INDUSTRIAL
EQUIPMENT
MONITORING
Vibration FFT with BPFO/BPFI/BSF/FTF bearing fault detection, 4-20mA HART interfaces, ATEX IECEx Ex ia certification, API 670 compliance, and OSIsoft PI integration — condition monitoring built for the plant floor.
The Engineering Problem
Industrial Equipment Failures Are Predictable — If You Have the Right Data
A centrifugal pump bearing announces failure weeks in advance — BPFO harmonics appear in the vibration spectrum long before seizure, motor current reveals rotor bar cracks, cavitation produces a distinct vane-pass acoustic signature. The signals are present; the question is whether the monitoring hardware can resolve them.
Fixed-interval PM generates planned downtime for equipment that doesn't need it and misses incipient failures on equipment that does. Condition-based maintenance requires hardware with sufficient dynamic range, bandwidth, and embedded DSP power to extract spectral fault features in real time.
We build monitoring hardware that resolves these signals — MEMS accelerometers flat to 10 kHz, 24-bit ADCs at >100 dB dynamic range, embedded DSP computing FFT spectra and bearing fault envelopes on the sensor node, and HART/Modbus interfaces that integrate into existing plant infrastructure without a control system replacement.
Industrial Monitoring Categories We Build
From pump health to pipeline integrity — precision condition monitoring hardware across industrial machinery and infrastructure.
Pump & Compressor Monitoring
Motor Current Signature Analysis
Pipeline & Flow Monitoring
Valve & Actuator Monitoring
Heat Exchanger & Cooling Monitoring
Structural & Foundation Monitoring
Electrical Panel & PQ Monitoring
ATEX Wireless Monitoring Nodes
Vibration FFT & Envelope Analysis
Real-time FFT computation on embedded DSP, velocity RMS and acceleration peak extraction, spectral band alarming, and BPFO/BPFI/BSF/FTF bearing fault frequency envelope detection.
4-20mA HART Interface Design
HART modem integration, multi-drop bus configurations, Universal and Common Practice command support, Device Description (DD) file development, and galvanic loop isolation.
Modbus RTU/TCP & OPC-UA
Modbus RTU slave and master implementations, OPC-UA server with information model development, OSIsoft PI Connector Relay integration, and ISA-18.2 alarm management compliance.
ATEX IECEx Ex ia Design
Intrinsically safe circuit design, Zener barrier and galvanic isolator entity parameter verification, Ex ia certified component selection, and ATEX/IECEx technical documentation for certification.
Embedded DSP & Edge Analytics
ARM Cortex-M DSP library integration, fixed-point FFT optimization, spectral leakage windowing, cepstrum analysis, and on-device machine learning for anomaly detection.
WirelessHART & ISA100.11a
WirelessHART field device stack implementation, TDMA scheduling, mesh network routing, and ISA100.11a backbone router integration for wireless infrastructure in process plants.
API 670 & ISO 10816 Compliance
API 670 machinery protection system design for critical turbomachinery, ISO 10816/20816 vibration severity threshold implementation, and SIL-capable relay output configurations.
CMMS & Historian Integration
SAP PM, IBM Maximo, and Infor EAM work order generation triggers, OSIsoft PI and Aspen InfoPlus.21 historian tag configuration, and predictive maintenance KPI dashboard feeds.
Chipsets & Platforms
Protocols, Platforms & Standards
Tested silicon and proven stacks — no experimental platform dependencies.
Pump & Compressor Predictive Maintenance
Bearing Health · Cavitation · Seal Degradation
BPFO harmonics at 3.05× shaft speed for a typical 6-ball bearing appear and grow weeks before failure — our nodes track these continuously and alarm when spectral bands cross ISO 10816 Zone C. We also monitor cavitation (broadband noise floor rise at vane pass frequency), seal degradation (sub-synchronous vibration), and impeller wear (deviation from baseline fingerprint). MCSA boards provide simultaneous electrical-domain confirmation of mechanical anomalies.
Pipeline & Remote Infrastructure Monitoring
Non-Invasive · GPS-Synchronized · Acoustic Emission
Negative pressure wave leak localization requires <1µs timestamp synchronization across monitoring nodes — our hardware uses GPS-disciplined timing to achieve this. Clamp-on ultrasonic flow nodes eliminate process penetration for retrofit installations. Acoustic emission sensors detect high-frequency stress waves from active corrosion and incipient leaks that pressure gauges cannot resolve.
ATEX & Hazardous Area Instrumentation
Zone 0/1/2 Certified · Ex ia · IECEx
ATEX Zone 1 IIC T4 intrinsic safety requires that stored energy in any field circuit capacitance or inductance never exceeds the ignition energy of the target gas group — under single-fault conditions. This governs every component value in the circuit, not just the firmware. We carry this through full certification — entity parameter calculations, Zener barrier matching, cable constraints, and Notified Body documentation.
Why Engineering Teams Choose Ankh
Signal Processing Depth
Our firmware engineers understand bearing fault physics — BPFO/BPFI/BSF/FTF are not acronyms to look up, they're frequency calculations running in our DSP firmware. We build monitoring hardware that produces actionable diagnostics, not just raw data.
Hazardous Area Experience
ATEX and IECEx Ex ia circuit design requires understanding intrinsic safety entity parameters at the component level. We've taken products through full ATEX certification and know where the design constraints bind.
Plant Floor Integration
We understand that new hardware has to fit into existing DCS and historian infrastructure without a rip-and-replace. Our devices speak Modbus, HART, and OPC-UA natively and integrate with whatever historian is already running.
Proven Uptime Impact
We've built monitoring hardware that's documented bearing failure prediction 3-6 weeks before failure in production installations. That's the only metric that matters on the plant floor.
12-Pump Predictive Maintenance Network
A Gulf Coast refinery needed to protect 12 critical process pumps in ATEX Zone 1 from unplanned bearing failures without wired installation disruption or manual data rounds.
IECEx Ex ia certified wireless vibration nodes tracking BPFO/BPFI/BSF/FTF continuously. Three bearing failures predicted with 3–5 week lead time in year one, enabling scheduled replacement during planned turnarounds.
- 3 bearing failures predicted with 3–5 week lead time
- $2.1M in avoided unplanned downtime costs in year one
- ATEX IECEx Zone 1 IIC certified hardware throughout
Municipal Pipeline Leak Detection Network
A municipal water utility needed leak detection and localization across 45 km of transmission mains without pipeline excavation or service disruption.
28-node negative pressure wave network with GPS-disciplined <1µs synchronization, localizing leaks to within 50 m from pressure transient time-of-arrival differences — no pipeline penetration required.
- Leak localization accuracy: ±50 m on 45 km network
- Four leak events detected in first 18 months of operation
- 12-month ROI on infrastructure investment via loss reduction
Let's Keep Your Plant Running.
Whether you're building a pump health monitoring system, a pipeline leak detection network, or ATEX-certified wireless instrumentation — we engineer the hardware and firmware that delivers actionable predictive maintenance intelligence.
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