Vibration Analysis for Managers

Pumps and Systems , June 2009

Of the technologies available for condition monitoring of rotating equipment, the quickest return on investment is from vibration analysis. For the novice, vibration data seems complex and is generally difficult to assess compared to other techniques. Once trained, however, the novice can recognize the patterns and diagnose a machine problem.

This article highlights a new type of vibration analysis training and implementation. It is directed toward managers and individuals who make the decisions to shut down equipment with vibration problems or keep it in operation until an outage. It is based on the most important techniques used in vibration analysis and is not intended for Level 3 or 4 vibration specialists and consultants.

The goal of this article is to introduce a new approach to implementation of vibration analysis programs. This approach will highlight the active role of decision makers, equipment owners and managers in the analysis of equipment vibration without being experts in vibration analysis.

Present Condition Monitoring (Vibration Analysis) Systems

At present, three major systems are popular:

1. Internal vibration analysis team, usually adopted by large companies
2. External consultant
3. On-line condition monitoring systems

Internal Vibration Analysis Team

This team often performs the studies on equipment reliability and makes suggestions for changes. The advantages of the internal vibration analysis team are:

1.      Close attention given to rotating equipment issues

2.      Fast response because they are company employees

3.      Reports will be well documented and organized in easily accessible files

4.      High specialization of employees is possible

5.      All suitable equipment will be covered by the condition monitoring program

6.      Data collection intervals will be reasonably short

The disadvantages of the internal vibration analysis team are:

1.      Relatively high cost of implementation

• Condition monitoring equipment installation, update and calibration
• Computers and office equipment
• Training
• Plant equipment modification to allow easy data collection
• Office space allocation for vibration analysis team

2.      Problems could be exaggerated to emphasize the team's importance. For instance, an analyst might recommend repair for equipment of unclear condition, when no repair is required. Maintenance-induced defects could increase.

The most efficient vibration analysis programs employ highly qualified vibration analysis specialists. An average or below average vibration analyst might be detrimental for the overall maintenance cost and general condition of plant equipment, due to his inability to detect critical problems. This negative effect comes not only from the average analysts, but also from the organizational structure in which the vibration analyst works. The analyst produces reports that provide the production/operation/maintenance management the data required to make decisions regarding equipment: whether to operate at full capacity, restrict the operational parameters, perform preventive tasks or stop the equipment for overhaul.

The equipment covered by vibration analysis reports falls into three categories: suitable for unrestricted operation, unclear condition and not operational. Management may be confused by an "unclear condition" description and require additional meetings, emails, letters and clarifications.

External Consultant

The second solution is to outsource the vibration analysis to an external consultant. The advantages include low implementation cost and access to the knowledge of a highly qualified specialist.

The disadvantages of an external consultant are:

1. The program cost is high, due to consultant fees.

2. Data collection intervals are generally long.

3. The response for specific issues may be slow.

On-line Condition Monitoring Systems

Some companies implement on-line condition monitoring systems for suitable equipment. Some of the new on-line systems, in addition to automatic shutdowns and alarms, also generate vibration data that requires interpretation in one of the two ways described above.

The advantages of online monitoring include:

• Automated scheduled data collection and no need for walk-around
• Minimized need to enter hot and dangerous areas
• Ability to capture data on running equipments only
• Short recording intervals
• Can be part of automated remote monitoring or protection system

The disadvantages of online monitoring are:

• Expensive installation of sensors, cables, instruments and communication infrastructure
• Data can be overwhelming if not managed properly
• Alarm settings maybe less sensitive to changing conditions of the equipment

The New Approach

The reason for requesting consultant services or employing a vibration analyst may be management's lack of vibration analysis knowledge, or the misconception that management does not have time to perform the vibration analysis.

This is valid for large companies, but there are many small to average-size companies where the manager/decision maker has time to perform the vibration analysis. Even a person trained in vibration analysis will spend more time reading the vibration analysis reports, clarifying the equipment condition and determining the corrective action than diagnosing the vibration spectra.

The manager with a good technical background, reasonable scope of work and comfort with computers should be ready to accept the challenge of specialized vibration analysis training. Managers and decision makers can perform vibration analysis, decide whether to keep the equipment operational or schedule the equipment for maintenance.

Vibration Analyst Techniques for Managers

A study of the techniques experienced vibration analysts use shows some methods that are well accepted and used regularly. One essential analysis technique is spectral analysis. Without spectral analysis, decisions based on overall vibration levels, band levels and bearing parameters are not accurate.

Table 1 summarizes the most common vibration analysis techniques and their importance for managers planning to become vibration analysts.

Table 1

Selecting the "Compulsory" and "Important" techniques only yields dedicated, achievable training for managers (see Table 2).

Table 2

The largest percentage of vibration issues are related to misalignment and unbalance and are easily detected using the selected techniques in Table 2. Looseness, hydraulic deficiencies, bearing failures, lubrication, gearbox-related issues