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Vibration Predictive Maintenance

Experience has proven that vibration measurements can be a powerful tool for diagnosing the mechanical condition of machinery. Increasing vibration levels usually indicate the development of machine defects.  A program of monitoring machine vibration at regularly scheduled intervals allows early detection of possible trouble spots.

A predictive maintenance (PdM) program can be tailored for your equipment employing periodic vibration checks to determine machinery condition. Scheduled repairs can be made before costly unscheduled downtime is incurred. The object of the program is to obtain long, trouble-free service from vital plant equipment, guarding against costly breakdowns. According to Maintenance Technology magazine, equipment that run until breakdown costs an average of three times as much to repair as equipment that is repaired before breakdown occurs. The cost savings from avoiding secondary damage from a breakdown can be considerable.

As with all diagnostic procedures, this type of program is not infallible nor is it the final answer to all maintenance problems.

Benefits of a Well Run Predictive Maintenance Program

• MINIMIZES UNSCHEDULED DOWNTIME – Early warning of mechanical troubles will help keep unscheduled downtime to a minimum.
• REDUCES MAINTENANCE COSTS – The cost of emergency breakdown maintenance shows in maintenance overtime, scrap product, lost productivity, and production overtime to make up for lost production time.
• ELIMINATES UNNECESSARY OVERHAULS – Knowing machinery condition allows you to schedule overhauls only when it is needed. Routine overhauls cost time and money.
• IMPROVES QUALITY – Product quality is improved where consistent performance of machinery and equipment has a direct bearing on the quality of the product.
• QUIETER OPERATION – Undesirable levels of vibration and noise degrade the working environment, often resulting in worker fatigue and lower productivity.
• INCREASES MACHINRY SAFETY – Machinery hazards can be detected and corrected before becoming serious.

How Does The Program Work?

• A list of equipment to be included in the program is compiled.
• Machine information is gathered and proper vibration parameters and alarm levels are established for each measurement point for each machine.
• Surveys intervals are established.
• A computer database is built containing each machine and point to be monitored in the program.
• From scheduled periodic checks, a timely report is provided showing all machines and check points at alarm levels of vibration. Machines in alarm are prioritized according to the severity indicated by the vibration levels.
• When unusual vibration problems are incurred, vibration analysis is available to pinpoint the mechanical defect.

Vibration Predictive Maintenance Advantages

• Repairs can be performed during scheduled outages.
• The plant can be shut down in a controlled manner, reducing scrapped product, power consumption, and secondary damage such as conveyor clogs, product setting up in pipes and conveyors, and the physical damage which often occurs with equipment failure with the plant in production.
• Spares and equipment can be procured and brought on location, reducing downtime considerably.
• Often, preliminary work can be performed before the equipment is shut down which reduces downtime.
• Extra attention can be given to a machine known to be in jeopardy, i.e., more frequent lubrication and/or cooling air for hot bearings until repairs can be scheduled.
• If the equipment is spared, the spare can be brought on line before failure occurs.
• Processes can be shifted to alternate systems when available.