Route-Based Vibration Analysis vs. Permanent Monitoring
Route-based vibration analysis and permanent monitoring are two distinct methods for monitoring the health of industrial machinery. Each method has its advantages and disadvantages, and understanding the differences between them can help to determine the best approach for a given application.
Route-based vibration analysis is a quick, cost-effective alternative to permanent monitoring; in this method, a technician will schedule periodic visits to a facility to perform vibration analysis on specific pieces of machinery. The technician will collect and analyze data from sensors mounted on each machine and recommend necessary repairs or adjustments. The relatively low personnel and hardware costs are the most significant advantages of route-based vibration analysis. Since the technician only visits the facility periodically, the labor costs are significantly lower than the costs of having a full-time employee on site. Additionally, the hardware required is minimal, as the technician only needs to bring sensors, cables, magnets, and a portable data analyzer.
Route-based analysis allows for a minimum amount of necessary hardware.
For route-based data collection, CTC always recommends having backup hardware on hand as well as utilizing a cable with a break-away safety feature. It can be extremely hazardous when a data collector cable gets wrapped around a rotating shaft. It could result in a life-threatening injury to the analyst or severe damage to the data collector. The break-away safety feature ensures a safe and quick disconnection from your mounted sensor on a running machine to protect the analyst from injury and save the data collector from being severely damaged.
Using a safety feature (left) can prevent potential injury or costly damage.
The primary disadvantage of route-based vibration analysis is that the data is only available on a limited basis. The technician can only collect data during the scheduled visits, so long-term trends and changes in performance are more difficult to monitor. Additionally, since the technician can only collect data from the sensors attached to each machine, any events that occur between visits may go unnoticed. Access to critical data points may also be limited based on human safety concerns if a vibration test point is inaccessible to an analyst due to height, clearance, high temperature, operating hazards, etc.
In contrast, permanent monitoring typically involves an on-staff reliability team responsible for monitoring equipment performance via data from permanently installed vibration sensors. One of the critical advantages of permanent monitoring for predictive maintenance is its ability to provide continuous and real-time data. This information can provide valuable insight into the performance of the equipment over time, which can be used to inform decisions on maintenance scheduling. For dangerous, hot, or hard-to-reach locations, sensors can be permanently installed while the machine is shut down. These remotely mounted sensors can provide continuous data on remote applications that would not be feasible through route-based collection.
Another benefit of permanent monitoring is that it can reduce the amount of manual labor required per collection point. Route-based data collection requires an engineer to inspect the equipment and take measurements, which can be done automatically with permanent monitoring. This reduces the time and resources needed for manual data collection, allowing for more efficient operations. Finally, permanent monitoring can also be used to improve safety. By monitoring the performance of the equipment in real-time, it is possible to detect any potential safety hazards before they become serious. This monitoring can help to reduce the risk of accidents and improve the safety of the work environment. Overall, permanent monitoring for predictive maintenance offers several advantages over route-based data collection; however, it also requires significantly more upfront costs.
A unique solution that enables the end user to benefit from the safety and accessibility advantages of permanently mounted sensors but avoid the upfront cost of a complete continuous monitoring program is to utilize a CTC SB or JB Series Vibration Switch Box. A switch box provides a safe place to collect cabling from remotely mounted sensors. A route-based analysis can then connect an analyzer to the switch box and collect data from the remotely mounted sensors. CTC SB and JB boxes offer the option for future online monitoring expansion with CTC's continuous output terminal blocks. This means that output wiring can be connected to the switch box later if the plant desires to take those sensors online for continuous monitoring in the future.
A junction box can benefit from the safety and accessibility advantages of permanently mounted sensors but avoid the upfront cost of a complete continuous monitoring program.
CTC generated this text in part with GPT-3. Upon generating draft language, the author reviewed, edited, and revised the language to their liking and takes ultimate responsibility for the content of this publication.
