Machinery Vibration Analysis and Program Support

Our Core Services:

Program Startup Services:

FREE Loaner Meters: (<< drop down to the following)

VAI provides FREE loaners to clients who contract us to analyze their data. These loaners are available for up to three (3) months for evaluation, when a client’s meter is being re-calibrated or repaired, or just when another meter is needed to get multiple plants “caught-up” on their data collection.

Special Discounts on New Meters:(<< drop down to the following)

VAI is the industry’s leading data analysis service provider. Since our ‘livelihood’ depends on the accuracy of our analysis we only use the industry’s BEST software and test equipment made by Emerson Process / CSI.  Because of VAI’s endorsement of their product, we’ve been given the opportunity to offer exceptional discounts to our client’s who have us analyze their vibration data. If you’re looking for the absolute best price on CSI’s products and exceptionally accurate data analysis services, call us now for a quote.

Rentals:(<< drop down to the following)

Meter rentals may be the best option for companies who want to use and / or evaluate CSI’s vibration test equipment but not buy it.  If that applies to you, call us now for an affordable quote. NOTE: If you contract VAI to analyze a minimum of 30 machines/month, you may qualify for a FREE loaner meter. Call us now at 815-742-1793 to discuss your needs.

FREE Database Creation, Maintenance and Optimization

VAI specializes in creating Databases and Routes and our services are FREE to clients who select us analyze a minimum of 30 machines monthly for 12 months. All clients have to do is provide a list of the equipment they want in the program and in the format shown below (Excel format works best):

SAMPLE SPREADSHEET WITH MACHINERY INFORMATION

• Machine ID – Provide an machine “ID” (up to nine (9) characters) for each machine.
• Machine Name – Provide a name for each machine (up to 29 characters).
• Operating Speed(s) –  Note: A/C motors typically operate at 900, 1200, 1800 and 3600 rpm. If not known, we may be able to obtain it from the vibration data. Also, state if on VFD
• General Component Description – This is what the machine looks like. Describe it as if you would describe it to someone over the phone (see examples above). Note if belts, coupling, or direct drive (DD).

Then provide one or more list of all machines listing them in the order you would like to collect the data (select an order which minimizes the number of steps taken in the plant). From your lists, VAI will create the database and route(s). Generally routes can contain as few as one (1) machine or as many as 70 however as a general guideline, routes should have between 20 – 30 machines to be efficient. If there are too many machines, time is wasted scrolling up and down to find the desired machines. If there are too few, time is wasted switching between routes.

The following is an example of a “Route”:

Sample Route List

Initial Data Analysis and Periodic Trending:

Once the vibration database and route(s) have been created, and the initial data collected as part of the Data Collector Training we provide, we’ll help you download the data. It is important to note that while VAI can provide a good analysis and summary of machine health based on just the initial data, a minimum of five (5) dataset is needed to identify degrading issues, determine the ‘normal’ range vibration levels due to changes in operating conditions, and provide a more accurate analysis of the data in general. As such, clients should expect to collect the first five (5) datasets on an expedited schedule, say twice weekly for the first three (3) weeks.  After the first five (5) sets of data have bee expedited, clients may take a more relaxed approach to the data collection. VAI strongly recommends monthly trending, however data can be collected once every two (2) or three (3) months. However, with less frequent trending, there may be a higher rate of unexpected failures. Monthly trending is recommended for all critical machines having rolling element bearings because they can progress from ‘good’ to ‘end of reliable life’ in as little as 45 days. Monthly testing will catch these types of failures whereas they may be missed with less frequent trending.

This is how we process client data: 

1. The Category IV Analysts analyze the first five (5) datasets:

Our ISO Cat. IV Analysts analyze the first five (5) sets of data and work with clients to resolve any outstanding machine issues.

2. Two (2) ISO Cat. II Analysts

Beginning with the 6^th dataset, up to two (2) Cat. II Analysts independently sort thru the data and identify any issues that point to a degrading issue (step changes, increasing trends and new frequencies).  They then forward all issues to the ISO Cat. III’s for a more detailed analysis. The following is an example (refer to red arrow) of what the ISO Cat. II’s look for:

3. Two (2) ISO Cat. III Analysts

Next, up to two (2) ISO Cat. III Analysts INDEPENDENTLY analyze all issues.  These Analysts are selected based on their backgrounds and experience so they can consider nearly all failure modes. They then provide recommended corrective actions and forward all issues to a ISO Cat. IV Analyst who then performs the highest review possible.

4. ISO Cat. IV Analyst

An ISO Cat. IV Analyst then performs the highest level of review possible. He also determines defect severity (GREEN / BLUE / YELLOW / RED), issues the report, and provides FREE 24/7 Technical Support. Our Cat. IV Analysts also provide on-going database maintenance and optimizations and keep the routes updated with changes. VAI has more ISO Certified Cat. IV Analysts than NASA and the US DOD and as a result, we can analyze data for specialized machines such as those listed in ‘Radiated Noise Reports’ and Nuclear Power Plants. We will also meet any database security requirements which means, NO data is stored on the cloud!

5. When additional datasets come in, we just repeat steps 2 – 4!   Accurate reporting and recommendations!  24/7 Technical Support!  No contractor expenses for collecting data!   Clients receive FREE access to their database!   And we’re very affordable!   

Our Reports:

Our reports are user-friendly and don’t contain any “fluff”. They are concise yet provide the information needed to understand all equipment issues.

Each component report has the following information (refer to screen print below):

• Component ID: The name or ID of the machine affected
• Point(s): The point or points affected
• Frequency(s): The frequency or frequencies affected
• Plot: Shows abnormal conditions flagged in RED
• Issue: Summarizes what the issue is
• Analysis: What VAI believes the issue is due to
• Recommendations: Summarize VAI’s recommended corrective actions.
• Component Health Colors:
  • GREEN means all is well
  • BLUE means an acceptable low level issue
  • YELLOW means a low level defect has been identified
  • RED generally means prompt corrective action should be taken
• Color Coded Sidebars: These ‘sidebars’ are located in the right margin, and provide a quick visual reference to the overall condition of each machine, allowing the reader to quickly find those machines that have significant issues.

KMK – please ask Ray Rhoe for a report with a RED sidebar in case I forget to provide it. The sidebar is missing from the following screen print

Regardless of your plant’s manufacturing processes, we provide accurate and affordable solutions. We can analyze vibration data for all types of machines, including motors, pumps, fans, chillers, extruders, compressors, gearboxes, unique one-offs and more.

COMPARE VIBRATION PROGRAMS