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 Master Distributor for Spectrolytic across Australia and New Zealand, CES supplies and supports the FluidInspectIR inline FTIR platform — the world-first technology for real-time, automated fluid condition monitoring.

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

Inline FTIR Fluid Monitoring

At the core of our fluid intelligence capability is FluidInspectIR®, delivering lab-equivalent (±5% per DIN 51453/51451, ASTM/DIN calibratable) analysis without the delays of 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 (%wt), water (ppm / %), glycol contamination
• Fuel dilution (%)
• Solvent and process fluid composition

This enables early detection of lubricant degradation, contamination ingress, acid formation and film strength loss — critical precursors to bearing failure, corrosion and accelerated wear.

Unlike periodic oil sampling programs, inline FTIR delivers continuous condition visibility with no manual intervention, reducing labour requirements and eliminating sampling inconsistencies.

Mechanical & Operational Monitoring Hardware

CES integrates additional industrial sensors to provide comprehensive asset health coverage:

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

Detect FAME content, fuel dilution, water ingress and combustion by-product contamination in diesel, biodiesel and gasoline systems.

Dissolved Gas Analysis (DGA)

Multi-gas transformer monitoring detects H₂, CO, CH₄, C₂H₂, C₂H₄, C₂H₆ and CO₂ to identify arcing, insulation breakdown and overheating in 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-accurate performance (±5% DIN/ASTM equivalent)

• Hourly, non-destructive inline analysis

• Elimination of manual sampling programs

• Multi-sensor fusion capability

• ATEX-certified and mining-hardened hardware

• Seamless integration into existing automation infrastructure

• Designed for scalability 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.