Vibration Analysis: Compliance, MTBF and Sustainable Reliability
Introduction
In today's industrial landscape, predictive maintenance alone isn’t enough — companies must achieve long-lasting reliability and minimal maintenance. Vibration analysis is central to this goal, enabling early detection of mechanical issues and design improvements that significantly extend mean time between failures (MTBF). At Environmentally Sound, our vibration consultants combine field data, advanced analysis and decades of experience to ensure equipment operates reliably, quietly and with a lower environmental footprint.
As independent vibration consultants with close to 30 years’ experience in vibration and structural dynamics, we use disciplined measurement, analysis and design to diagnose root causes, validate fixes and deliver compliance across aerospace, industrial, construction and precision environments.
What Is Vibration Analysis?
Vibration analysis involves measuring and interpreting the oscillations of machinery and structures to identify potential faults. By examining parameters such as frequency, amplitude and phase angle, engineers can detect issues like imbalance, misalignment and bearing defects before they escalate into major failures. Crucially, reducing vibration at source directly improves MTBF, minimises maintenance and extends product life.
The Role of a Vibration Engineer
While sensors and software collect data, interpretation requires the expertise of seasoned vibration engineers. Factors such as sensor placement, duty cycles, structural dynamics and compliance criteria all affect results. Our team brings deep practical experience so clients gain not just data, but actionable solutions that increase equipment longevity.
Importance in Predictive Maintenance
Condition Monitoring
Every machine has a unique vibration signature under normal operating conditions. By establishing baselines and monitoring changes, developing faults can be detected early. Proactive interventions reduce unplanned downtime, maintenance costs and environmental impact.
Case Study: Food Processing Plant
In a high-output food processing facility, vibration monitoring identified bearing wear on a critical mixer. Replacement during a planned shutdown prevented disruption, prolonged asset life and reduced emergency maintenance.
Failure Prevention and MTBF Gains
Reducing vibration responses directly extends MTBF by lowering fatigue stresses and wear rates. This is why vibration limits are written into standards such as API 619 — less vibration means longer bearing life and fewer interventions. Our vibration analysis services help companies achieve these gains systematically.
Case Study: API 619 Compliance and MTBF Improvement
On a gas compressor project, our consultants reduced bearing vibration to well below API 619 limits. The client remarked: “This is the lowest vibration we have ever had on one of our products.” API 619 specifies bearing vibration thresholds precisely to protect reliability: lower vibration increases MTBF. The compressor achieved compliance and a clear uplift in expected service life with reduced maintenance. Read the API 619 case study.
Applications of Vibration Analysis
Industrial Machinery: Monitoring and improving motors, pumps, compressors and gearboxes to detect and resolve faults early.
Automotive and Aerospace: Analysing engines, transmissions and structures for compliance, reliability and NVH refinement.
Infrastructure: Assessing impacts from construction, rail and roadworks on surrounding buildings and facilities.
Steps in Vibration Analysis
1. Data Acquisition
Accurate vibration analysis begins with quality data collection — selecting the right sensors, optimal placement and correct sampling. Without this discipline, analysis cannot be trusted.
2. Modal Analysis
Modal analysis identifies a structure’s natural frequencies and mode shapes, refining models and preventing resonant failures. This step links real-world measurement with design optimisation.
Case Study: API 619 Gas Compressor
During qualification testing, excessive vibration at the bearings indicated a resonance within the frame/drive assembly. Using modal analysis and model updating with field data, we identified the critical modes and refined the design. After optimisation, vibration levels dropped below the API 619 compliance limit — ensuring certification, reducing bearing stresses and delivering measurable gains in MTBF. See the full project.
3. Data Analysis Techniques
Time Domain Analysis: Detecting transient events and impacts.
Frequency Domain Analysis: FFT used to identify fault frequencies.
Envelope Analysis: Identifying early-stage bearing defects.
Operational Deflection Shapes (ODS): Visualising vibration behaviour under load to target corrective design changes.
4. Model Updating
We integrate vibration test data into FEA and CAD models for accuracy. This iterative process improves simulation confidence, leading to optimised designs that reduce vibration, improve MTBF and cut lifecycle costs.
Case Study: Thrust Reverser Actuator System (TRAS)
A TRAS system failed vibration tests. Using ODS and resonance analysis, we identified the failure mode and optimised the design, achieving compliance and reliability under demanding aerospace standards.
From Vibration Analysis to Sustainable Reliability
Our philosophy is simple: the less a product vibrates, the longer it lasts, the less maintenance it requires and the more environmentally sound it becomes. By combining vibration analysis with advanced diagnostics and design expertise, we help companies create products that achieve compliance, require minimal maintenance and deliver maximum MTBF — reducing waste, energy loss and unplanned interventions.
If you need independent vibration consultants to deliver analysis for predictive maintenance or compliance, please contact us or call 01908 643433.
Authored by: Paul Schmitz MBA CEng MIMechE MIoA — Director
Published: • Last updated:
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