The Benefits of Wireless Condition Monitoring

Not only does the use of wireless condition monitoring cut down on unplanned downtime by allowing for predictive and proactive maintenance, but it also provides other key benefits for facilities:

Increased Efficiency

Wireless monitoring reduces manpower needs, such as someone having to get on a lift or into a difficult location in order to check equipment health. With condition monitoring, the system will tell the user when equipment is failing, allowing time to plan repairs during a non-peak production time.

Improved Safety

Several key safety concerns can be eliminated when equipment is being wirelessly monitored With condition monitoring, there is no need to inspect equipment while it is running. Another safety benefit is not having to go into difficult to access areas, such as heights or tight spaces. Preventing unplanned equipment failure also eliminates the urgency associated with reactive maintenance. When you are in a hurry to get something fixed, the chance of injury significantly increases. Having the ability to plan ahead prevents injuries.

Ease of Installation

Wireless monitoring systems are easier to install than their wired counterparts and when the right sensors are utilized, you can get the same level of detail from the node whether it is wired or wireless. It is typical to begin monitoring the same day with a wireless installation, making deployment a smooth and painless process. Wireless systems are also adaptable to any industry or equipment, are available in rugged outdoor and washdown-rated options and are a cost-effective option for monitoring many assets easily.

Diagnostic Data Capabilities

Wireless condition monitoring systems are not all the same and it is important to understand what type of diagnostic data is required for each asset. Some vibration sensors, for example, only provide very basic data and would require manual measurement to truly diagnose a root cause. Other vibration sensors deliver the full waveform and complete spectral data, meaning all data necessary to completely diagnose the problem is already available. Understanding the options on the market today and knowing what level of diagnostics will be required for your business will ensure you are optimizing your predictive capabilities and achieving the best equipment reliability.

Wired vs. Wireless Sensors

The types of measurement data your assets require will help determine if a wired or wireless monitoring system is best for your plant.

Wireless sensors allow for quick and easy deployment of condition monitoring. They are ideal in cases where accessibility makes it difficult to connect wires. Wireless monitoring is also preferred when there is some distance between monitoring locations. A wireless system can reduce cost by not having to run long wires. Because wireless sensors are battery operated, they do not collect data constantly. Instead, wireless sensors collect data based on a predetermined schedule or event triggers that are set during installation.

Wireless monitoring should be used for assets where gaps in the data stream will not have a detrimental effect on system reliability. The gaps in the data are usually inherent to the data collection logic, which is often set up to collect data at certain times of day or when other conditions are met. Most wireless monitoring systems are best suited for steady state machines that are either on or off. Examples include fans, pumps or other process equipment that do not have frequent starts and stops within a day.

The ability to detect faults at the earliest stages of failure, especially for low-speed equipment, may require more sophisticated technologies than the capabilities of wireless systems. Wired systems can run and collect data 24/7. Wired continuous monitoring systems provide the ability to record and act on alarms at any time based on real-time events. A wired system is often the best choice for critical equipment when immediate alerts are required.

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