People working on computer

Vibration Data Analysis

Pump suction pipe resonating due

to location of vertical pipe support.

Testing and Troubleshooting

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Test Equipment Sales & Service

OUR SERVICES:

Our Quals & Experience >>

About Our Qualifications:

  • We have more ISO Category IV 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’ve been doing business since 2001.
  • We only use the industry’s best rated and top-tier test equipment and software.
  • We guarantee the accuracy of our analyses with a money back guarantee
  • We provide FREE benefits to clients we analyze data for
  • All Analysts are ISO Certified and they must keep their certification current

About Our Experience:

Ray W. Rhoe is President of Vibration Analysts, Inc.  Ray graduated from The Citadel in 1978 and obtained a Professional Engineer’s License. He started working in a “Noise and Vibration Group” at an east coast shipyard responsible for building and overhauling US Navy nuclear submarines.  Ray later became the company’s Pump Component Engineer and then transferred to a large nuclear power utility working as their Pump Component Specialist. By combining his pump and vibration experience, and by attending several advanced vibration training courses, Ray worked his way up to be the Plant’s Vibration Engineer.  While working in the nuclear industry, Ray completed a large Operating Deflection Shape Test (ODS) test on a 1250-megawatt Turbine Generator and two (2) elevations of the Main Turbine Building. Ray’s experience also includes precision balancing, troubleshooting component and structural resonances, and providing ISO Vibration Certification Training (Categories I, II and III).

Ray started working as an Independent Vibration Consultant in 2001, and shortly after he patented his data analysis process.  After recognizing the many benefits of this patent, Ray incorporated his business and we became “Vibration Analysts Inc”.  It’s who we are; it’s what we do!

Ray’s Professional Training includes:

  • Practical Solutions to Machinery Vibrations – Update International
  • ISO Level I / Category II Vibration Certification – Vibration Institute
  • ISO Category III Vibration Certification – Vibration Institute
  • ISO Category IV Vibration Certification – Vibration Institute
  • Operating Deflection Shapes (ODS) and Modal Analysis – CSI Inc.
  • Basic Machinery Diagnostics – Bently / Nevada
  • Advanced Machinery Diagnostics – Bently / Nevada
  • Balancing and Rotor Dynamics – Vibration Institute
  • Finite Element Analysis – RODYN

As an ISO Category IV Analyst, Ray also provides the following training courses:

  • Vibration Data Collector
  • Single Plane Balancing
  • ISO Category I Vibration Certification
  • ISO Category II Vibration Certification
  • ISO Category III Vibration Certification
  • CSI AMS Software Training (Vibration Database Management)

WHO’S ANALYZING YOUR DATA?

Free Client Benefits >>

We provide many FREE benefits when we analyze the data for 30+ machine-trains per month for 12 months:

  • On-Site Data Collector Training. No travel, labor or other cost. ZIP!
  • Database and Route Creation, Maintenance and Optimization
  • 24/7 Technical Support and Emergent Data Analysis
  • Data Storage and Retrieval on our server
  • Database Access (so you can view your data at any time)
  • FREE short-term loaner test equipment (just pay for shipping)

We also provide the ABSOLUTE BEST prices for new CSI Hand-Held 2140 Vibration Test Meters.

For details and pricing, call us at 815-742-1793.

For more information about our special benefits, refer to the links below  >>

FREE On-Site Data Collector Training

FREE On-Site Data Collector Training:

We provide FREE on-site Data Collector Training to clients who have us analyze the data for of 30 or more machines per month, for a 12 months. This training is completely FREE; there are no travel, labor or other fees associated with this training.

Training topics include personal safety, setup and use of the industry’s leading test equipment, determining the best machine test point locations, how upload new routes and download data. After the classroom training, the students will go into the plant and collect your initial data while VAI mentors and monitors the students.  We will do all this absolutely FREE for clients who have us analyze their data as noted above.

FREE Database Management

FREE Database Management:

VAI provides FREE database and route creation, maintenance and optimization services. Creating an vibration database can be a very time consuming and challenging process. Not only do you have to know to use the industry’s most advanced (and complicated) software, you also must know how to select all of the correct parameters that exist when programming a meter to collect vibration data. This includes window type, lines of resolution, fmax, number of averages and more. You also have to be able to create and optimize the “routes” needed to support the data collection process.

Large databases can take months for new users to build, however our Analysts can build large, accurate and complete databases in as little as one (1) week.  Our Analysts have the knowledge and experience to accurately input all data collection and analysis parameters, build efficient databases and routes, and have your database up and ready to receive the data in as little as one (1) week.

Remember, the accuracy of your data analysis is directly related to the quality of the data collected.  For those who want to challenge their sanity, the following are just a FEW of the parameters that need to be selected for EVERY component and in EVERY machine train.

For a fast and accurate solution to creating your database, call us at 815-742-1793.

FREE 24/7 Technical Support

FREE 24/7 Technical Support:

We provide FREE 24/7 technical support in all areas, including emergent data analysis.  This means that if you ever have a machinery vibration issue (off-hours, weekends, holidays) just collect the data and send it to us for an analysis at no cost.

We also make database and route changes, support inquiries about test equipment sales and service, loaner and rental meters, and much more.  If we can help, we will at no cost to our clients.

Need help? Call us at 815-742-1793.

FREE Database Access

FREE Database Access:

Lets say you just received a report that says the levels at 1x on a critical machine have been gradually increasing over the past year (upper image).  What if you received another report that said a machine showed a sudden step increase at 1x and had a significant increase in the number of non-harmonic frequencies related to a bearing fault (lower image)?  Wouldn’t it be nice if you could login to the database and view the data for yourself … rather than just rely on a report?

VAI makes this possible by providing access to all clients who choose us to analyze their data. This access is available 24/7 and we’ll even provide a free tutorial on how to use the software.

To begin the process, just call us at 815-742-1793.

Test Equipment Sales & Service

Test Equipment: Sales, Service, Rentals and Loaners:

New Sales:

For our data analysis clients, we provide the best price on the industry’s best-rated hand-held CSI 2140 vibration meters, and provide FREE on-site Data Collector Training so that your staff can start collecting data.

Rental Units:

Want to evaluate a meter long term (over a month) to evaluate before buying?  This would be the best way for a company to try CSI’s 2140 vibration meter before buying it.  We also rent to companies who need rental units while their meter is being repaired and for those who just need to ‘catch-up’ on their data analysis.

Loaners:

We provide FREE loaners to our data analysis clients.  These loaners are available when a meter is being repaired or when an additional meter is needed to get “caught-up”.  Just pay for the shipping and we’ll get one out the door!

Vibration Data Analysis >>

Periodic Trending & Analysis >>

Periodic trending and data analysis:

After collecting Acceptance and Baseline data, periodic data collection and analysis should be performed on a regular bases.  Monthly trending is recommended because many machines have rolling element bearings and these bearings can degrade from a ‘good’ condition to a ‘bad’ one in as little as 45 days. Periodic trending ‘captures’ these and other ‘rapid’ failure modes that could result in unexpected component failures.

Monthly trending is also recommended because many equipment owners loose interest in their programs because there’s an increased rate of unexpected equipment failures.  These unexpected equipment failures occur because many machines do not run continuously and the data for many of these machines may not be collected for one or more quarters.  When this happens, many machines only get trended annually and experience high failure rates.  To be effective, vibration data must be collected and analyzed on a monthly basis.

When starting a new vibration program, we recommend five (5) datasets be collected on all machines, and as quickly as possible.  While this may be cumbersome, by repeating the data collection process will not only hone the Data Collector’s skills, it will also provide the needed ‘historical database’ upon which all future data can be analyzed.  There are also many other reasons for expediting the initial data collections:

Many machines are ‘sensitive’ to operating conditions (for example, positive displacement pumps and certain types of air compressors).  By quickly building a database that has at least five (5) datasets in it, the Analyst will be able to see what the normal and expected frequencies and amplitudes are at different operating conditions (load, pressure, temperature, dP, etc.).  By acquiring data that’s been collected over a (hopefully) wide range of amplitudes, the Analyst can minimize the number of false alarms that normally occur if the data were collected periodically.

By quickly building a database with at least five (5) datasets in it, the Analyst will be better able to detect and identify failures-in-progress, as compared to waiting up to 5 months or more. By preventing just one (1) critical machine from failing, the Analyst could possibly save enough money to pay for the vibration test equipment.  Also, although rare, some new or rebuilt machines can experience early bearing failures.

With the minimum five (5) datasets, the Analyst can now detect and identify low level issues before they get degrade, possibly resulting in a machine failure. At this time, this Analyst can now help the plant schedule repairs and minimize the repair cost, because it’s so much cheaper to replace a degraded bearing, than wait until it fails resulting in a catastrophic failure of the rotor (possible when a bearing fails catastrophically).

Emergent 24/7 Data Analysis >>

Emergent data analysis services

Is your Analyst out sick or on vacation?  Is your plant between Analysts?  We can help!

We can analyze data and provide a response typically within 2-hours or less.

The cost for our analysis is $ 1,000 USD and we accept Purchase Orders and Credit Cards (VISA, AMEX and MASTERCARD) to expedite the process.

Be prepared to send us screen prints of your data and a couple of photos of the machine-train to VAI@infowest.com and vaiuser@vibrationanalysts.com

Be sure to provide all of the following data and a summary of the machine’s history and maintenance activities:

  • 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

Remember, the accuracy of our analysis depends on the quality and completeness of your data, and although we may ask for additional data, there will only be a one-time charge for our analysis.

Call us at 815-742-1793 to get the process moving.  

People working on computer
Special Client Benefits >>

Special Client 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!

Test Equipment: Sales, Service, Rentals and Loaners:

New Sales:

For our data analysis clients, we provide the best price on the industry’s best-rated hand-held CSI 2140 vibration meters, and provide FREE on-site Data Collector Training so that your staff can start collecting data.

Rental Units:

Want to evaluate a meter long term (over a month) to evaluate before buying?  This would be the best way for a company to try CSI’s 2140 vibration meter before buying it.  We also rent to companies who need rental units while their meter is being repaired and for those who just need to ‘catch-up’ on their data analysis.

Loaners:

We provide FREE loaners to our data analysis clients.  These loaners are available when a meter is being repaired or when an additional meter is needed to get “caught-up”.  Just pay for the shipping and we’ll get one out the door!

Database Management >>

Database Creation & Maintenance

Database Creation and Maintenance:

VAI has created well over 100 databases for clients worldwide, many with more than 300 machine-trains.  Our databases are built for maximize efficiency, data acquisition, and accuracy of the analysis.  We ensure complete and comprehensive data collection and route efficiency.

Our ISO Category IV Certified Vibration Analysts know how to select the best data acquisition parameters, including Fmin and Fmax, Lines of Resolution, number of averages, window type, waveform parameters, and more.  Every database we build is built to to ensure the data is accurate, complete and ready for analysis.

Regardless of the number or type of machines you have, our Analysts can quickly, accurately and affordably build your database saving you a great deal of time and money trying to learn the process.  We can typically complete a database with up to 300 machines in less than a week, and to begin the process, you only need to provide us with a spreadsheet listing the machines and the following machine data:

  • Equipment Engineering Part Number: Up to 9 characters (example: 1CDO1PA)
  • Full Name: Up to 29 characters (example: “Unit 1 Condensate Pump A”)
  • The overall design of the machine (how you would describe it to someone over the phone). Here are three (3) examples:
    • Horizontal motor / coupling / horizontal gearbox w/2 shafts / coupling / horizontal pump
    • Vertical motor / pump impeller mounted on motor output shaft (direct drive)
    • Vertical motor / coupling / 90-degree gearbox / belts / horizontal pump
  • Unloaded driver speeds: Typically 900, 1200, 1800 or 3600 rpm for motors if not on a VFD
  • The rpm of the driven machine (if known): Example: 435 rpm
  • State whether the motor is on a VFD or not:  (Yes or No)
  • List the machines (one or more lists) in the order that you’d like to collect the data
    • Remember to list the machines in the order which will minimize the number of steps taken in the plant

After we receive the above information, we’ll start building your database.

THE FOLLOWING SERVICES ARE FREE TO CLIENTS WHO HAVE US ANALYZE THEIR DATA:

  • FREE Database and Route Creation, Maintenance and Optimization
  • FREE 24/7 Technical Support and Emergent Data Analysis
  • FREE On-Site Data Collector Training (no cost whatsoever)
  • FREE Database Storage and Access via CSI’s AMS MHM software
  • FREE “Loaner” CSI 2130 / 2140 Meters (just pay for the shipping)

For help with any question, call us at 815-742-1793.

Route Creation & Optimization
Route Creation & Optimization

We can quickly and accurately create as many routes as desired, modify existing routes to add, delete or modify the order of the machines, and usually within two (2) hours. To provide the best results possible, we only use the industry’s best database software and test equipment made by Emerson Process / CSI.

To begin process, just provide provide us with one or more lists of the machines in the order you’d like to collect the data.  It’s always best to list the machines in the order that minimizes the number of steps taken in the plant. The number of machines in a route should be between 20 and 30.  If you have too many, you’ll likely spend time looking for a machine.  If you have too few, you’ll spend time switching between the routes.  These are recommendations only, and we’ll be glad to create the routes as you desire.

As soon as your database and routes are complete, you’ll be ready to start collecting and analyzing your data.  If you should need guidance on how to operate the vibration test equipment, we’ll be glad to provide on-site Data Collector Training (this service is FREE to clients who have us analyze their vibration data).

Want to evaluate the CSI 2140 meter before buying? We have many loaners available for our clients and all you have to do is pay for the shipping. You can also use a loaner if needed to get  ‘caught up’ on your data collection activities, or for when your meter needs to be sent out for repair or calibration.  It’s very rare a meter fails, but we offer this benefit to our clients in case it does.

We also sell NEW CSI 2140 meters at guaranteed lowest prices to our clients, and we provide long-term rentals at affordable rates.

The following services are FREE to clients who have us analyze their data:

  • FREE Database and Route Creation, Maintenance and Optimization
  • FREE 24/7 Technical Support and Emergent Data Analysis
  • FREE On-Site Data Collector Training (no cost whatsoever)
  • FREE Database Access via CSI’s AMS MHM software
  • FREE “Loaner” CSI 2130 / 2140 Meters (just pay for the shipping)
  • FREE guidance available from VAI; just call us at 815-742-1793

Testing & Troubleshooting >>

Acceptance Testing

Acceptance Testing:

Starting a new vibration program?  Installing new equipment?  Want to test new or refurbished equipment and verify they are ‘good to go’?  We can help!

Our Category IV Analysts are highly trained and qualified to perform all types of acceptance tests on new and refurbished machines.  We go beyond just collecting a set of data set and confirming it ‘passed or failed’.  We witness and participate in all aspects of the Acceptance Test,  We verify supplier’s gauges and instrumentation are calibrated, and that specified test conditions are met before starting the data collection.  We perform all type of tests: Start up, Coast down, Natural frequency, Resonance, High-resolution as well as Multi-channel condition based tests while changes in operating conditions (rpm, pressure, flow, dP, temperature) are varied.  You will receive accurate and detailed reports, copies of all data, as well as a summary of the test results, conclusions and recommendations.

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 Testing

Baseline Vibration Testing:

After performing the Acceptance Test of a new or rebuilt machine at the supplier’s facility (and assuming it passes) it is shipped to the plant.

If it is a new or rebuilt motor and it has rolling element bearings, it should always be tested (uncoupled) in the ‘motor shop’ for excessive impacting in the waveform data. Typically waveform impact levels should not exceed 1 g’s-Pk. If the levels exceed this amount, the bearings may have been brinelled during shipping or handling.  It certainly wouldn’t be the first time a new / rebuilt motor passed the Acceptance Test but had elevated vibration levels when delivered to the plant.  In addition to testing the waveform impact levels, perform a TIR on the motor output shaft by hand (motor secured). Maximum recommended TIR is 1.5 mils; more than that for an 1800 rpm motor, and the vibration levels will likely be excessive. More so for a 3600 rpm motor.

Assuming the waveform impact levels and TIR values are good, the next test to be performed is called a Baseline TestThis test is performed after the machine has been installed in the plant and all maintenance activities completed and verified correct. For example, the alignment is within specifications, soft-foot has been eliminated under the motor feet, new bearings were installed, pipe strain was eliminated, all fasteners properly torqued, new lube in the coupling (if applicable); everything is within specification.  

At this time the machine is started and test data is immediately collected to make sure the levels are not excessive.  While this initial data is collected, the operator(s) should be adjusting system operating conditions so they mimic normal operating conditions the component is expected to operate at.  Once everything is as it should be, another set of data is collected and this will represent the baseline data upon which all future data will be compared. Barring any shipping, maintenance or resonance issues, the vibration levels should be reasonably low.

If they are elevated compared to previous trend data from the old pump, the Analyst will need to investigate and determine what has changed. For assistance with troubleshooting vibration problems, please call us at 815-742-1793.

Periodic Testing

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:

    • 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.
    • 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.
    • 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

Component Troubleshooting:

It happens. Things like pulling an old (yellow) motor out and installing a refurbished motor. Everything WAS fine, but now you have a vibration problem, and the levels are definitely high. So what do you do?  You disassemble and recheck everything only to put it back together and still have high vibes.  You’re perplexed and asking your staff what could it be!  This would be the perfect example of when to call in a Vibration Analysts.  We can quickly collect the data and by analyzing the frequencies, amplitudes, and the pattern of levels across the machine, come up with a very short list of what to check for.

For example:

Did you notice the cracked concrete foundation in the photo above? Maybe their is an air pocket and with the change in component mass and stiffness, it’s exciting a localized resonance.  Maybe the foundation was damaged during motor replacement?

Did maintenance perform a running soft-foot adjustment?  Maybe one or more of the motor feet is sloped and shimming is the issue?

What was the as-left balance value at the supplier’s facility? You did instruct the supplier to test and balance if needed in the PO didn’t you?

Maybe the new motor’s mass and stiffness are such that they’ve created a foot-related resonance? If so, that’s an easy fix … if you know what to look for!

Is the problem frequency 1x operating speed?  Are the levels elevated in the axial direction?  If so, there’s probably an issue that is affecting the alignment, such as a worn or degraded coupling, too much or too little coupling lube, bent motor output shaft (it happens more than you think).  Could also be a worn or degraded coupling key or keyway, bottomed-out fasteners holding the machine in place, and so much more.

Our ISO Category IV Analysts can quickly troubleshoot all these and many more issues, and they are available to support and test emergent issues just like this.  To get a Cat. IV Analyst on his way to your plant now, give us a call at 815-742-1793.

Multi-Channel Testing

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.

During multichannel testing, our Analysts typically use a Teac 16-channel ‘IN’ / 16-channel “OUT’ recorder. These are very high end units, but can reliably collect and store hours of continuous hi-resolution waveform data on up to 16 or even 32 channels (or more!). This allows our Analysts to measure even the slightest changes that occur over time due to any number of changing conditions (rpm, load, pressure, dP, temperatures, and time), and on up to 16 (or more locations) at the same time. A/C motor startup? No problem. DC motor gradual ramp up and down? Piece of cake. Gradual changes that occur over 24 hours? Can do.

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 Testing

ODS animation showing how a pump and it’s suction piping vibrate at pump Vane Pass frequency

ODS and Modal Analysis Testing

ODS & Modal Analysis tests are very similar.  ODS tests involves collecting data while the machine is in operation so that the machine self-generates the collected data. In Modal Analysis Testing, the data collector has to excite the machine’s vibrations by the use of ‘impact’ hammers, which can include those comparable to a sledge hammer (very labor intensive). Regardless of which test is performed (ODS or Modal) these tests are labor intensive and all other testing to trouble shoot the issue should be performed first.

Modal Analysis Testing is different because Analysts use ‘modal hammers’ to create the vibration data needed to create the 3D animations.  When testing operable machines in the field, ODS testing is preferred because it is much less labor intensive. However, when testing non-excited structures and piping, the use of modal hammers is required due to the lack of an active energy source.

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!
  1. 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).
  1. 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.
  1. 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.
  1. 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.
  1. 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.
  1. 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.

On-Site Balancing >>

On-Site Balancing

On-Site Balancing Services:

Single Plane Balancing may become necessary when amplitudes at 1x operating speed reach excessive levels (generally considered to be over 0.325 IPS-Pk at operating speed). In the majority of cases observed by VAI, and assuming the absence of a resonance, the radial levels are typically much higher while the axial levels remain relatively low. If the axial levels increase proportionally (or nearly so) to the radial levels, this would point to an issue affecting the alignment.

VAI strongly advises against untrained staff performing balancing moves. This is because of the extreme kinetic energy should a balance weight come off at operating speed. The potential risks include serious personal injury and/or component damage.

Component balancing involves collecting as-found amplitudes and phase data. A ‘trial’ weight is then added, and another set of data is collected.  Using vector mathematics on polar graph paper, the correct amount of weight and it’s location can be determined as long as the trial weight produces a change in the data. Our approach eliminates the need for purchasing expensive balancing software, and we cover all of these topics in our two (2) day balancing training course.

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.

Our ISO Certified Vibration Analysts can perform single plane fan balancing because they have been highly trained and certified. Balancing is usually needed when amplitudes get too high at 1x operating speed. In nearly all cases, the radial vibration levels become noticeably higher while the axial levels remain fairly low, although this is not always the case.  For safety reasons, VAI advises against untrained staff performing balancing moves because if a weight comes off, the kinetic energy could possibly injury or kill someone; not to mention causing possible damage to the machine. There is no need to purchase expensive vibration test equipment or balancing software; our Analyst will do everything except turn wrenches (due to insurance concerns).

Should you wish to provide your maintenance staff with the knowledge to perform their own balancing moves, we provide a two (2) day course that 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 determine if the increased vibration levels are due to unbalance or some other machine fault.

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.  In addition to balancing your machine, our vibration Analyst will collect and analyze both the machine’s pre- and post-balance data to determine if there are any other issues, such as a degraded bearing, bent shaft, or issues that are affecting the alignment.

For more information about our balancing services, please call us at 815-742-1793.

Test Equipment Sales & Service >>

Test Equipment: Sales, Rentals and Loaners

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.

 

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.

 

Loaner Meters:

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

 

We’re a FULL Service Vibration Consulting Company!

Client Testimonials >>

Client Testimonials
  • 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.

 

  • 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.

 

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.

These are just some of the ways VAI can help your vibration program.  To learn how we can meet or exceed your data analysis and program needs, call us at 815-742-1793.

YOUR VIBRATION PROGRAM

With VAI’s Support:

  • You only pay for the machines analyzed
    • One low monthly cost
    • No contractor travel or labor expenses
  • Program not affected by employee illness, turnovers, vacations, strikes or employee transfers
  • We provide FREE On-Site Data Collector Training.
    • Just collect the data and email it to us for analysis
  • VAI ensures all vibration test points are properly located and marked
  • VAI uses the Industry’s best test equipment and software.
    • Don’t buy the wrong equipment based on cost!
      • Biggest mistake for new program owners
  • VAI provides FREE database access
    • No cost for the software!
  • Our analysis is the most accurate in the Industry!
  • VAI provides FREE 24/7/365 Technical Support!
  • We can have your program can be up and running in one (1) week.
  • You collect the data; we analyze it
    • YES it’s that easy!

WithOUT VAI’s Support:

  • Requires a dedicated employee
    • Salary and benefits cost up to $ 120,000 / year
      • Consider employee turnovers and the re-hiring process
    • Who supports the program when the Analysts is absent?
      • Analyst is on vacation, sick leave or transfers
  • Requires funding to purchase the database software
    • Requires time for the Analyst to learn and build the database
  • Requires funding for employee training
    • New Employee Orientation Training
    • Technical Vibration Training:
      • Data Collector Training
      • Database Software Training
      • ISO Cat. I, II & III
  • Will non-core duties override the Analyst’s responsibilities?
    • They usually do!
  • Your Analyst can not support the program 24/7/365
  • It takes an Analyst up to 5 years to REALLY become proficient
    • They don’t know what they don’t know!
    • Consider turnovers and their impact on your program

Ready to Get Started?

Contact us today for a FREE quote!