Vario Vibration Analysis Project

Project Overview

A longstanding client of Smart CI Group engaged our Key Reliability Division to deliver the installation of advanced vibration analysis equipment to their existing production machinery. This project forms part of a wider reliability initiative, designed to improve machine condition monitoring, predictive maintenance, and overall equipment effectiveness (OEE) across the site.

Our team provided a turnkey installation, including the design, fabrication, and installation of stainless steel containment systems to house and protect power and data cabling. The containment system ensured reliable connectivity between the client’s Insen32 monitoring panel and the individual vibration monitoring points located throughout each machine.

This installation is part of an ongoing multi-phase programme, with the same design concept being replicated across multiple machines throughout the facility, supporting the client’s long-term reliability and asset management strategy.

Scope of Works

Design & Planning

Designed a robust, hygienic, and durable stainless steel containment system suitable for an industrial environment.
Planned and coordinated all cable routes to optimise accessibility, safety, and system performance.
Liaised with the client’s engineering and reliability teams to ensure compatibility with existing Insen32 control infrastructure.

Fabrication & Installation

Manufactured custom stainless steel containment to enclose and protect both power and data cabling.
Installed containment systems and cabling to the local Insen32 monitoring panel, extending to vibration monitoring sensors mounted on multiple points across each machine.
Ensured all terminations, routing, and fixings met the client’s reliability and cleanliness standards.

Commissioning & Handover

Verified data transmission from each vibration sensor to the Insen32 system.
Conducted system tests and visual inspections to confirm installation integrity and functionality.
Provided detailed as-built documentation and site integration support for ongoing rollouts.

Outcome

The project was completed on time and to the client’s exact specifications, delivering:

Reliable real-time vibration monitoring across all key machinery components.
Improved capability for predictive maintenance and fault detection.
A standardised design and installation model for future site-wide implementation.
Durable, hygienic containment ensuring longevity and system protection in a demanding industrial environment.

This installation now serves as the template design for multiple additional machines across the same site — helping the client to establish a consistent, scalable approach to condition monitoring and reliability engineering.

Why Smart CI Group Key Reliability Division?

Our Key Reliability Division specialises in delivering engineering solutions that enhance operational reliability, reduce downtime, and improve asset performance.
For this client, our in-house expertise provided:

End-to-end reliability project delivery, from design to commissioning.
Bespoke containment and cabling systems designed for harsh industrial environments.
Seamless integration of vibration analysis and monitoring technology into existing plant infrastructure.
Proven capability to standardise reliability improvements across multiple assets and production lines.