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Vibration measurement in chemical plant: key to efficient condition monitoring

Bearing faults, imbalance, misalignment of rotating parts, wear and material fatigue - all of these problems can be detected in good time using the condition monitoring method of vibration measurement. For this reason, the experts at A. Hock installed eight Honeywell Versatilis vibration sensors in a chemical plant at the end of 2023 and read them out using the LoRaWAN easybox.

The data was analysed in accordance with DIN ISO 10816 and compared with the data from hard-wired measurements. The results are clear.

Project data

industry: chemical industry

services: implementation of a condition monitoring solution

products: LoRaWAN easybox & Honeywell Versatilis Transmitter


Excursus: The advantages of vibration measurement

Vibration measurement is extremely useful for demand-orientated maintenance of industrial systems and machines with rotating components. By recording mechanical vibration, patterns can be recognised within a very short time and potential problems can be identified. This has numerous advantages:

  • Cost reduction: Vibration measurement helps to avoid unplanned downtime and expensive repairs.
  • Increased efficiency: Early identification of imbalances or misalignments optimises the operation and performance of machines.
  • Extending service life: Measurement helps to extend the service life of machines and systems.
  • Increased safety: Operational safety is increased through the early detection of potential hazards.
  • Data history: By recording vibration data over a longer period of time, trends can be analysed and failures better predicted.

You can find more information on vibration measurement in the magazine article.

Use of vibration sensors & the LoRaWAN easybox

The task at the chemical plant was to implement a condition monitoring solution that provides meaningful data for preventive maintenance. The plant also has hard-wired measuring spots. A comparison was therefore made between the wireless and wired measurement methods. The aim was to determine whether both methods deliver identical results.

The procedure: Eight wireless Honeywell Versatilis™ sensors equipped with the latest LoRaWAN® protocol were placed on fans and motors throughout the chemical plant. They recorded the vibrations over a period of several weeks.

The LoRaWAN® easybox received the measurement data from all the vibration sensors. This ultimately formed the basis for the analysis. Temperature, pressure, humidity and acoustics were also analysed over time.

The measurements according to DIN ISO 10816

For the evaluation, the experts used standardised methods and threshold values - laid down in the standard for machine monitoring DIN ISO 10816 (new: DIN ISO 20816). The threshold values are categorised into four zones, which vary depending on the type and size of the system: A (good), B (satisfactory), C (unsatisfactory) and D (unacceptable).

It was important to install the vibration sensors at the right points in the system in order to be able to measure the vibrations in different directions.

The conclusion on vibration measurement

  • Wireless vs. wired measurements: All wireless measurements provide an assessment of the motor condition that is consistent with that of the wired measurement.
  • Sensor installation and monitoring: Correct installation of the sensor enables continuous monitoring of the condition of rotating system components, as required by ISO 10816.
  • Easy integration without additional infrastructure: Thanks to the LoRaWAN easybox, all exposed components can be detected without the need for additional infrastructure.
  • Dashboard with early warning system: The dashboard with traffic light system helps maintenance personnel to intervene in good time and prevent component failure.

The synergy of wireless sensor technology, careful analysis of the recorded data and intelligent alarm systems laid the foundation for preventive maintenance in the chemical plant. The goal was thus achieved.

Do you need advice on our condition monitoring solutions?

Then please contact our product experts.

Dominic Hock

Dominic Hock

Managing Director

I’m happy to support you with projects and enquiries in the field of valve technology as well as measurement and control technology. My areas of expertise are automation technology and networks.