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What are the best practices for using vibration analysis in equipment maintenance?

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Vibration analysis is a powerful technique for detecting and diagnosing faults in rotating machinery, such as motors, pumps, fans, and compressors. By measuring and analyzing the vibration signals from the equipment, you can identify problems like misalignment, imbalance, looseness, wear, and bearing defects before they cause breakdowns or costly repairs. In this article, you will learn some of the best practices for using vibration analysis in equipment maintenance.

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1 Choose the right sensors and locations

The quality and accuracy of your vibration analysis depends largely on the type and placement of the sensors you use to collect the data. Ideally, you should use accelerometers that can capture the frequency range and amplitude of the vibration signals you are interested in. You should also mount the sensors as close as possible to the source of the vibration, and in the direction that reflects the most information about the fault condition. For example, if you are looking for radial or axial misalignment, you should place the sensors in the radial or axial direction, respectively.

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anand Prakash

Senior Process Engineer NPD & New projects at WIKA Group. Working on Process Engineering ,New Projects,Plant Cognitive ergonomics,Selection & commissioning of new machines,SOP,WI & promoting Good manufacturing practices.
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Recently we are in a trouble in our assembly area as we used sensors with less proximity area while product interactions are wide. In my POV ?? using the right sensors and locations for vibration analysis in equipment maintenance enables early detection of issues, accurate diagnostics, predictive maintenance, improved equipment reliability, cost savings, and enhanced safety, making it a valuable tool for optimizing equipment performance and minimizing downtime.

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David D'Amico

? Manufacturing Design Engineer Intern | BS in Industrial & System Engineering | Ex - Boeing, Tesla, & General Atomics | SHPE Familia
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Select appropriate vibration sensors based on the equipment type, operating conditions, and vibration frequency range of interest. Install sensors at critical locations on the equipment where vibrations are most likely to occur or where they can provide the most valuable data. Conduct a thorough assessment of equipment requirements and consult with vibration analysis experts to determine the optimal sensor types and locations.

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2 Establish a baseline and set alarms

Before you can detect any changes or anomalies in the vibration patterns of your equipment, you need to establish a baseline or reference level that represents the normal operating condition. You can do this by taking measurements when the equipment is new or after a major overhaul, and when it is running under steady load and speed. You should also set alarm levels or thresholds that indicate when the vibration exceeds the acceptable limits or shows signs of deterioration. These alarms can help you prioritize your maintenance actions and prevent further damage.

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David D'Amico

? Manufacturing Design Engineer Intern | BS in Industrial & System Engineering | Ex - Boeing, Tesla, & General Atomics | SHPE Familia
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Establish a baseline vibration profile for each piece of equipment during normal operation. Set alarm thresholds based on acceptable vibration levels to detect deviations from the baseline that may indicate potential issues or impending failures. Ensure alarms are configured to trigger timely notifications to maintenance personnel. Use historical data and trending analysis to establish baseline vibration levels and define alarm thresholds tailored to each equipment type and application.

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3 Perform regular and consistent measurements

Vibration analysis is most effective when you perform it regularly and consistently, so that you can track the trends and patterns of the vibration signals over time. You should follow a schedule that matches the criticality and reliability of your equipment, and use the same sensors, locations, settings, and methods for each measurement. You should also record the environmental and operational conditions that may affect the vibration, such as temperature, humidity, load, and speed. This will help you avoid false alarms or misinterpretations of the data.

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David D'Amico

? Manufacturing Design Engineer Intern | BS in Industrial & System Engineering | Ex - Boeing, Tesla, & General Atomics | SHPE Familia
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Implement a scheduled vibration monitoring program to perform regular and consistent measurements across all monitored equipment. Establish a frequency for vibration data collection based on equipment criticality, operating conditions, and maintenance requirements. Consistent measurement intervals enable early detection of changes in vibration patterns and facilitate proactive maintenance interventions. Develop a comprehensive vibration measurement schedule and integrate it into routine maintenance activities to ensure consistency and reliability.

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4 Use appropriate analysis tools and techniques

The vibration signals from your equipment can contain a lot of information and complexity, so you need to use appropriate tools and techniques to extract and interpret them. Depending on your goals and resources, you can use different types of analysis, such as spectrum analysis, time waveform analysis, envelope analysis, or phase analysis. You can also use software or hardware that can process and display the data in various formats, such as frequency spectra, time waveforms, orbits, or waterfall plots. You should also consult with experts or guidelines that can help you identify the common fault signatures and symptoms of your equipment.

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David D'Amico

? Manufacturing Design Engineer Intern | BS in Industrial & System Engineering | Ex - Boeing, Tesla, & General Atomics | SHPE Familia
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Utilize advanced vibration analysis tools and techniques to interpret vibration data accurately and identify underlying issues. Employ signal processing methods such as FFT (Fast Fourier Transform) analysis, time waveform analysis, and frequency spectrum analysis to extract valuable insights from vibration signals. Leverage predictive maintenance software and condition monitoring systems to streamline data analysis and visualization. Invest in training for maintenance personnel to enhance their proficiency in using vibration analysis tools and interpreting vibration data effectively.

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5 Act on the results and verify the effectiveness

The final and most important step of using vibration analysis in equipment maintenance is to act on the results and verify the effectiveness of your actions. If you detect a fault or a potential failure, you should take corrective measures as soon as possible, such as adjusting, repairing, or replacing the faulty component. You should also perform a follow-up measurement to confirm that the vibration has improved or returned to normal. You should also document and report your findings and actions, and update your baseline and alarm levels accordingly.

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David D'Amico

? Manufacturing Design Engineer Intern | BS in Industrial & System Engineering | Ex - Boeing, Tesla, & General Atomics | SHPE Familia
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Take prompt action based on the results of vibration analysis findings to address identified issues and prevent equipment failures. Implement appropriate corrective actions, such as equipment adjustments, repairs, or component replacements, to mitigate potential risks and restore optimal equipment performance. After implementing corrective measures, verify the effectiveness of interventions by conducting follow-up vibration measurements and trend analysis. Establish a closed-loop feedback system to track the outcomes of corrective actions and ensure continuous improvement in equipment reliability and maintenance practices.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Cesar Conservani

Sócio Diretor na CESARCON ASSESSORIA
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Todos os tópicos listados s?o importantes, mas considero imprescindível um sistema de aquisi??o/analise/alerta on line. Este sistema deverá ter análise por IA de tendência e referências cruzadas com outras variáveis do equipamento monitorado (rota??o,tens?o,corrente,velocidade e temperaturas)

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What are the best practices for using vibration analysis in equipment maintenance?

1

2

3

4

5

6

1 Choose the right sensors and locations

2 Establish a baseline and set alarms

3 Perform regular and consistent measurements

4 Use appropriate analysis tools and techniques

5 Act on the results and verify the effectiveness

6 Here’s what else to consider

Manufacturing Engineering

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What are the best practices for using vibration analysis in equipment maintenance?

1

2

3

4

5

6

1 Choose the right sensors and locations

2 Establish a baseline and set alarms

3 Perform regular and consistent measurements

4 Use appropriate analysis tools and techniques

5 Act on the results and verify the effectiveness

6 Here’s what else to consider

Manufacturing Engineering

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