Beyond PLCs: Why Vibration Monitoring with Bently Nevada Matters
Introduction: The Limits of PLCs in Modern Plants
PLCs are reliable for automation logic and sequencing. However, over 68% of unplanned downtime is caused by mechanical failures—not process errors.
Without additional monitoring tools, these hidden issues lead to breakdowns. High-value machines require early fault detection systems to reduce risk.
Why Process Control Is Not Condition Monitoring
PLCs track variables like pressure and flow. But many mechanical faults do not affect these readings.
60%+ of machinery failures show no sign in process data before failure occurs (ARC Advisory Group).
Thus, relying only on PLCs leaves plants exposed to unexpected mechanical breakdowns.
What Bently Nevada Adds to the Equation
Bently Nevada offers advanced tools for vibration monitoring. These include:
- Proximity probes for shaft displacement
- Seismic sensors for casing vibration
- Real-time diagnostics and trend analysis
Their technology is used in 85% of global oil & gas plants and 70% of power plants. It detects issues like:
- Misalignment
- Unbalance
- Bearing defects
How Vibration Monitoring Protects Critical Equipment
Rotating equipment wears over time. Without monitoring, small faults escalate into large failures.
According to the U.S. DOE:
- Vibration monitoring reduces unplanned outages by 50%
- Extends machine life by 30%
Maintenance becomes planned and cost-effective—not reactive and expensive.
Why Integration with PLC/DCS Systems Matters
Bently Nevada’s System 1 software supports OPC UA, Modbus, and other protocols. This ensures seamless data sharing with your existing control systems.
Integrated condition monitoring leads to:
- 25% reduction in maintenance labor hours
- Faster fault diagnosis
- Improved plant-wide decision making
Case Example: Financial Impact of Monitoring
The table below shows savings from using Bently Nevada vibration monitoring in a refinery:
| Metric | Without Monitoring | With Bently Nevada |
|---|---|---|
| Annual Failures | 4–5 | 1–2 |
| Downtime Cost/Year | $800,000+ | $300,000–$400,000 |
| ROI Period | — | 6–12 months |
The Bottom Line: Prevention Is Better Than Repair
PLCs are vital—but not enough. They don’t detect internal mechanical risks early.
Bently Nevada adds a crucial protection layer through advanced vibration analysis. It helps reduce downtime, increase uptime, and extend asset lifespan.
With integrated monitoring, reliability teams make smarter decisions faster. In today’s competitive industrial landscape, that’s a major advantage.
Final Takeaway
Combining Bently Nevada with your control systems is not just good practice—it’s a strategic move. Protect your investments, improve uptime, and enable predictive maintenance that delivers real results.
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