EMCOR Uses Vibration Analysis to Facilitate its Predictive Maintenance

Predictive maintenance has been a growing trend in the field service business for some time now, and an increasing number of providers are using digital technology to deal with issues in their nascent stages.

With predictive maintenance, various connected sensors embedded in assets such as machines in factories, wind turbines, processing plants and more, can constantly feed data back to a central hub and pick up on the early warning signs of a fault developing. A technician can then be dispatched, and the problem resolved, before it develops into a full-scale shutdown which costs clients productivity and money.

There are many distinct types of data collection which feed into predictive maintenance, and each has its place depending on the type of machine being monitored and the type of maintenance required in that industry.

Vibration Analysis

One method often employed by field service providers in various industries is vibration analysis.

As the name suggests, vibration analysis uses connected sensors to collect data relating to the vibrations being experienced by machines. This information is then compared with the vibrations which are associated with known failure conditions and used to predict when a fault might be developing. The ability of vibration analysis to predict potential failures makes it an incredibly useful tool when it comes to planning scheduled maintenance, boosting asset performance, and preventing unscheduled downtime.

Vibration analysis helps conduct condition monitoring to identify potential failures, which ultimately saves money by:

• Reducing unplanned downtime and scheduling work that fits an organization’s plans
• Saving money by boosting product quality through equipment operating at designed performance levels
• Eliminating wasted production costs while unplanned repairs are made
• Delivering products on time with reliable equipment

Vibration analysis requires field service providers to measure various points on an assets vibration spectrum and use that data to produce a model which illustrates its expected vibration behavior. Through this method a baseline of acceptable vibration can be established which informs condition monitoring by setting out which vibrations do not indicate a failure state, and which are worthy of deeper investigation.

Vibration data must then be translated from the format in which it has been collected – typically frequency, amplitude, etc. – and digitally reconstructed into a model suitable for analysis. The resultant waveform diagram shows oscillation amplitude over a period of time.

Analysis of the harmonics contained within the data can then identify expected synchronous peaks, or high points in your vibration data that should repeat. Any spikes which occur at unexpected times – such as when there is no motor rotation or pumping cycle – could indicate a developing issue.

EMCOR

As a global player in the business of providing construction, building, and industrial services, EMCOR understands how essential it is to keep assets running at optimal condition and has been researching how to better detect impending failures.

"We’ve found that up to 35% of existing equipment has some level of emerging malfunction that would otherwise go unnoticed," said EMCOR Northeast in a white paper. "So, when motors, pumps, bearings, fans, and other similar components vibrate in ways they are not meant to, continuous and uneven wear can occur. This can cause equipment failure and downtime that interrupts operations, causing lost time, money, and productivity to the business."

Once it had discovered these conditions, EMCOR knew it needed to offer its clients an effective method of making sure they could be spotted at the earliest possible juncture and resolved by an attending maintenance technician. Through a deeper understanding of the patterns of these assets wearing out and developing faults, the services provider could also make more intelligent decision regarding maintenance scheduling and other relevant concerns.

It settled on vibration analysis as a proven and demonstrable data collection method which could be combined with its existing industry expertise to offer a competitive predictive maintenance solution to its clients.

"One of the most effective ways to avoid these problems is to implement a vibration analysis program prior to vibration issues arising," continued EMCOR. "Using today’s most advanced vibration analysis technology, Northeast’s experts establish a vibration baseline for critical equipment. After doing so, Northeast measures performance regularly, watching for significant baseline deviations. It’s one of the smartest ways to prevent major failures, minimize operational disruptions, and reduce overall business impact of equipment failures."

Final Thoughts

Vibration analysis is a powerful arrow in the field service quiver and can increase customer experience by reducing downtime, making scheduled maintenance more intelligent and convenient, increasing asset lifespans, and saving money.

EMCOR has effectively demonstrated in the field just how effective this method of predictive analysis can be.

You can hear President of EMCOR Facilities Services, Mike McElrath, speak at Field Service Connect 2022, taking place in November at the Hyatt Regency Austin, TX.

Download the agenda today for more information and insights.