From water treatment plants to manufacturing facilities, rotating machinery powers Australia’s essential services. But when it breaks down, costs add up fast. Vibration analysis helps stop problems before they start. Thus, vibration analysis is a cornerstone in maintaining rotating equipment across Australia’s industrial sectors.
Let’s explore how vibration analysis in rotating machinery enables Australian industries to reduce downtime, detect faults early, and extend equipment life.
What is Vibration Analysis?
Vibration analysis is a powerful diagnostic tool that identifies, monitors, and prevents mechanical failures in industrial machinery and components that perform rotating or reciprocatory motion. This makes it a key identifier of potential mechanical failures, preventing costly unplanned downtime and equipment failures.
Typically, vibration analysis is performed on machines such as compressors, pumps, turbines, and other rotary equipment. Vibration analysis uses vibration sensors installed in key machinery to measure the frequency of vibrations and detect abnormalities. This includes misalignments, loose components, bent shafts, and defective bearings.
The key metrics recorded in vibration analysis include amplitude, frequency, velocity, and acceleration. Assessing these parameters helps technicians and engineers assess the health and performance of the machinery, pinpoint possible issues, and implement necessary corrective action.
Key Vibration Metrics Explained
The key vibration metrics and what they are used for are as follows:
| Vibration Metric | Unit of Measurement | What It Measures | Primary Use / Application | Typical Monitoring Method |
|---|---|---|---|---|
| Displacement | Micrometers (µm) or mils | Total distance a machine component moves from its mean position during vibration | Detects imbalance, misalignment, or mechanical looseness in low-speed machinery | Proximity probes or displacement sensors |
| Velocity (RMS) | mm/s or in/s | Speed of the vibrating component over time | Indicates overall machine health; used for trending and severity analysis (ISO 10816) | Velocity sensors or accelerometers with velocity integration |
| Acceleration (Peak / RMS) | m/s² or g (gravity) | Rate of change of velocity — measures vibration intensity | Identifies early-stage bearing wear, gear faults, and impacts | Piezoelectric accelerometers |
| Amplitude | Micrometers (µm), mm/s, or g (depending on metric) | Magnitude or strength of vibration signal | Quantifies vibration severity and helps compare to alarm thresholds | Derived from displacement, velocity, or acceleration signals |
| Frequency | Hz (Hertz) | Number of vibration cycles per second | Helps identify fault sources (e.g., unbalance = running speed, misalignment = harmonics) | FFT (Fast Fourier Transform) spectrum analysis |
| Crest Factor | Ratio (Peak ÷ RMS) | Ratio of peak acceleration to RMS value | Detects intermittent impacts and bearing damage | Calculated from time-domain acceleration data |
| Kurtosis | Dimensionless | Statistical measure of waveform sharpness | Early detection of bearing defects or lubrication issues | Computed through digital signal analysis |
| Frequency Spectrum (FFT) | Hz vs Amplitude graph | Frequency domain view of vibration amplitude distribution | Diagnoses specific mechanical faults like unbalance, looseness, misalignment, gear issues | FFT-based vibration analyzer |
| Envelope Analysis | dB or relative amplitude | Demodulated vibration signal highlighting high-frequency events | Excellent for early bearing fault detection | Envelope demodulation using accelerometers |
| Phase | Degrees (°) | Angular difference between vibration signals of components | Used for confirming unbalance, shaft misalignment, or coupling issues | Dual-channel or phase-reference vibration analyzer |
| Temperature (Supportive Metric) | °C / °F | Heat buildup associated with mechanical friction or bearing wear | Supports vibration data to diagnose overheating or lubrication failures | Infrared sensors or thermocouples |
Table 1: Metrics Associated With Vibration Analysis
Common Faults Detected by Vibration Analysis
By implementing vibration analysis of equipment, the following key issues can be detected:
- Misalignment: Notably high axial vibration when compared to radial readings from the same device.
- Unbalance: High radial vibration recorded and a large, prominent peak noted, with a constant amplitude and phase angle, and an increase in amplitude with operating speed.
- Bearing Wear: Noticeable high-frequency noise observed at certain frequencies.
- Looseness: Vibration peaks in half-harmonics and higher harmonics.
- Gear Mesh Faults: Calculated as (Shaft RPM) x (Number of teeth), a peak is noticed at the gear mesh frequency (GM) and its harmonics.
- Resonance: High vibration amplitude is recorded when the machine’s operating frequency matches its natural frequency.
- Cavitation: Identified by random, noisy, high-frequency impacts and caused by the formation and collapse of vapour.
How Vibration Analysis Supports Predictive Maintenance
Reactive response to equipment failure equates to expensive downtime. On the other hand, predictive maintenance equates to planned interventions.
Vibration analysis equipment, like sensors, is a great tool for enabling predictive maintenance. They shift the dynamic from reactive to predictive maintenance, enabling:
- Early fault detection through vibration data.
- Accurate diagnosis using detection techniques like Fast Fourier Transform (FFT).
- Optimised maintenance scheduling with a condition-based approach.
- Minimising cost and machine downtime.
- Extending equipment life with timely intervention.
- Preventing hazardous failures and establishing safe operational conditions.
Integrating with Other Condition Monitoring Tools
For efficient fault detection, the data analysis service for vibration monitoring can be combined with the following condition monitoring tools:
- Thermography: This detects heat generated by friction from machine components and is often accompanied by mechanical faults that also cause vibration.
- Oil Analysis: Identifies wear particles and lubricant degradation, which can reveal key issues like bearing or gearbox problems.
- Acoustic Monitoring and Ultrasound: Can be used to detect high-frequency sounds originating from bearing friction, gas/steam leaks, and electrical arcing.
- Current and Electrical Monitoring: Analyses electrical signatures, such as current and voltage, to assess motor health.
- Motor Circuit Analysis: This assesses the condition of electric motors, which can be used alongside vibration analysis to diagnose a wide range of potential faults.
Predictive Maintenance Tools vs. What They Detect
Additional predictive maintenance tools that are used alongside vibration analysis are as follows:
| Tool | Best For Detecting | Complements Vibration Analysis? |
|---|---|---|
| Thermal Imaging | Overheating components | Yes |
| Oil Analysis | Lubrication contamination and wear debris | Yes |
| Acoustic Monitoring | Steam traps and valve leaks | Yes |
| Vibration Analysis | Mechanical faults in rotating parts | Core tool |
Table 2: Tools Used in Industrial Predictive Maintenance
Benefits for Industrial and Environmental Operations in Australia
Installing vibration monitoring equipment offers industries significant benefits.
Why Local Industries Rely on It
Ground vibration analysis can be used in both landfill and construction sites. Plus, landfill sites can use vibration analysis to monitor leachate pump motors.
Construction vibration analysis equipment can assess the health of heavy machinery used in civil projects.
Water treatment industries can ensure uninterrupted aeration systems. Further, in manufacturing industries, vibration monitoring and analysis can be used to detect faults in conveyor and processing equipment.
Additionally, environmental contractors can maintain mobile units and remediation equipment equipped with vibration monitoring.
Economic and Operational Impact
The impact of vibration monitoring on operational efficiency includes:
- Reduced unplanned downtime
- Improved safety
- Extended machinery life
- Cost savings on emergency repairs
Thus, vibration analysis can improve the ROI of industries.
ROI from Vibration Analysis – Before vs After Implementation
A tabulated comparison of the ROI provided by implementing vibration analysis is as follows:
| Metric | Before Vibration Analysis | After Implementation |
|---|---|---|
| Unplanned Downtime | 10 – 15 hours/month | < 2 hours/month |
| Equipment Replacement Cycle | Every 2 years | Every 4 – 5 years |
| Average cost | 6164.66 AUD | 1849.40 AUD |
Table 3: Comparison of ROI Metrics Before and After Investing in Vibration Analysis
How Vibration Analysis is Conducted
For effective vibration analysis, the steps implemented are as follows:
Tools and Techniques
Tools used include accelerometers, handheld vibration meters, FFT analysers, proximity probes, and vibration sensors. Further, based on the requirements of the specific industry, you may go for either route-based monitoring (done with handheld analysers) or continuous monitoring (implemented using sensors).
Data Interpretation and Reporting
Data recorded is analysed using methods like Spectral analysis (Fast Fourier Transform (FFT)), Amplitude analysis, and Waveform analysis. Then, engineers look for similar patterns in the vibration “signatures”. Based on this information, diagnostic and corrective steps are taken for preventive maintenance.
Choosing a Vibration Analysis Provider in Australia
While one may opt for continuous vibration monitoring solutions, one may also opt for the services of a vibration analysis service provider for your industrial application.
What to Look For
When selecting a service provider, you need to look at the following factors:
- Availability of certified vibration analysts
- Availability of data analysis service for vibration monitoring
- Experience in your sector or across multiple sectors (industrial, landfill, water treatment)
- Whether or not they offer broader environmental services (e.g., asbestos remediation, air quality)
Why Partner with a Multi-Service Environmental Firm
By selecting a multi-service environmental firm, you will get the following benefits:
- Centralised compliance, safety, and maintenance
- Streamlined service contracts
- Deep understanding of Australian regulations and industrial standards
- Turnkey services with monitoring, detection, and remediation.
- Proactive management of any potential issues.
Final Thoughts
Vibration analysis is a cost-effective, powerful, predictive maintenance tool for maintaining industrial machinery health. Thus, they are the best option when you wish to save on costly corrective and emergency maintenance actions and avoid unexpected downtimes.
Effective Preventive Maintenance with Vibration Analysis
Looking to improve your equipment reliability and reduce costly downtime? Consult teams that offer expert vibration analysis and monitoring services as part of a comprehensive industrial maintenance and environmental support package.
Frequently Asked Questions
How Do You Detect Misaligned Components With Vibration Analysis?
Misalignment often appears as a high-amplitude vibration at 1X, 2X, and sometimes 3X the machine’s rotational speed. The specific pattern of these harmonics can indicate the type of misalignment.
What Are Some of the Ground Vibration Analysis Equipment?
Seismographs, geophones, and accelerometers are the main equipment used in ground vibration analysis.
Why Are Construction Vibration Analysis Equipment Necessary?
Construction vibration analysis equipment are essential for assessing the impact of vibrations from construction and associated activities on nearby structures, sensitive equipment, and human safety.
Can Vibration Analysis Be Used for Slow-speed Machinery?
Yes. However, for slow machinery, vibration analysis requires specialised sensors and techniques instead of general-purpose accelerometers.
