Monthly trending and data analysis:

After collecting the Acceptance and Baseline Test data, monthly data collection and analysis should be performed.  A monthly frequency is recommended because most machines have rolling element bearings which can degrade from ‘good’ to ‘bad’ in as little as 45 days. Monthly trending ‘captures’ these failure modes whereas quarterly trending could result in an unexpected failure.  Monthly trending is also recommended because many equipment owners are not “happy” with the results of quarterly programs and often loose interest in their programs.

Furthermore, quarterly trending allows many machines to slip between the cracks because not all machines are operating all the time to support data collection.  If not  have more failures and can’t ensure quarterly data is collected on every single machine (some machines may even go a year or more without having any data collected).

It’s been our experience that since equipment owners are not ‘that’ happy with the results of quarterly trending, and because of the increased rate of rolling element bearing failures, we STRONGLY recommend monthly trending.

When starting out with a new vibration program, we recommend a minimum of five (5) datasets on all machines be collected as soon as possible.  While this may be cumbersome, the Analyst could collect data daily for the first five (5) days the program is put in place. Not only will this hone the Analyst’s data collection skills, it will build a ‘history’ of all machines in the database.  There are also other reasons for expediting the initial data collections:

1. Having a minimum of five (5) datasets will allow the Analyst to determine which machines are ‘sensitive’ to operating conditions (especially positive displacement type pumps and certain types of air compressors).  By referring to five (5) historical datasets, the Analyst can not only view the normal and expected frequencies and their amplitudes at different times, but this data will have the Analyst minimize the number of false alarms that would normally occur if the data were collected on a monthly basis.
2. Promptly detect and identify failures-in-progress versus waiting up to 5 months or more and having a machine fail.  By preventing just one (1) critical machine from failing, it’s possible the Analyst can save the plant enough money to pay for the program’s test equipment.
3. Although rare, some new or rebuilt machines can experience early bearing failures.
4. Another reason Periodic Testing should be performed, is because the data collected over time (months; years) allows the Analyst to detect and identify low level issues before they get worse and greatly reduce a machine’s reliability or fail. As with any machine, it has a limited life, and if end-of-life failures can be detected, the machine can be secured before the failure occurs. This allows the plant to schedule the downtime to make repairs and minimize the repair cost because it’s much cheaper to replace a bearing, than it is to replace the entire rotor (which is likely when a bearing fails catastrophically).

Emergent data analysis services

We provide emergent (1-time) data analysis services for non-clients, and we guarantee a response within 2-hours.

The cost for each 1-time analysis is $ 1,000 USD. We accept Purchase Orders and Credit Cards (VISA, AMEX and MASTERCARD).

After payment has been confirmed, send us screen prints of your data (list below) to VAI@infowest.com and vaiuser@vibrationanalysts.com

Where possible, be sure to provide all of the following data, known history and any known maintenance issues:

• Spectral trend plots of all horizontal, vertical and axial test points on both the driver and driven machine, and gearbox if applicable
  • All amplitudes should be in Velocity IPS-Pk
• Waveform trend plots for each of the above points
  • All amplitudes should be in Acceleration g’s-Pk
• Provide multi-point spectral plot(s) of all points across the machine
  • All amplitudes should be in Velocity IPS-Pk
• Provide multi-point waveform plot(s) of all points across the machine
  • All amplitudes should be in g’s-Pk
• If multiple IDENTICAL machines are available, provide all the above for the bad machine, and one of the good machines.
• Provide hi-resolution data if available, and any other pertinent information you believe we may need

Then call 815-742-1793 with your credit card information and expect an answer within two (2) hours.

Remember, the accuracy of our analysis depends on the quality and completeness of your data.

Not that although we may ask for additional data or information, there will only be a one-time charge for our analysis.

Special Offers & Benefits:

When we analyze the data for at least 30 machines a month for 12 months, we provide clients:

FREE On-Site Data Collector Training:

For clients who contract the data analysis of 30 or more machines on a monthly basis for 12 months, we provide FREE on-site Data Collector Training. This training is completely FREE; no travel, labor or other fees; there will not be an invoice for this service. Training includes personal safety, how to setup and use a meter, how to select the best vibration test point locations, how upload new routes into the meter and send collected data to VAI for analysis. After this training, your staff will be able to independently collect vibration data at any time. And again, this training is absolutely FREE.

FREE Database Management:

VAI provides FREE database and route creation, maintenance and optimization services for the life of any vibration program that we analyze the data for. Large databases can take new users a LONG time to build, however our Analysts can build comprehensive databases for over 300 machines in as little as one (1) week. Our Analysts have the knowledge and experience to accurately input all data collection and analysis parameters, they can build efficient databases and routes, and in as little as one (1) week, have your program up and running, ready to receive the data.

FREE 24/7 Technical Support:

We provide FREE 24/7 technical support. This means that if you ever have a machinery vibration issue (off-hours, on weekends or holidays) just collect the data and email it to us for an emergent analysis at no additional cost. We also offer technical support on routine or advanced testing, machinery troubleshooting, database and route changes (new / modified equipment) management, sales and service, loaner and rental meters, and much more. In essence, if we can help you, we will and at no cost for the technical support. This service is FREE to clients who contract the monthly analysis for 30 or more machines for at least 12 months.  Just call us at 815-742-1793 to see how we can help!

FREE Vibration Database Access:

Consider a competitor’s report that says the data points to an alignment issue on a critical machine. Maybe they identify the point(s) affected. But can you readily log in and view the data for yourself to see what’s going on? VAI provides all clients FREE access (read-only) to their database so they can view their own data at anytime and consider what the report says. What if a machine fails without any prior notification? Wouldn’t it be nice if you could log in and look at the data for yourselves to see if there were any indications?  Sudden failures are rare, but they do happen. Typically due to rolling element bearing cage failures.  With our services, you get to see the data for yourself!

About Our Qualifications:

We’ve been doing business since 2001, so we have to be doing something right!

We have more ISO Category IV Certified Vibration Analysts than NASA and the US DOD combined.

We received a US Patent for the industry’s leading and most accurate vibration data analysis process.

We use an assembly line process which provides exceptionally accurate results when analyzing mass quantities of machine vibration data.

We ONLY use the industry’s best rated and top-tier CSI 2130 & 2140 handheld vibration meters and CSI’s AMS Machinery Health Manager software.

We also use Teac 16 / 16 multi-channel digital recorders and ‘platinum’ grade sensors when collecting ultlra-high resolution waveform data.

We stand behind the accuracy of our analyses with a money back guarantee

We provide FREE on-site Data Collector Training (and other FREE benefits) to clients who have us analyze their data on a monthly basis.

All of our Analysts are ISO Certified and must maintain their certification.

Acceptance Testing

Acceptance Tests are typically performed on new or rebuilt machines that are considerably expensive and / or critical to the plant. These tests are performed before shipment and at the supplier’s place of business to verify that the machines meet specifications as stated in the Purchase Order (you DID state what the maximum levels were, didn’t you?).  During these tests, the machine is operated at specified test conditions, during which time a plant representative (typically the Analyst) collects and analyzes the data to ensure the machine meets all specified conditions such as maximum levels at operating speed and very low levels at bearing fault frequencies and waveform amplitudes.

Our Certified Vibration Analysts are available to witness and perform acceptance tests on your behalf. We will be there to ensure the specified test conditions are met (pressure, dp, temperature, run-time before data collection begins, rpm and any other required operating conditions). This includes machine start-up and coast-down tests, natural frequency and resonant “bump” tests, collecting data sets at different operating conditions (load / speed / temperature / etc.). We will also collect phase data and waveform impact levels, and all in accordance with the requirements stated in the approved test plan. After all test data has been collected and analyzed, we will provide a detailed report which includes all test data, results, conclusions and recommendations.

Before you install new or rebuilt machines that are critical or highly valued to your company, make sure you perform this test. It prevents problems downstream that may include the supplier’s failure to provide a quality product and tests the machine at peak operating condition. If all the vibration test criteria has been met at the suppliers facility, but the levels are high at your plant, then either there was as accident during shipping, the machine was not installed correctly, or there’s a resonance of the assembly; all of which can be tested and determined by an experienced ISO Certified Analyst from VAI. For more information about these tests, refer to Baseline Testing (next section).

Baseline Vibration Testing:

After the Acceptance Test of a new and rebuilt machine at the supplier’s facility, the next test that should be performed is a Baseline Test.

A Baseline test is performed after a machine has been installed at the plant and all maintenance activities have been completed and verified to be correct. This includes verifying the alignment is within specifications, soft-foot has been eliminated, new bearings have been installed, pipe strain eliminated, and all fasteners have been properly torqued. Note that in many cases involving a new or rebuilt motor, it’s always wise to perform an uncoupled motor run in the ‘shop’ because it wouldn’t be the first time that a new / rebuilt motor passed the Acceptance Test, but had elevated vibration levels when delivered to the plant (motor fell during loading / shipping and landed on the output shaft causing run-out).

Assuming the levels during the uncoupled motor run were low, the next step is to assemble the machine in the plant.  After maintenance activities have been completed, the machine is started and test data is immediately collected to make sure the levels are not excessive. Barring any shipping, maintenance or resonance issues, the vibration levels should be reasonably low. If they are elevated, the Analyst should be investigate to determine what changed, because the “only changes” that could cause elevated amplitudes between the Acceptance and Baseline Tests are shipping incidents (accidents, potholes) installation issues due to improper maintenance, and resonances of the installed system.

For assistance troubleshooting elevated vibration levels, contact VAI. Our Analysts are highly experienced with troubleshooting problems uncovered during a Baseline Test.

Periodic Testing:

Periodic testing is performed after new or rebuilt machines have been installed and verified to be acceptable. Periodic testing consists of collecting route-based data on a regular schedule; monthly being the industry standard.  Monthly testing is recommended because rolling element bearings can degrade from ‘good’ to ‘bad’ in as little as 45 days. Monthly trending ‘captures’ these indications however quarterly will not. Also, we’ve learned that many equipment owners are not “happy” with their program because there will be more failures along the way. It’s been our experience that since equipment owners are not ‘that’ happy with the results of quarterly trending, we STRONGLY recommend monthly trending where possible.

Regarding periodic trending of a new or rebuilt machine, VAI recommends collecting a minimum of five (5) datasets as soon as possible. For example, while tedious, the Analyst can collect data daily for the first five (5) days or as quickly as possible. There are a number of reasons for expediting the initial datasets:

1. A minimum of five (5) datasets are needed for the Analyst to determine the expected range of vibration levels and frequencies for most operating conditions. That’s because some machines are ‘sensitive’ to operating conditions (especially positive displacement type pumps and certain types of air compressors).  By quickly collecting five (5) datasets, the normal and expected frequencies and amplitudes , an Analyst can minimize or prevent the false alarms that would normally occur with the 5-10 datasets. Furthermore, the five (5) initial datasets should be expedited where possible, even collecting a set of data daily.
2. Detect and identify early failures so that corrective actions can be put into place. Although rare, some new / rebuilt machines can experience early bearing failures. By preventing the failure of one (1) critical machine, it’s possible the Analyst saved the plant enough money to pay for the test equipment, in full.
3. Another reason Periodic Testing should be performed, is because the data collected over time (months; years) allows the Analyst to detect and identify low level issues before they get worse and greatly reduce a machine’s reliability or fail. As with any machine, it has a limited life, and if end-of-life failures can be detected, the machine can be secured before the failure occurs. This allows the plant to schedule the downtime to make repairs and minimize the repair cost because it’s much cheaper to replace a bearing, than it is to replace the entire rotor (which is likely when a bearing fails catastrophically).

Component Troubleshooting:

Multi-Channel Testing

Our vibration analysis services include the capability to continuously record very high resolution data on up to 16 channels for several hours. This test method allows our Vibration Analysts to measure and quantify changes in the data over time due to variations in temperature, pressure, load and rpm.

Multi-Channel vibration testing offers several benefits, including:

Comprehensive Data Collection:

Multi-channel testing allows simultaneous collection of vibration data from multiple points on a machine or structure, thereby providing a more comprehensive understanding of the system’s behavior. This behavior, which can be quantified, can be affected by changes in operating conditions (temperature, load, operating speed, pressure, and even environmental conditions).

Identifying Complex Vibration Patterns:

With multiple channels, you can capture intricate vibration patterns and interactions between different components. This is particularly valuable for diagnosing complex machinery issues.

Efficient Monitoring:

By continuously monitoring and measuring the live vibration data, machine performance over an extended period of time can be evaluated.  Increases in amplitude over a short period of time can be measured allowing engineers to project what the levels may be at some point in the future.

Condition Monitoring:

Continuous multi-channel testing enables real-time condition monitoring of machinery. It helps in detecting early signs of deterioration or faults, allowing for proactive maintenance and minimizing unplanned downtime.

ODS and Modal Analysis Testing

ODS & Modal Analysis tests are very similar, however during ODS testing the machine self-generates the vibration energy needed to create the animation. On the other hand, Modal Analysis testing uses manual labor to generate the vibration energy, which is why ODS testing is preferred.  Even so, ODS and Modal Analysis tests are very labor intensive, which is why all other testing should be performed first.

Our Certified Vibration Analysts also perform ODS testing that models how a machine / structure / piping assembly moves in real life. By viewing the machine’s animation, clients can observe how the assembly responds to different operating conditions. Our Vibration Analysts provide accurate recommendations that, in most cases, clients can immediately recognize as being accurate and realistic.

Operational Deflection Shape (ODS) testing

ODS testing consists of three main steps:

1. Building a 3-D model of the machine / structure / system using dedicated software.
2. Collecting x, y and z vibration data at each point within the model
3. Meshing the data so the model moves as a complete ‘assembly’ at a frequency.

The results of an ODS test provide a visual 3-D animation showing how a machine moves in real time at any frequency. The benefits of this type of test include:

1. A visual model of how the assembly is moving. Consider a metal I-beam that has a vertical crack in the middle of the beam. While this defect may not be readily apparent, the 3-D model when activated, will exaggerate the beams deflection, clearly showing an anomaly where the crack is, leading inspectors directly its location. ODS testing also provides insights into natural frequencies, mode shapes, and dynamic responses of how machines and structures move. ODS testing is however, labor intensive and a simple model may have over to 100 points. Since x, y, z data must be collected at each point, that’s a lot of data collection!

2. By collecting ODS data under actual operating conditions, the ODS animation can identify issues such as misalignments, unbalanced components, and structural weaknesses. For example, VAI determined that the mounting pedestal under a 90-degree safety related gearbox, was moving erratically. Upon closer inspection, we determined the gearbox casing was approximately 1/2” thick, while the mounting pedestal under it, had only ¼” walls .. AND it had two (2) large openings to support coupling maintenance (the weak link was UNDER the more massive and rigid gearbox).

3. ODS testing provides animations that show how machinery or structures respond to different operational loads. This data can be used to modify system strength, optimize machine performance, improve efficiency, and enhance the overall reliability of the machine.

4. In the case of unexpected vibrations or performance issues, ODS test data helps to identify the root cause(s). This information is valuable for troubleshooting and implementing corrective measures.

5. By understanding the dynamic response of machines and structures, ODS testing can aid us in developing effective preventive maintenance plans. Maintenance activities can be scheduled based on actual operational conditions and run-times, reducing downtime and maximizing machinery life.

6. ODS testing can also be used during the design and manufacturing process to validate the structural integrity and dynamic behavior of components and structures. It ensures that the equipment meets design specifications and quality standards.

7. ODS testing can help identify dynamic issues that might reduce the overall safety of machinery and structures, thereby helping to prevent catastrophic failures that could pose safety risks to personnel and the plant.

Our advanced testing and troubleshooting capabilities include:  

• ODS (OPERATING DEFLECTION SHAPE) TESTING
• MODAL ANALYSIS TESTING
• MULTI-CHANNEL RECORDING AND ANALYSIS

ODS (Operating Deflection Shape) and Modal Analysis tests have similarities. ODS testing involves collecting data while the machine is in operation, allowing the machine to generate the vibration data needed to create 3D animations. Modal Analysis Testing however requires the use of ‘impact’ hammers which can be quite fatiguing to use for large projects. Due to the labor-intensive and time-consuming nature of these tests, especially Modal Analysis Testing, all other testing should be performed first.

In summary, Operational Deflection Shape testing provides a slow motion, exaggerated 3-D animation of how a machine or structure is moving. This allows clients to implement corrective maintenance, perform necessary optimizations, and enhance machine / structure reliability.

Advanced Testing

Single Plane Balancing

Our Vibration Analysts can perform single plane fan balancing, which may be needed when amplitudes get too high at operating speed. In nearly all cases, the radial vibration levels will be noticeably higher than the axial levels.

For safety reasons, VAI advises against untrained staff performing the balancing procedure. This is because if a balance weight should loosen and come off during the procedure, the kinetic energy can be extreme if not lethal and possibly damaging the component.

VAI’s Certified Vibration Analysts can perform precision balancing because they have been highly trained and certified. There is no need to purchase expensive vibration test equipment or balancing software; our Vibration Analysts will do everything except turn wrenches (due to insurance concerns).

This training is provided over the course of two (2) days and covers all aspects of single plane balancing (95% of all balance jobs). Topics include safety, test equipment, how to collect the data, the use of polar graph paper (vs. expensive balancing software), how to calculate balancing moves, and how to distinguish between unbalance and the other machine faults that cause an elevated 1x frequency.

Single Plane Balancing may become necessary when amplitudes at 1x operating speed reach elevated levels. In the majority of cases observed by VAI, and assuming the absence of axial resonance, it’s noted that radial directions typically exhibit higher amplitudes, while axial levels remain relatively low.

VAI strongly advises against allowing untrained staff to perform balancing moves due to the extreme kinetic energy associated with balance weights at operating speed. The potential risks if a weight comes off includes serious personal injury and/or damage to components.

The balancing process involves collecting initial amplitudes and phase data. A ‘trial’ weight is then added, and another set of data is collected. Utilizing vector mathematics, the correct amount of weight and its precise location can be determined if the trial weight produces a response. Our approach eliminates the need for purchasing expensive balancing software.

TEST EQUIPMENT: Sales, Rentals and Loaners

New Sales:

For clients looking for the absolute best price on the industry’s best-rated hand-held vibration test meter, we offer substantial discounts to clients who select us analyze their vibration data. And as part of our service, we provide FREE on-site Data Collector Training so that your staff can begin  immediately collecting data.

FREE Loaners:

We provide FREE loaners to clients who contract us to analyze a minimum of 30 machine-trains each month for one (1) year.  These loaners are available when a client’s meter is being re-calibrated, repaired, or when another meter is needed to get “caught-up”.

Rental Units:

Need to get caught up? Want to evaluate before buying? This may be the best option for a company who wants to try CSI’s best-rated vibration test equipment before buying.  We also rent to companies who need a rental unit while their meter is being repaired and those who need to ‘catch-up’ on their data analysis.

Client Testimonials can be summed up as follows:

Client Testimonials can be summed up as follows:

Accuracy and Precision:

“Their analysis provided unparalleled accuracy in identifying real machinery issues.”

“They can accurately detect and identify vibration issues at the earliest possible stages.”

Reliability and Machine Health Assurance:

“Our equipment’s reliability has improved significantly during their watch.”

“VAI’s services continue to optimize the health and reliability of our machines.”

State-of-the-Art Technology:

“Very impressed by VAI ‘ONLY’ using state-of-the-art test equipment like the CSI’s vibration meters.”

“Their patented data analysis process is doing a terrific job. Very accurate!”

Expertise of Certified Analysts:

“VAI’s Certified Vibration Analysts have exceptional knowledge. Not only are they expert vibration analysts, but they also have a solid understanding of how machines are designed and built.

“Their analysts perform different parts of the analysis based on their knowledge and experience. This allows ‘the team’ to accurately analyze and process exceptionally large quantities of data within 24 hours.”

Comprehensive Analysis:

“They go beyond just identifying issues; they also provide an accurate list of the possible causes, prioritizing the most likely first, and providing accurate corrective recommendations.”

“Their approach covers all aspects, ensuring nothing is overlooked. And if it were, I’m confident they would modify their approach to making it better!”

Efficient Problem Resolution:

“Quick and timely identification and resolution of vibration-related problems.”

“Their services help us address issues before they turn into major problems.”

Professionalism and Communication:

“VAI established very clear and professional communication at the start of our program; very easy to work with.”

Positive Impact on Operations:

“Their services had a positive impact on our overall operational efficiency. They are even able tell us when we have too many (or too few pumps running) just based on the vibration data!”

Our machinery downtime has gradually decreased since VAI has been analyzing our data, and we continue to substantial return on investment as we continue to optimize our vibration program.

The above are just some of the ways VAI can help you with your vibration program.

To learn how we can meet your data analysis and program needs, call us at 815-742-1793.