Predictive Maintenance:
Component-Specific Solutions
Actuators
Common Liabilities:
Seal failure leading to hydraulic or pneumatic leaks
Step loss or feedback errors in servo systems
Binding from contamination or mechanical wear
Motor overheating or mechanical stalling
Predictive Maintenance Solutions:
Vibration and ultrasonic monitoring for mechanical issues
Thermography of drive and motor heat signatures
Current monitoring of servo motor draw and irregularities
Leak detection for pneumatic/hydraulic systems
Mechanical Bearings
Common Liabilities:
Fatigue from overloading or misalignment
Lubrication failure (over- or under-lubrication)
Contamination ingress leading to wear
Installation damage or incorrect fit
Predictive Maintenance Solutions:
Ultrasound and vibration analysis for early-stage defects
Acoustic lubrication guidance
Infrared thermography for overheating
Routine ultrasonic trending to determine lubrication intervals
Terminal Blocks
Common Liabilities:
Loose or corroded connections causing overheating
Insulation degradation from moisture or heat
Arc flash risk from exposed or overloaded terminals
Dust buildup causing conductive paths
Predictive Maintenance Solutions:
Infrared imaging of connection points under load
Ultrasonic inspection for early arcing sounds
Torque verification and re-tightening programs
Visual inspection during shutdowns
Refrigeration Systems
Common Liabilities:
Overheating from coil fouling or airflow restriction
Fan or compressor failure
Refrigerant charge loss or pressure imbalance
Electrical faults in contactors or control boards
Predictive Maintenance Solutions:
Thermal imaging of condenser coils and fan motors
Vibration and current analysis of compressors
Leak detection and refrigerant pressure trending
Inspection of control wiring and contactors
Gear Boxes & Gear Reducers
Common Liabilities:
Gear wear or misalignment causing vibration and noise
Lubrication failure leading to overheating
Shaft misalignment stressing motor couplings
Seal failure allowing contamination
Predictive Maintenance Solutions:
Vibration and ultrasonic analysis to detect gear mesh issues
Infrared thermography to identify overheating
Oil analysis for wear metals and contamination
Shaft alignment verification
Fans & Blowers
Common Liabilities:
Unbalance causing vibration and fatigue
Bearing failure from contamination or poor lubrication
Belt or coupling misalignment
Blade erosion or buildup impacting efficiency
Predictive Maintenance Solutions:
Vibration analysis for balance, bearing, and misalignment issues
Thermography to detect motor or bearing heat
Visual inspections for debris buildup or corrosion
Ultrasound to check for looseness or turbulence
Motors (AC, DC, & Servo)
Common Liabilities:
Bearing wear or failure from misalignment or contamination
Insulation breakdown and winding shorts
Rotor bar defects or imbalance
Overheating from overload or phase imbalance
Predictive Maintenance Solutions:
Vibration analysis for bearing health and imbalance detection
Motor circuit analysis (MCA) for insulation and rotor faults
Infrared thermography for overheating and poor ventilation
Current and power analysis for phase imbalance or overload
Refrigerant Expansion Valves
Common Liabilities:
Valve sticking or clogging
Improper superheat adjustment reducing efficiency
Flash gas or liquid slugging into compressors
Contaminant buildup from poor filtration
Predictive Maintenance Solutions:
Thermal imaging of inlet/outlet lines
Superheat and subcooling monitoring
Functional testing during load conditions
Inspection and replacement of filters/driers
Boilers & Steam Traps
Common Liabilities:
Failed traps causing energy loss or flooding
Pressure vessel corrosion or scale buildup
Burner or control failure leading to safety risks
Heat loss from poor insulation or refractory damage
Predictive Maintenance Solutions:
Ultrasonic testing of steam traps and piping
Thermal imaging of burners and insulation
Combustion efficiency monitoring
Pressure and temperature trending over time
Transformers
Common Liabilities:
Insulation failure or overheating
Moisture ingress leading to internal arcing
Loose connections or winding degradation
Load imbalance causing premature wear
Predictive Maintenance Solutions:
Infrared thermography to detect uneven heating
Power quality analysis for imbalance or harmonics
Ultrasonic inspection for arcing or corona discharge
DGA (dissolved gas analysis) for oil-filled units (if applicable)
VFDs & Inverters
Common Liabilities:
Harmonic distortion damaging connected loads
Overheating due to poor ventilation or overcurrent
Capacitor aging or failure
Loose connections or internal arcing
Predictive Maintenance Solutions:
Thermal scanning of heat sinks, capacitors, and terminals
Power quality analysis for harmonics and imbalance
Current signature analysis for erratic motor loads
Visual inspection and filter replacement schedules