Vibration Specialty Corporation (VSC) : Preventing Equipment Failure with Advanced Vibration Analysis
Vibrational analysis is an indispensable tool in modern industrial maintenance, providing vital insights into equipment health by tracking variations in the vibration signature of the machinery. Vibration Specialty Corporation (VSC) has taken conventional vibration analysis to a new level by capturing significantly more data in its most raw format in order to detect minute problems earlier than ever.
A century-old history of preventing machinery failures and repairs has made VSC a trusted leader in the predictive maintenance space. Founder Nicholas W. Akimoff made a breakthrough in the field by leveraging the concept of vibration analysis and precision balancing to manufacture and patent the first balancing machine in the U.S. VSC has carried on his legacy by developing modern technologies for advanced machinery fault detection and resolution across multiple industries, including power generation, industrial gases and pulp and paper.
“Our technology enables us to predict imminent equipment failure and bring it to our clients’ attention before their operations are impacted,” says Jeff McGuckin, owner.
During its emerging phase, VSC began patenting individual concepts with their partner Strong Force, which has grown into an expansive and diverse nearly 500 patent portfolio covering all aspects of the industrial ecosystem. This comprehensive patent portfolio encompasses signal communications, databases, data storage, signal processing, signal manipulation, data presentation, artificial intelligence, digital twins, the industrial Metaverse, and much more. Prior to VSC’s innovative methods, performing a vibration analysis involved taking typically four spectra at a specific frequency range and lines of resolution and then averaging all four spectra together to create an averaged spectrum. Unfortunately, the averaging process of the spectra diminishes the important faults that we want to know about in their infancy because, in these early stages, the problem only Vibration Specialty Corporation (VSC) Preventing Equipment Failure with Advanced Vibration Analysis 10 MOST PROMISIN G SOLUTIONS PROVIDERS – 2024 OIL AND GAS Our technology enables us to predict imminent equipment failure and bring it to our clients’ attention before their operations are impacted shows up in around one of the four averages and, therefore, does not have enough weight by itself to stand out after the averaging process. Over time, as the fault progresses, it will show up in more of the averages. But why wait when you could identify the problem much earlier and take a simple maintenance action like just lubricating the bearing and stopping the fault from advancing at all?
The averaging method proved effective, given the available resources at the time. However, advancements in technology demanded a more robust solution. Capturing the parameters at a given point in time, akin to taking a photograph, could omit critical data. A photo that is too zoomed in may have a proper resolution to see details of an object but does not capture the entire object because it is too close. The additional challenge was that once captured, like these images, the vibration spectra could not be altered or reprocessed. So, if you did not get what you needed for a proper analysis, you then had to get another set of data.
VSC addressed the issue by using a patented data streaming technique where they digitally capture large sets of gap-free raw data at extremely high sample rates allowed by modern computing. This eliminates the need to commit to specific data parameters upfront. The collected stream of data, typically ranging from 30 to 40 seconds, allows for limitless post-processing. Analysts and artificial intelligence can apply infinite filters and analytical techniques to examine the data in-depth, uncovering issues in their infancy.
Precision and quality are critical aspects of VSC’s operations. Bearing failures that previously went undetected are now identified, allowing for repairs before they become costly failures. Just as vital, mechanical false alarms are also ferreted out so unnecessary repairs are not endured as a waste of important resources. For instance, the continuous operation of screw compressors is essential for maintaining cold storage facilities to keep food products at specific temperatures. This equipment is prone to thrust bearing failures, which result in extensive damage and expensive repairs. VSC leverages its technology to detect the key indicators of the component malfunction, carefully discerning between the compressor’s normal and elevated high-frequency vibration to notify clients in advance about the need for maintenance. This allows them to prevent any mechanical setbacks that can halt operations.
The technology is currently deployed with select customers in a beta version. VSC collects their feedback and continues to perfect the technique and enhance user-friendliness before market release.
VSC’s offerings extend beyond vibration analysis to provide precision balancing for clients across Canada and the U.S. At their Philadelphia, PA facility, they can balance a variety of industrial equipment with diverse rotor sizes, from large rotors weighing up to 20,000 pounds to small rotors measured in grams. Skilled technicians ensure strict tolerances during the balancing process, putting every piece of equipment back into smooth operation. Field balancing services are offered for bigger machines like gears, motors, and turbines. A team travels to the client site with a portable balancing machine, eliminating the need for costly and time-consuming shipping of heavy machinery. This on-site service allows for immediate balancing after repairs like motor rewinding or turbine re-blades, ensuring minimal downtime for customers.
Clients also have the option to collect their vibration data using the technology and send it for remote analysis using their Vibration as a Service (VaaS™) or opt for a VSC team member to analyze the information on-site. Their proactive approach enables customers to schedule repairs during planned shutdowns and avoid unexpected downtime.
Upholding a commitment to improve its technology and diagnostic capabilities, VSC is setting the standard for equipment monitoring in the industry. Precision diagnosis of issues before they become extensive and costly makes it the perfect partner for clients seeking to optimize their operations.