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Rotating machine vibration analysis services

Machine vibration inspection is a crucial process for ensuring the reliability, efficiency, and longevity of rotating and reciprocating equipment. It helps detect early signs of wear, imbalance, misalignment, and other mechanical issues before they lead to costly failures.

1. Why Conduct Vibration Inspections?

  • Prevent Equipment Failures – Identify faults before they cause breakdowns.

  • Reduce Maintenance Costs – Early detection allows for planned maintenance instead of costly emergency repairs.

  • Increase Safety – Prevent catastrophic failures that can lead to injuries.

  • Optimize Performance – Ensure machinery operates within safe vibration levels for maximum efficiency.

 

2. Common Causes of Excessive Vibration

  • Imbalance – Uneven mass distribution in rotating components.

  • Misalignment – Shaft misalignment between coupled components.

  • Looseness – Unsecured bolts, worn bearings, or structural weaknesses.

  • Bearing Wear – Deterioration due to contamination, overloading, or lack of lubrication.

  • Gear Issues – Damaged or worn-out gear teeth causing irregular motion.

  • Electrical Problems – Motor issues such as voltage imbalance or electrical noise.

 

3. Vibration Measurement Methods

 

  • Handheld Vibration Meters/analyser (KM VIB05+, KMWIS, KM Balancer II+, KM Balancer Pro) : Portable devices for quick vibration checks. Suitable for routine maintenance.

  • Fixed Vibration Sensors (KMWG-W60 gateway with VIB 3008 triaxial sensor) : Continuous monitoring systems for critical machinery. Provide real-time data for condition-based maintenance.

  • Vibration Analysis Software : Uses Fast Fourier Transform (FFT) analysis to identify vibration patterns. Helps diagnose the exact source of vibration problems.

 

4. Key Vibration Parameters

  • Velocity (mm/s or in/s) – Measures severity of vibration; common in ISO 10816 standards.

  • Acceleration (g or m/s²) – Useful for detecting high-frequency faults like bearing defects.

  • Displacement (µm or mils) – Measures physical movement of a component, useful for low-speed machines.

 

5. Vibration Inspection Procedure

 

a. Pre-Inspection Checks

  • Review machine history and past vibration reports.

  • Identify key measurement points on the machine.

  • Ensure the machine is operating under normal conditions.

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b. Data Collection

  • Use vibration sensors or meters at critical points (bearings, shafts, casings).

  • Measure readings in three directions: axial, radial, and tangential.

  • Compare data to baseline and industry-standard vibration levels.

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c. Analysis & Diagnosis

  • Use FFT analysis to identify frequency components.

  • Compare with known vibration signatures (e.g., imbalance, misalignment, bearing faults).

  • Identify potential corrective actions.

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d. Corrective Actions

  • Balancing – Adjust mass distribution in rotating parts.

  • Alignment – Use laser alignment tools to correct shaft positions.

  • Tightening – Secure loose bolts and components.

  • Lubrication – Ensure proper lubrication of bearings.

  • Component Replacement – Replace worn-out bearings, gears, or motor parts.

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e. Standards & Guidelines

  • ISO 10816 / ISO 20816 – Provides vibration severity limits for different machine types.

  • ANSI / ASA S2.41 – Vibration guidelines for motors and generators.

  • API 670 – Standard for vibration monitoring in rotating equipment.

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f. Tools & Equipment for Vibration Inspection

  • Vibration Meters – For general measurement.

  • Laser Alignment Tools – For shaft alignment.

  • Vibration Sensors (Accelerometers) – For continuous monitoring.

  • Data Acquisition Systems – For long-term vibration analysis.

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