I am interested in analyzing the cost differences between online wireless vibration monitoring and route-based vibration monitoring. Is there a standard industry rate per data point for vibration routes? Additionally, if a plant runs an internal vibration program, what is the average number of points per vibration analyst they handle? Any insights on this would be greatly valued. Thank you. - Jacob Loverich
When considering a new project, the use of wireless technology for monitoring velocity and acceleration can have a significant impact on Return on Investment (ROI) compared to traditional wired solutions. The advantages of 24-7 monitoring integrated with an Equipment Condition Monitoring (ECM) system are invaluable compared to monthly check-ins. Even in an existing location, there will still be costs associated with technician data collection, but having a dedicated analyst can streamline the process. The continuous monitoring benefits are still present, making it easier to justify the investment when considering the true cost of downtime for your operations. In response to Jacob Loverich's inquiry about comparing the costs of online wireless vibration monitoring versus route-based monitoring, it's important to weigh the benefits and potential cost savings of each approach. For internal vibration monitoring programs, there may be a typical number of points per analyst responsible for, depending on the industry standard. Any insights or recommendations on this topic would be greatly appreciated. Thank you, Victor E Rioli.
Andy Rodes, the VP of Operations at VibeCloud Reliability, discusses the comparison between the costs of online wireless vibration monitoring and route-based vibration monitoring. He has been in the industry for nearly two decades and has extensive experience in analyzing various approaches when it comes to condition monitoring. According to Rodes, there is no fixed industry standard cost per point for vibe routes from third-party service providers like his company. When running a vibration program internally, Rodes suggests that having two certified vibration analysts, with one gathering data and the other analyzing it, can handle around 4-6k points with monthly readings and analysis. Factors such as the location of the facility, number of components monitored, and sampling frequency play a crucial role in determining the scope and cost of monitoring solutions. Rodes emphasizes the importance of using wireless sensors with a minimum of 10khz velocity spectrum range to provide analysts with the most data for accurate analysis. While sensor pricing can be complex, Rodes mentions that their preferred sensor starts at $26 per month and includes everything from sensors to full analysis by certified analysts. In conclusion, Rodes points out that for facilities looking to monitor 75 components or more, monthly walking route vibration analysis is usually more cost-effective compared to online monitoring solutions with wireless sensors. He also mentions working on a white paper to further explore the pros and cons of wireless sensors versus walking route monitoring. For more information, readers can reach out to Rodes for a copy of the white paper once it is completed.
When considering a monitoring solution for your assets, it is recommended to opt for a hybrid approach. Utilize online monitoring for your most critical Tier 1 assets, while utilizing route-based monitoring for Tier 2-3 assets. A well-implemented route-based program can efficiently collect data on 70 assets and 315 bearings every day. This translates to a cost of $11.43 per bearing. On the other hand, an online monitoring program provides comprehensive spectral data 240 times a month with advanced sensors and analysis tools. The monthly cost for this program ranges from $29 to $35 per bearing, providing significantly more data and expertise compared to traditional monthly monitoring. Contact us for a detailed breakdown of the pricing and services included in both our online and route monitoring programs. Let's discuss further how we can tailor a solution to meet your specific needs. ------------------------------ Michael Bernhard ------------------------------
Thank you to all who contributed to the discussion. Your input is greatly valued and has provided me with valuable guidance. -------------------------------- Jacob Loverich ------------------------------ Original Message --------------- Original Message: Sent: 06-13-2023 15:18 From: Michael Bernhard Subject: Route vs Online Vibration Monitoring Cost Jacob, It is advisable to consider a combination of online and route-based monitoring solutions. Online monitoring may be more suitable for tier 1 critical assets, while route-based monitoring can be effective for tier 2-3 assets. A well-structured route-based program can gather data on around 70 assets and 315 bearings per day. With a daily labor rate of $1500-$2000, the cost would amount to $3600 for 70 assets or approximately $11.43 per bearing. On the other hand, an online program involves various charges depending on the system used, sensor quality, and data reliability. Our system, for instance, collects full spectral data 8 times a day (240 times a month) using a Tri-Axial/temp sensor and includes installation, hardware, software, and CAT III monitoring for equipment with prescriptive asset alerts. The monthly cost per sensor ranges from $35 to $29 per bearing, providing significantly more data points compared to monthly route-based monitoring. I can provide a detailed breakdown of pricing and services for both online and route-based monitoring options. Please let me know if you would like more information. -------------------------------- Michael Bernhard Original Message: Sent: 06-08-2023 09:43 From: Jacob Loverich Subject: Route vs Online Vibration Monitoring Cost I am interested in comparing the costs of online wireless vibration monitoring versus route-based vibration monitoring. Is there a standard industry cost per point for vib routes? Additionally, for internally run vib programs at plants, what is the average number of points per vibration analyst? Your insights and opinions on this matter would be greatly appreciated. Thank you. Jacob Loverich
When utilizing route-based data collection, a key advantage is having a technician physically inspecting the machines. This allows for early detection of issues such as oil leaks, slipping belts, and more before they become apparent on a remote monitoring system. This proactive approach can save both time and money in preventing potential equipment failures. Barry Busey Regarding the comparison between route-based and online vibration monitoring costs, it is beneficial to consider a blended solution. Online monitoring is ideal for critical assets, while route-based monitoring can efficiently cover Tier 2-3 assets. A well-executed route-based program can gather data from 60-80 assets per day, equating to approximately 70 assets and 315 bearings. With a daily labor rate ranging from $1500 to $2000, the cost for a day of route data collection and analysis is estimated at $3600, or $11.43 per bearing. On the other hand, an online monitoring program involves various costs depending on the system and sensor quality. Our system, for example, captures full spectral data 8 times a day using a Tri-Axial/temp sensor, providing detailed insights and alerts without the need to purchase equipment. The monthly cost per sensor ranges from $29 to $35, offering significantly more data points and expert analysis compared to traditional monthly monitoring. In conclusion, a comprehensive analysis of pricing and services for both online and route-based vibration monitoring programs is essential to determine the most cost-effective solution for your specific needs. Feel free to reach out for further information and a detailed overview of our offerings. Your proactive approach to monitoring can contribute to significant cost savings and enhanced equipment reliability. Michael Bernhard
Hi Jacob, while I can't provide a concrete industry standard as prices can vary by providers and the specific needs of your operation, I can tell you that the cost of online monitoring systems tends to be more expensive upfront compared to route-based monitoring. However, they can be cost-effective in the long run as they are typically more comprehensive, providing real-time, continuous data. As for your second question, again, the number can fluctuate greatly depending on the size of the setup and sophistication of the program. However, in my experience, it could range from managing a few hundred up to a thousand data points per analyst. An accurate estimation would need to consider the type of assets, their risk profile, and the company's reliability goals. Hope this helps a bit on your journey.
Hi Jacob, the cost analysis can be quite complex and it's dependent on various factors, such as the size of your plant and the particular equipment you're monitoring. For instance, the cost per data point can be reduced significantly when you're dealing with a larger number of points. When it comes to an internal vibration program, the number of points each analyst can handle can vary considerably, often centered around the type of machinery and analyst experience. While I don't have explicit numbers to share, I'd suggest reaching out to solution vendors directly for a more detailed assessment, or consider hiring a consulting firm that specializes in this area.
Hi Jacob, while I can't provide a standard rate per data point for vibration routes as they often depend on the specific contract with the service provider, I can talk about the number of points per analyst in-house. Typically, a full-time vibration analyst managing an internal program might handle between 800-1500 points, depending on the complexity of the machinery and the rigour of the program. As for cost differences, online wireless systems can be cost-intensive to install but provide continuous monitoring and may eventually save expenses associated with failures and repair. Route-based monitoring is more manual, thus less costly to install, but it might require more investment in the long-term for field analyst hours.
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Answer: 1. What are the key cost differences between online wireless vibration monitoring and route-based vibration monitoring? - The key cost differences include initial setup costs, ongoing maintenance costs, and data collection efficiency. 2. Is there a standard industry rate per data point for vibration routes? - The industry rate per data point for vibration routes can vary depending on various factors such as the complexity of the equipment, the technology used, and the service provider. It is recommended to reach out to different providers to get accurate pricing information.
Answer: - The average number of points per vibration analyst can vary depending on the size of the plant, the complexity of the equipment, and the resources available. It is advisable to assess the specific needs of the plant to determine the optimal number of points per analyst.
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