperature gradients need to be evaluated:

  • Building envelope moisture and insulation analysis
  • Furnace or freezer insulation failures
  • Process operations and performance analysis
  • Rector analysis
  • Machine tooling stress
  • Steam systems

Vibration Analysis

Vibration analysis allows us to evaluate the operating condition of your rotating equipment. Using the latest analytical resources, our certified analysts are able to capture real-time data and analyze your equipment for faults.

  • Misalignment
  • Bearing faults
  • Mechanical looseness
  • Structural issues
  • Bent shaft
  • Cocked bearing
  • Unbalance
  • Gear faults
  • Lubrication issues
  • Flow turbulence
  • And more

Serious damage and downtime can be avoided with early detection and root-cause analysis of failure. FCX’s engineers work directly with your maintenance personnel to identify failures, causes, and to address preventative measures.

Motor Circuit Analysis

Motor circuit analysis utilizes computer-driven analytical equipment to collet electrical data on your electric motors and motor power feed systems. FCX’s trained engineers use this data to determine the operating condition. Our expert technicians evaluate the electrical stability of your motors and provide recommendations for corrective actions in a controlled schedule.

FCX’s engineers and analysts rely on engineering principles to develop action plans that can maximize runtime and availability of your motor systems. These principles include:

Resistance Phase to Phase

The analyst evaluates the electrical connection conditions by taking micro-ohm level readings between each set of phases. A high resistance reading or imbalance between phases indicates a connection problem.

Resistance to Ground

Commonly referred to as a Megger test. FCX’s test equipment energizes the circuit using 500VDC or 100VDC. The data results are compared against previous results, similar motor results, and IEEE standards. This data is then used to evaluate the electrical insulation of the motor and the power circuit.

Capacitance to Ground

Capacitance data allows the analyst to evaluate moisture presence or contaminate buildup in motors. An increasing trend in capacitance level indicates increasing levels of moisture or contaminant buildup on the windings. The motor should be serviced to avoid deterioration of the insulation.

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