Overview
Our unique Machine Care Plus® Equipment Fluid Analysis and Condition Monitoring Service
is very different from conventional methods as it delivers to the user precise
Engineering Decisions that minimise equipment support costs and maximises
availability. The service is specifically designed to incorporate:
- Multiple Equipment Types e.g. Diesel Engines, Gearboxes, Hydraulic Systems etc.
- Multiple Condition Monitoring Techniques e.g. Fluids (oil, fuel, coolant), HUMS,
Vibration etc.
- Supporting Information e.g. Asset Management, Usage, Maintenance History etc.
We have a proven track record of achievements with a number of high profile customers.
This includes more than two decades of experience working with the UK Ministry of
Defence (all three services), other Armed Forces and major Equipment Manufacturers
and we are the recognised provider of fluid sampling and analysis products and services
to the British Army.
Information regarding those key processes that are central to the delivery of the
Machine Care Plus® service is available below. To view process information, click
on the relevant box in the process flow diagram opposite.
Please Contact Us with any enquiries
or if you require further information. We would very much welcome an opportunity
to discuss your equipment condition monitoring requirements.
The essence of this key process is to ensure that:
- A representative fluid sample (oil, fuel, coolant) is taken in a safe and effective
manner.
- Vital supporting information, such as identification of the sampled asset, accurate
asset usage, and any maintenance or servicing carried out on the equipment since
the last sample, is captured.
This in turn raises the quality of data and information generated by the interpretation
process.
AES Ltd will liaise with potential customers and, after an initial consultation
and assessment of customer requirements, we will advise on safe and appropriate
methods for the sampling of equipment. AES Ltd can supply a range of specially designed sampling
equipment, including sample bottle kits. Examples of the type of sampling equipment
that we can supply are shown here.
Sampling Taps
A sampling tap can be used for equipment with a pressurised oil system and a fixed
oil sampling point. AES can supply the tap with adapter styles and thread sizes
to fit most equipment sampling points.
Oil Extraction Tap Assembly
Hydraulic Tap Case Hose
Vacuum Pump
The vacuum pump is used for extracting oil samples from any equipment without a
fixed oil sampling point, or from equipment with a non-pressurised oil system. The
pump is used in conjunction with tubing and a sample bottle to enable a representative
sample to be extracted via a suitable access point such as the equipment dipstick.
The vacuum pump can also be used for coolant and fuel sampling.
Vacuum Pump
Bottle Kits
AES can supply a range of bottle kits containing sample bottles in various sizes
and quantities. Bottle kits contain everything that the customer will require for
dispatching samples for analysis, including envelopes for posting sample bottles
to the laboratory. The kits can also include Sample Information Reports (SIRs) and
SIR envelopes, should SIRs be required.
Bottle Kit
Hydraulic Bottle Kit
Sample Information Report (SIR)
The Sample Information Report is a basic form that when completed captures all of
the key information relating to the sampled asset that is used during the interpretation
process. SIRs can be supplied with bottle kits, if required, but the form can also
be downloaded from the Machine Care Plus® website, and customers that have been
supplied with a login to the Machine Care Plus® application have the ability to
complete an online version of the SIR (e-SIR). Completed SIR forms are dispatched
directly to the AES Early Failure Detection Centre (EFDC) for loading into the Machine
Care Plus® online application, ahead of the interpretation process.
Once a fluid sample has been extracted, it is sent to the laboratory for analysis.
The range of tests carried out by the laboratory will be dependant upon the type
of fluid, the type of equipment that the sample was extracted from, and the specific
test package required by the customer. Click here for more information on the various
fluid sample testing and analysis packages available. The test results data is e-mailed
to AES Ltds’ Early Failure Detection Centre (EFDC) where it is matched with its
corresponding Sample Information Report (SIR).
EFDC staff check and validate the fluid test data received from laboratory and the
information recorded on the SIR. After validation, the data from the laboratory
and the corresponding SIR is entered into AES Machine Care Plus® software application.
The data is interpreted by the Expert Decision Support System (EDSS) software and
the output is then checked and verified by highly experienced EFDC technical staff
before being fed back to the customer in the form of a detailed assessment of equipment
and fluid condition, together with corresponding maintenance recommendations. The
EDSS is designed to integrate data collected from many sources, automatically interpret
this data to provide an accurate diagnosis and make firm recommendations/remedial
actions to improve machinery health and prevent failures. It is able to handle multiple
equipment types and systems, including diesel engines, power transmissions and hydraulic,
fuel and coolant systems. Data is primarily obtained from fluid samples, but can
also be from sensors (i.e. HUMS), usage meters, physical inspection, and maintenance
histories etc. There is an important distinction to be made between testing and
interpretation. Testing produces data, whilst interpretation yields recommendations.
The EFDC is the focal point for the Machine Care Plus® Equipment Fluid Analysis
and Condition Monitoring Service. As well as validating fluid test results and equipment
data, the EFDC's highly experienced ex-military staff also monitor equipment condition,
identify any signs of distress, and alert customers whenever action needs to be
taken. Once the diagnosis, health priority and maintenance recommendations have
been committed to the system, users can securely browse or download their results
from the Machine Care Plus® online application.
The testing and data flow process is displayed on the diagram shown below.
The Machine Care Plus® online application provides customers with secure Internet
access to all of their fluid sampling results. The application provides a comprehensive
yet concise view of equipment information, equipment sample history, and sample
test and analysis results, including prioritised sample health diagnosis and corresponding
maintenance recommendations. It is also possible to record and display any servicing
or maintenance tasks that may have been carried out on equipment.
The application also includes a flexible and easy-to-use reports suite that enables
customers to configure and download a range of comprehensive reports relating to
sample analysis results and asset health. Click here to see an example report.