Advanced Monitoring Hardware

Complete Energy Solutions (CES) delivers a robust, industrial-grade hardware ecosystem engineered for continuous asset condition monitoring in harsh and remote operating environments.

As the official Distributor for Spectrolytic across Australia and New Zealand, CES supplies and supports the FluidInspectIR®, inline oil and fluid monitoring platform, providing real-time automated condition monitoring for critical assets.

Our hardware architecture is designed to capture chemical, mechanical and operational performance data at the source, enabling accurate diagnostics, predictive analytics and seamless enterprise integration.

Inline Oil & Fluid Monitoring

At the core of our fluid intelligence capability is FluidInspectIR®, delivering lab-equivalent accuracy (±5%) through continuous inline monitoring without the delays associated with traditional laboratory sampling.

The system performs hourly, non-destructive inline measurements of:

• Oxidation, nitration and sulphation
• Total Acid Number (TAN) & Total Base Number (TBN)
• Kinematic viscosity (40°C / 100°C)
• Anti-oxidant and anti-wear additive depletion (e.g., ZDDP)
• Soot loading
• Water and glycol contamination
• Fuel dilution 
• Solvent and process fluid composition

This enables early detection of lubricant degradation, contamination ingress, acid formation, and loss of lubrication performance — key indicators of accelerated wear, corrosion, and potential component failure.

Unlike periodic oil sampling programs, inline monitoring provides continuous condition visibility with minimal manual intervention, improving consistency while reducing labour requirements and sampling delays.

Mechanical & Operational Monitoring Hardware

CES integrates additional industrial sensors to provide comprehensive asset health monitoring across fixed and mobile assets.

Vibration Monitoring

High-sensitivity accelerometers detect imbalance, misalignment, cavitation and bearing wear in real time. Frequency pattern analysis enables early identification of mechanical faults in pumps, crushers, turbines, conveyors and mobile plant.

Temperature & Pressure Sensors

Continuous monitoring of thermal and hydraulic conditions identifies overheating, lubrication starvation, leaks and abnormal load behaviour.

Optical Particle Counters (ISO 4406)

Integrated contamination monitoring measures particle size distribution to assess fluid cleanliness levels in high-dust mining and industrial environments.

Fuel & Contamination Sensors

Monitoring solutions are available for:

• FAME concentration in biodiesel systems
• Water contamination in fixed FAME concentration applications
• Ethanol concentration in gasoline systems
  
• Fuel dilution and combustion contamination monitoring

Dissolved Gas Analysis (DGA)

Multi-gas transformer monitoring detects H₂, CO, CH₄, C₂H₂, C₂H₄, C₂H₆ and CO₂ to identify insulation breakdown, arcing, and overheating in critical power infrastructure.

GPS & Telemetry Modules

Ruggedised tracking devices provide geo-location, speed, acceleration and theft prevention capability for mobile and remote assets.

Controller & System Interfaces

Plug-in integration with:

• PLCs
• SCADA systems
• DCS environments
• VSDs
• Engine ECUs
• PID controllers
• Relay-based protection systems

This allows capture of operational metrics including RPM, torque, flow rates, voltage, current, alarms and fault codes — creating a complete digital profile of asset behaviour.

Engineered for Harsh Environments

All CES hardware is selected and configured for demanding industrial conditions, including:

• Extreme heat and UV exposure
• High vibration and shock loads
• Dust-heavy mining environments
• Offshore and corrosive atmospheres
• Explosive-risk areas (ATEX-certified components where required)

Low-power architecture and rugged enclosures ensure reliability in remote WA and multi-site deployments.

Key Advantages

• Lab-equivalent analytical accuracy (±5%)

• Hourly, non-destructive inline analysis

• Reduced reliance on manual sampling programs

• Multi-sensor integration capability

• ATEX-certified and mining-hardened hardware

• Seamless integration with existing automation infrastructure

• Scalable deployment across fleets and multi-site operations

CES hardware forms the foundation of a predictive, data-driven asset management ecosystem — transforming raw operational inputs into measurable reliability and performance outcomes.