A common question in vibration analysis is: What is the proper frequency of inspection for a facility’s equipment? Unfortunately, there isn’t a straightforward answer. Several factors must be considered, including safety, the criticality of the equipment, historical data, the operating environment, and the equipment’s condition.
Safety
Safety is the top priority. When a failure occurs, it can compromise hazardous chemicals, fumes, or other critical safety measures. In such cases, an online monitoring system might be the best solution. Alternatively, weekly or even daily monitoring using a portable walk-around data collection system may be appropriate. While online systems can be expensive in the short term, they offer the most reliable protection against catastrophic failures.
Criticality of Equipment
The criticality of the equipment must also be considered. For equipment that is essential to production or operations, an online monitoring system or daily, weekly, or monthly data collection may be necessary. Determining the inspection frequency requires evaluating factors such as the equipment’s importance and the potential impact of downtime. While weekly or monthly inspections may suffice in many cases, they can be both time-consuming and costly.
Historical Data
Historical data, such as Mean Time Between Failures (MTBF), plays a vital role in setting inspection frequencies. Equipment with a history of premature failures should be monitored more frequently than equipment that has demonstrated long-term reliability. The rate of failure is another critical consideration. For instance, if an asset typically fails within a month despite appearing to be in good condition, biweekly data collection may be warranted.
Environmental Conditions
The operating environment is another important factor. Equipment operating in harsh conditions—such as areas with extreme heat, dust, dirt, or moisture—requires more frequent monitoring to ensure proper data collection and to detect issues early.
Current Equipment Condition
The current condition of the equipment must also be assessed. Machines with known or diagnosed problems, such as a bearing fault, should be monitored more frequently until repairs can be completed.
In Summary
There is no definitive answer for determining the frequency of vibration analysis inspections when starting a program. Inspection frequencies will evolve as the program matures, problems are resolved, and site-specific factors become clearer. Conducting a criticality survey is an excellent way to organize assets, rank them based on the factors discussed, and prioritize monitoring efforts accordingly.
Finally, remember that no vibration analysis program will ever be perfect. Continuous adjustments to inspection intervals will be necessary as conditions change and new data is collected. Flexibility and adaptability are key to ensuring the long-term success of your vibration monitoring program.