What is Predictive Maintenance and Why is it Important?

Predictive maintenance is an approach that relies on measuring the actual condition of equipment to predict maintenance needs in advance, rather than operating equipment until it fails (post-failure maintenance) or stopping it at fixed intervals for maintenance (periodic/preventive maintenance). The goal is to catch a developing problem early on, before it disrupts production.

In rotating equipment (pumps, fans, compressors, electric motors, gearboxes), problems such as bearing wear, imbalance, axial misalignment, or looseness manifest as changes in mechanical vibration behavior weeks, sometimes months, before they become a complete failure. Vibration analysis provides early warning by monitoring these changes.

The goal of predictive maintenance is not to eliminate maintenance altogether; rather, it aims to reduce unplanned downtime, schedule maintenance tasks, utilize spare parts and labor more efficiently, and prolong equipment life.

• Reduced risk of unplanned downtime: problems are caught before they cause a breakdown.
• Maintenance can be planned: the shutdown can be timed to the most appropriate time.
• Avoiding unnecessary disassembly/part replacement.
• Maintaining equipment reliability and energy efficiency.

How does vibration analysis work?

Every rotating machine produces a specific vibration signature during operation. In a healthy machine, this signature is relatively stable. When a problem develops, originating from a bearing, gear, blade, or rotor, the amplitude and especially the frequency content of the vibration changes. Vibration analysis measures and interprets this change.

Measurements are taken using sensors (accelerometers, etc.) placed at appropriate points on the machine (usually in bearing/rolling areas). The collected signal is evaluated as the overall vibration level on the time axis and decomposed on the frequency axis (spectrum/FFT analysis). Frequency analysis helps to identify the source of the problem (e.g., imbalance, misalignment, bearing damage).

The output produced by AES Innovation in this context is a condition-monitoring and analysis report: it includes measurement results, identified potential sources, and recommendations based on engineering assessment. This is not a conformity/inspection report; it is a mechanical engineering condition assessment.

• General vibration level measurement (amplitude monitoring)
• Source separation using frequency/spectrum (FFT) analysis.
• Bearing area measurements and early signs of bearing damage.
• Trend tracking: the change in value over time.

Which equipment can it be applied to?

Vibration analysis is applicable to a large portion of rotating or rotating-part equipment. Application points and interpretation vary depending on the type of equipment, rotational speed, and bearing type.

The following equipment are typical application areas; their criticality and role in the process determine the frequency and priority of monitoring.

• Pumps (centrifugal and similar rotary pumps)
• Fans and exhaust fans
• Compressors
• Electric motors
• Reducers and gearboxes
• Bearing and bearing units
• Rotary general process machines

Measured Parameters: Vibration, Bearing, Alignment and Balance

Predictive maintenance involves evaluating not only the overall vibration level but also several different indicators that point to the source of the problem. This allows us to understand the cause, going beyond simply saying 'high/low vibration'.

Vibration data can often identify problems caused by misalignment (axial misalignment) and imbalance. This allows for the corrective action (alignment correction, dynamic balancing, bearing replacement, etc.) to be implemented after diagnosis.

• Overall vibration amplitude and trend (condition monitoring)
• Frequency components (distinction between imbalance, eccentricity, and looseness)
• Bearing condition indicators (early signs of damage)
• Misalignment and balance assessment.
• Integration with field alignment and dynamic balancing services when required.

Assessment Framework and Reference Standards (ISO 20816)

Internationally accepted technical references are used in interpreting vibration measurements. Foremost among these is the TS ISO 20816 series, which addresses the measurement and evaluation of machine vibration. This series is an updated version of the previously widely used ISO 10816 series; therefore, the current reference is ISO 20816. For approaches to condition monitoring, the ISO 13373 series provides a reference.

ISO 20816 classifies machines according to their type, power, and mounting method, and allows for the evaluation of measured vibration levels within this classification framework. The evaluation generally relies on a logic that divides the machine's condition into zones such as 'acceptable', 'requires monitoring', and 'requires action'.

This page does not provide numerical limit values from the standards by rote; because the applicable class and limit values vary according to the type, size, installation conditions of the machine, and the relevant standard section. Which class and evaluation framework is applicable to your equipment is determined before the measurement and explained in the report along with the justification.

• TS ISO 20816: Mechanical vibration measurement and evaluation (current reference)
• TS ISO 10816: 20816 replaces the previous series (historical reference)
• ISO 13373: Condition monitoring (via vibration) approach
• The evaluation framework is determined according to the equipment class; threshold values are selected specifically for the application, not by rote.

Not Legally Required — So Why Should You Get One?

An important note of honesty: Vibration analysis and predictive maintenance are not legally mandatory. There is no regulation requiring them for periodic inspections. Therefore, vibration analysis is not a 'mandatory periodic inspection' required by legislation, but rather an engineering measurement and best practice service voluntarily chosen by the company for its own reliability and efficiency goals.

This service does not replace, but complements, existing legally mandated periodic inspections (e.g., regulatory checks for relevant equipment) that your business is subject to. While legal inspections aim at compliance/safety, predictive maintenance aims to improve business continuity and efficiency by continuously monitoring the health of the equipment.

Although voluntary, the reason for choosing it is economic: an unexpected failure of a critical pump or compressor can lead to production losses, emergency maintenance, and parts costs far exceeding the cost of measurement. Catching the problem early transforms this loss into a planned and controlled intervention.

• It is not legally required; it is optional good engineering practice.
• It does not replace existing legal periodic inspections; it complements them.
• The reasoning is both technical and economic: to reduce the cost of unplanned downtime and breakdowns.
• Early detection of critical equipment damage can prevent major problems.

Predictive Care Integrated with Thermography and Fat Analysis

Vibration analysis is a powerful tool on its own; however, using multiple monitoring methods together provides a much more reliable picture of the equipment's condition. Different methods corroborate and complement each other because they identify different symptoms of the problem.

At AES Innovation, it is possible to offer vibration analysis together with thermography (thermal imaging) and oil analysis as an integrated predictive maintenance package. Vibration indicates mechanical problems, thermography shows signs of overheating/overloading, and oil analysis shows lubrication and wear status; when used together, the diagnosis becomes more accurate.

Furthermore, when combined with electric motor expertise and alignment/balancing services, a holistic maintenance approach is achieved, going beyond simply identifying a problem and extending to the corrective step.

• Vibration analysis: mechanical problems (imbalance, misalignment, bearing issues, looseness)
• Thermography: detection of overheating, overloading, and contact problems.
• Oil analysis: lubrication status and wear indicators.
• Alignment and balance: post-detection correction guidance.
• Combining methods increases diagnostic reliability.

How to progress with AES Innovation?

The process begins with defining your equipment inventory and criticality priorities. Which machines will be monitored, where measurements will be taken, and which assessment class will be applied according to ISO 20816 are planned before the measurement.

Following field measurements, the collected data is analyzed and a status monitoring/analysis report is prepared. The report includes the current situation, identified potential problem sources, and recommended actions (continue monitoring, planned intervention, additional measurements, etc.). Tracking trends through periodic monitoring maximizes the value of predictive maintenance.

This content is for informational purposes only and provides a general engineering framework; evaluation, field measurement, and engineering review are required for specific equipment.

• Determining equipment and criticality priorities.
• Selection of a measurement plan and an appropriate evaluation framework.
• Field measurement, analysis and condition monitoring report.
• Trend tracking and recommendations through periodic monitoring.

Related Services

• Engine Test
• Thermography
• Machine CE

Frequently Asked Questions

Is it legally mandatory to have a vibration analysis performed?

No. Vibration analysis and predictive maintenance are not legally mandatory; there is no periodic inspection regulation requiring it. It is an engineering measurement and good practice service that businesses voluntarily choose to use to detect failures early, reduce unplanned downtime, and maintain productivity. It does not replace existing legal periodic inspections; it complements them.

Which equipment is it applicable to?

A wide range of rotating and rotating-part equipment includes: pumps, fans/aspirators, compressors, electric motors, gearboxes, and bearing/bearing units. Application points and interpretation are determined according to the type of equipment, its rotational speed, and its criticality in the process.

Which standards are being referenced?

The current reference for the measurement and evaluation of machine vibration is the TS ISO 20816 series; this series is an updated version of the previously used ISO 10816. The ISO 13373 series is also a reference for the condition monitoring approach. These standards are technical references; they are not a source of legal obligation. The applicable evaluation class and limit values are determined specifically for the equipment.

Does the report include documentation stating that my equipment is 'suitable'?

No. The output of this service is a status monitoring/analysis report; it is not a certificate of conformity, certification, or inspection report. The report includes measurement results, identified potential sources of problems, and recommendations based on engineering assessment.

Should I have the vibration analysis done in isolation, or in combination with other methods?

Vibration analysis is valuable on its own, but its diagnostic reliability increases when used in conjunction with methods such as thermography and fat analysis. Different methods corroborate each other because they identify different signs of the problem. AES Innovation can offer these as an integrated predictive care package.

Do I need to stop production for the measurement?

Vibration measurements are typically taken while the equipment is in normal operating condition, as the vibration signature generated during operation is evaluated. The measurement plan and site conditions are determined in conjunction with your company to minimize the impact on production.