Modernise your machines

Modernise your machines - the nuts & bolts of what's really going on

Your existing plant and equipment have a compelling story to tell, but may be prevented from speaking clearly. However, there is no need to replace working plant and equipment just to add monitoring capabilities. DCO’s technology can give them a voice! If you could update your existing machines - what would they tell you? The critical components for understanding what’s really happening are the sensors to collect data and the software to interpret. It’s time to modernise your machines and unlock the hidden data within steam traps, steam systems, motors and drives, and heat exchangers.

Access hidden information with new sensing capabilities

Updating legacy equipment with new sensing capabilities can bring processes into the 21st century. Yet most manufacturers have a diverse plant full of equipment with different capabilities, roles within the process, age and complexity. For this reason, sensors cannot be a ‘one size fits all’ and those measuring a limited number of parameters only provide snapshots of your process. In contrast, DCO's energy harvesting sensors can be easily retrofitted to existing machines and quickly customised to reflect the whole of your system.

In addition to standard configurations, DCO’s sensors support additional plug-and-play options, allowing for extension of the number and type of physical parameters that can be monitored. For example, a monitoring solution for a control valve can be extended to measure adjacent pipework temperatures. By updating your machines with DCO’s sensors, you level the playing field for new machines and legacy equipment by giving them all a voice.

Take a deeper look

If you already have installed sensors, are you getting the information you need? Monitoring provides immediate and easily interpreted assessment of steam traps, heat exchangers and air handling system performance. Specifically, our temperature and acoustic monitoring can detect trap failure and alert engineers of leakage. Moreover, monitoring of pressure in air systems can indicate performance loss in air handlers. For heat exchangers, real-time input and output temperatures indicate correct system operation. These important indicators can verify the health and functionality of your equipment.

Mechanical sensing via precision vibration sensing enables monitoring of movement on fine and gross scales. Within moving systems, our sensors can identify internal mechanical failures or developing problems through analysis and comparison of vibration, temperature and power consumption data. For motors and actuators, anomalies in vibration sensing and motor current signature analysis can signal faults and provide pre-failure indication of problems.

Similarly, acoustic and vibration sensing permits identification of problems local to and adjacent to many systems containing pipework. Examples include high velocity steam and water hammer in pipework. By seeing this information on a dashboard, engineers can determine the root cause and pinpoint problem locations.

With extended sensing capabilities, DCO’s sensors capture this vital information and create a high-definition picture of your process. In addition, all the data gathered on your equipment’s internal components (temperature, pressure, vibration, energy usage) become centralised within an organised, easy to understand information system. Engineers can view this data on any device at any time.

Use predictive maintenance

Another feature of remote monitoring is the ability to predict when maintenance on a machine will be most beneficial. Our dashboard analytics help you identify any performance changes or inconsistencies that could lead to mechanical production failures. By detecting anomalies in real time, your engineers can address problems before they cause havoc down the line.

DCO Systems’ monitoring solutions provide extensive insight on your machines and equipment. Finding out what’s really going on with your machines can reveal new solutions and drive more informed decisions. DCO’s solutions are available now and immediate. Don’t delay unlocking the voice within your machines!

To find out more go to email: or call: 01285 359059.

3 Global Business Park
14 Wilkinson Road
Cirencester GL7 1YZ
United Kingdom

+44 (0)1285 359059

DCO sensors are ISO:9001 approved
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