Efficient Plant Nov./Dec 2019 - 24

feature | vibration monitoring

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Online
Vibration
Monitoring
ROUTE-BASED VIBRATION and maintenance programs have
served the needs of plants for decades. Today, there is growing demand
for more asset data to meet process-availability metrics. Route data
collection is time consuming and less cost effective, particularly for
heavy-industrial operations or plants with inaccessible assets in challenging environments. Many reliability engineers also find that the pointin-time snapshot that route-based programs provide is not enough to
protect the critical equipment needed to ensure operational excellence.
For plant operations and reliability managers to begin the journey toward
real-time data collection using an online predictive-monitoring system,
here are three recommendations.

IDENTIFY YOUR CRITICAL ASSETS
Criteria for a route program are different from those for an onlinemonitoring system. In some cases, route programs overlook assets where
access is difficult because the environment or guarding prevents optimal
data collection. Start with a fresh asset list so management can properly
evaluate criticality, probability of failure, and failure modes and effects.
This type of assessment is a critical step in keeping upfront costs down

24

| EFFICIENTPLANTMAG.COM

Three recommendations help you realize
the benefits of moving away from a
route-based monitoring system.

Pat Cornelison & Jamie Flerlage
Cornerstone Controls Inc.

and ensuring a high ROI, especially for those assets that tend to fail
quickly or assets that could fail between route data-collection periods.

ESTABLISH A VISION FOR OPERATIONAL CERTAINTY
With a fresh asset list established, operators can realign their quality and
throughput metrics with their predictive maintenance and monitoring
initiatives. By identifying the assets that have an impact on production
efficiency or product quality, reliability engineers cannot only prioritize
which assets to measure but also establish metrics for machine efficiency.
In both cases, management will gain insight into overall operational
effectiveness by linking production success metrics to operational
effectiveness. Finally, identifying these metrics enables management to
establish short- and long-term metrics to determine internal rates of
return for their online system investment.

START WITH A PILOT PROGRAM
To determine if an on-line monitoring-and-prediction system is the
right solution for your plant, consider a 30-to-60-day pilot program.
Modern on-line vibration processors allow inexpensive and temporary

NOV/DEC 2019


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Efficient Plant Nov./Dec 2019

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