IRD Mechanalysis Ltd

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Vibration Measurement Tools

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Maintenance Strategies: There are four well established maintenance strategies that apply to
most process plants, these are:
1. Running Hours - maintain at OEM specified intervals, e.g. oil changes, replace seals etc.
2. Life Maintenance - run to failure e.g. sealed machines, light bulbs, domestic fridges, etc.
3. Breakdown Mtce. - only maintain on breakdown (greatest impact to production)
4. Condition Based - maintain on condition by routine measurements (proactive maintenance)

Vibration based condition monitoring is widely acknowledged as the proactive maintenance

strategy offering the maximum return on investment and the quickest to give positive results. It
optimises plant up time, machinery availability and maximises productivity.

The classic ‘Machinery Bath Tub Curve’ illustrates the

typical wear life of a machine. Applying planned
periodic monitoring techniques, industry is able to take
machinery to its point of exhaustion yet preventing
unscheduled outages. Maintenance costs are reduced.

Applying a vibration based programme Plant Operators

will benefit, with varying degrees of success from basic
to advanced systems. While this is an outcome of
capital investment, success depends on the availability
and continuity of expertise. Whether in-house or sub contract, management commitment at Board
level is essential. The programme must be part of a company’s strategy for optimising
shareholder’s investment including care of the environment. Note: Excessively vibrating machinery
use up to 15% more energy.

The Vibration based condition monitoring strategy, benefits and shortcomings are summarised:
SN MEASUREMENT STRATEGY
Routine Vibration Checks– Basic
2 Routine Vibration Checks – Advanced
3 Vibration Based Condition Monitoring
4 Emergency Site Diagnostics –
perhaps outsourced
BENEFITS
Low investment, simple to operate,
semi-skilled. Data is now objective
Moderate investment, only 1 days
training indicates prime faults
Whole plants monitored giving detailed
fault indication for better decisions
In depth analysis on-site for instant
results and rotor balancing
SHORTCOMINGS
Overall vibration levels indicating change
in machine behaviour. Call an expert.
Results can create uncertainty calling for
more advanced analysis. Call an Expert
About $25,000 capital investment, needs
trained manpower, system continuity.
Similar investment as #3 but requires a
skilled engineering service.

Industry has a habit of demanding and procuring advanced technology yet without enjoying the full
value of their investment; this is a management issue. It is human nature to desire the latest
gadgets (most bells and whistles) yet do not optimise the power of some sophisticated and
powerful instruments on the market. Many users demand advanced 2 or 4 channel analysers for
routine programmes yet fail to appreciate the logistics of capturing multi-channel data; ‘Keep It
Simple’.

Large process plants operating 24/7 who desire to establish a comprehensive condition monitoring
programme should consider using lower cost volume data collectors and an advanced analyser
that communicates with common software. Clerks and Plant Operators (the latter to fill their time
on evening and night shifts) can easily be trained to walk around the plant collecting data. The
mere fact that they have seen their machines will be of benefit; they may notice oil leaking or loose
drive belts etc. In the day shift, technicians can download the data and analyse those machines in
alarm. The analyst may then need to revisit the machinery with the more advance instrument to
take phase readings as well doing stroboscopic studies etc. Thus a two tier instrument selection
will give the greatest return on the investment and tools will be better utilized. The following listed
products are not exhaustive but an indication based on the measurement strategy stated above.
condition management solutions
 Vibration Measurement Tools IRD Mechanalysis Ltd

There are many instruments on the market but the following match the main categories:

Routine Vibration Checks– Basic.

Overall measurements would be trended.
Digital meters are auto ranging made easy for
operators to record. Displacement or Velocity
in RMS to compare with ISO 10816-1 or 3
vibration standards related to machine types.
Model IRD811 covers all measurement units:
microns, mm/sec, g and gSE (spike energy)
Models IRD306 IRD306DI IRD306DP IRD811
Disp. & Velocity Large Machines General All Measurements

Routine Vibration Checks – Advanced

This Vibration Diagnostic SmartMeter offers on the spot automated diagnostics. It is a
4 in 1 tool that does not require a computer but is suitable for identifying prime faults on
machinery. For shaft speed checks or slow motion studies it has a built-in Strobe.
Bearing temperature is a key indicator of condition, the meter incorporates an IR
temperature detector. It also indicates TWF (time wave form), FFT spectrum analysis
and frequency bands. It measures all the standard vibration parameters including
enveloping of bearing condition. For commissioning engineers it is an excellent site
tool that is very user friendly. An economic yet powerful package.
Model IRD449

Vibration Based Condition Monitoring

Condition monitoring requires regular collection and
trending of machine data. By undertaking frequency
band trending, the early development of specific
faults are identified for proactive maintenance. The
system comes with PC based software for trending &
analysis. ‘Interpreter’ decision support software is
also available that diagnoses vibration signatures. Volume Data Collector Multi-Channel Analyser

Emergency Site Diagnostics

Some plants only call for assistance when they suspect a machine.
Using a subcontractor who is a specialist in vibration diagnostics means
that highly skilled engineers are employed on an as needed basis.
Plants with a small number of strategic machines often outsource such
services. The Service Provider or Consultant will probably use the
model IRD944 since it is operated without needing a laptop. The
instrument has 120GB memory and the data can be off loaded later.
IRD944 MechAnalysis

Taking you Further:

Critical machines will require on-line vibration protection systems where warning and trip relays are mandatory. On-Line LAN or
WAN software is available for local and remote analysis. IRD Mechanalysis also provides consultancy and training services but you
can download IRD’s Engineered Solutions and Customer Services at www.irdmechanalysis.com for more knowledge transfer.

The Vibration People of IRD Mechanalysis can be contacted at the following branches or your local distributor:

Mumbai Delhi Kolkata Chennai International

Tel: +91(0)22-2852-0178
Fax: +91(0)22-2852-1814 Tel: + 91(0)11-2237-3916 Tel: +91(0)33-2355-2062 Tel: +91(0)44-2823-0726 Tel: +91-22-2852-0178
sales@irdmech.com Fax: +91(0)11-2237-0778 Fax: +91(0)33-2355-9214 Fax: +91(0)44-2823-4702 Fax: +91-22-2852-1814
Service@irdmech.com salesNR@irdmech.com salesER@irdmech.com salesSR@irdmech.com sales@irdmech.com
IRD® is the Registered Trademark of IRD Mechanalysis® Ltd. Copyright © 2013 IRD Mechanalysis® Ltd, Mumbai India

condition management solutions