Vibration Monitoring of Water, Wastewater and Stormwater Treatment Plants

June 5, 2024 | Product News

This article describes how the rotating machinery at a Water Treatment Plant, Wastewater Treatment Plant and Stormwater Management System should be monitored to enable proactive maintenance, reduce downtime, increase equipment lifespan, and improve operational efficiency by identifying potential issues before they escalate into major problems. It outlines how vibration monitoring can help you take a proactive approach to maintain the operational efficiency, safety, and environmental integrity of water, wastewater and stormwater treatment facilities. It allows for early detection of equipment issues, optimized processes, and overall, more sustainable, and reliable plant operations.

Why is vibration monitoring of water, wastewater and stormwater plants needed?

Vibration monitoring is crucial in water, wastewater and stormwater plants for several reasons. These plants house equipment and machinery that are essential for the treatment and processing of water, wastewater and stormwater. Monitoring vibration helps ensure the smooth and efficient operation of these facilities, as well as the safety of personnel and the environment. Here are some key reasons why vibration monitoring is essential:

Equipment Health and Condition Monitoring: Water and wastewater plants, and stormwater facilities typically rely on a variety of rotating machinery, such as pumps, motors, blowers, and mixers. Continuous vibration monitoring allows operators and maintenance personnel to assess the health of these machines. Unusual levels of vibration can indicate wear and tear, misalignment, unbalance, or other issues that might lead to equipment failure. Detecting problems early enables proactive maintenance and reduces the risk of costly breakdowns.

Figure – Why Vibration Monitoring

Early Fault Detection: Monitoring vibrations helps identify potential faults or malfunctions before they cause severe damage to the equipment. Early detection allows for timely repairs or replacements, minimizing downtime and avoiding more extensive and expensive repairs.

Energy Efficiency: Unwanted vibrations in equipment can result in energy inefficiencies. Monitoring vibration levels enables operators to optimize equipment performance, reducing energy consumption and operating costs.

Process Optimization: The efficiency of the treatment processes can be affected by vibration-related issues. Monitoring vibrations can help identify process inefficiencies caused by equipment problems, allowing for adjustments and improvements to maintain optimal treatment performance.

Environmental Protection: These treatment plants play a vital role in protecting the environment. Vibration monitoring helps prevent potential environmental hazards by identifying equipment problems that could lead to leaks, spills, or other incidents that might harm the surrounding environment.

Personnel Safety: Excessive vibrations in equipment can pose safety risks to plant personnel. Vibrations can lead to equipment failure, which might result in accidents and injuries. By monitoring and addressing vibration-related issues promptly, the safety of plant workers can be significantly improved.

Regulatory Compliance: Industrial treatment plants often need to adhere to strict regulations and guidelines. Vibration monitoring may be a requirement in some regulatory frameworks to ensure the proper functioning and maintenance of critical equipment.

Asset Management and Longevity: Monitoring vibrations provides valuable data for asset management. Understanding the condition of equipment helps in planning maintenance schedules and replacement cycles, extending the life of the machinery and avoiding unplanned downtime.

How is vibration monitoring used in these industries?

Vibration monitoring plays a crucial role in the water, wastewater and stormwater industries by helping to ensure the reliable and efficient operation of equipment and infrastructure. Here are some ways in which vibration monitoring is used in these industries:

Pump and Motor Monitoring: Pumps and motors are extensively used in water, wastewater and stormwater treatment plants. Vibration monitoring helps in detecting abnormalities in the rotating equipment, such as misalignment, bearing wear, unbalance, and mechanical looseness. By monitoring vibration levels, plant operators can identify potential failures and schedule maintenance proactively, minimizing downtime and reducing repair costs.

Pipe and Valve Monitoring: Vibration monitoring is employed to detect pipe and valve failures in treatment systems. Excessive vibration can indicate issues like water hammer, fluid flow problems, or structural weaknesses in the piping network. Continuous monitoring allows for early detection of leaks, pipe bursts, or valve malfunctions, enabling prompt repairs and preventing water loss or environmental contamination.

Blower and Compressor Monitoring: Blowers and compressors are vital components in aeration systems used in wastewater treatment. Vibration monitoring helps to identify issues such as worn bearings, unbalance, and alignment problems in these machines. By detecting these problems early on, maintenance can be scheduled to avoid costly breakdowns and optimize energy efficiency.

Mixing and Agitation Equipment: In various treatment processes, mixing and agitation equipment are used to ensure proper blending of chemicals and facilitate solid-liquid separation. Vibration monitoring assists in identifying problems like impeller damage, bearing wear, or mechanical faults in mixers and agitators. Timely maintenance based on vibration data helps to prevent equipment failure and optimize process performance.

Structural Monitoring: Water, wastewater and stormwater treatment infrastructure often includes large structures like reservoirs, tanks, and dams. Vibration monitoring is employed to assess the structural integrity of these assets. By monitoring vibration levels and frequencies, engineers can detect any abnormal vibrations that may indicate structural damage, settling, or excessive loads. This information helps in evaluating the safety of the structures and planning necessary repairs or reinforcements.

What are the challenges in vibration monitoring of these industrial treatment plants?

While vibration monitoring offers numerous benefits in water, wastewater and stormwater plants, there are also several challenges that need to be addressed. Here are some common challenges associated with vibration monitoring in these industries:

Harsh Environment: These treatment plants often have harsh and corrosive environments, with high humidity, chemical exposure, and elevated temperatures. These conditions can affect the performance and lifespan of vibration monitoring equipment, such as sensors and data acquisition systems. Specialized vibration monitoring equipment with robust construction and suitable materials is required to withstand these environments.

Sensor and or Transmitter Placement: Proper sensor placement is crucial for effective vibration monitoring. However, in such treatment plants, it can be challenging to identify the optimal locations for vibration transducers due to limited accessibility, crowded equipment layouts, and complex piping networks. It may require careful planning and consideration of factors such as vibration transmission paths, potential sources of vibration, and critical equipment locations. Metrix can be relied upon to help with proper vibration transducer placement.

Data Interpretation: Vibration monitoring generates a significant amount of data, and interpreting this data correctly can be challenging, that is why people have relied upon Metrix Vibration for their simple 4-20 milliamp output for trending purposes for decades. This simple tool allows plant operators to easily see changes in vibration levels. After early warning is provided plant operators and maintenance personnel can focus on the machines that need attention. This allows experts that have a good understanding of vibration analysis techniques and interpretation methods to identify problems and avoid impending failures. Training and expertise in vibration analysis are useful for effective decision-making based on the collected data.

Integration with Maintenance Strategies: Vibration monitoring should be integrated into a comprehensive maintenance strategy to be effective. The challenge lies in establishing an effective system that connects the vibration monitoring data with maintenance planning and scheduling. This integration involves setting up thresholds and alarms, establishing protocols for action based on vibration data, and ensuring timely follow-up on identified issues to prevent failures or breakdowns.

Cost Considerations: Implementing a vibration monitoring program requires an investment in equipment, software, and training. Small and medium-sized plants with limited budgets may face challenges in allocating resources for vibration monitoring. Cost-effective solutions and prioritization of critical equipment are important considerations to overcome this challenge. Metrix provides solutions that are economical, easy to install and that are modular to fit within any budget.

Addressing these challenges requires a combination of appropriate technology, expertise, and effective implementation strategies. By overcoming these obstacles, these treatment plants can optimize their maintenance practices, improve equipment reliability, and ensure the efficient operation of their facilities.

What solutions do we advocate for vibration monitoring of water, wastewater and stormwater plants?

Some general solutions that are commonly advocated for vibration monitoring of such industrial treatment plants are noted below. These solutions can help optimize the vibration monitoring process:

Robust Vibration Sensors and Transmitters: High-quality vibration sensors and transmitters specifically designed for harsh environments are crucial for accurate and reliable monitoring. These sensors are capable of withstanding the corrosive and demanding conditions found in such plants. They are adequate protection against moisture, chemicals, and temperature variations.

Wireless Monitoring Systems: For Balance of Plant rotating machines, implementing wireless vibration monitoring systems can simplify installation and reduce the complexity of cable routing in treatment plants. Wireless systems enable flexible transducer placement and provide data transmission to central monitoring stations. This allows for easier access to vibration data, efficient data management, and timely analysis.

Advanced Signal Processing and Analysis: Vibration monitoring systems should incorporate advanced signal processing algorithms and analysis techniques to filter out background noise and extract meaningful information. These techniques help in accurately identifying vibration patterns, detecting anomalies, and providing early warning indications of potential equipment failures.

Remote Monitoring and Analytics: Cloud-based or remote monitoring platforms allow plant operators and maintenance personnel to access vibration data and analysis remotely. This provides the convenience of real-time monitoring, data visualization, and trend analysis from any location. It facilitates proactive decision-making, immediate response to critical alerts, and comprehensive data-driven maintenance strategies.

Integration with Maintenance Management Systems: Integrating vibration monitoring systems with existing maintenance management systems or computerized maintenance management systems (CMMS) streamlines the workflow and enhances maintenance planning. By connecting vibration data with work order generation, scheduling, and asset management, it ensures seamless coordination between vibration analysis results and maintenance activities.

Expert Support and Training: Vibration monitoring in water, wastewater and stormwater treatment plants can benefit from expert support and training. Metrix offers technical assistance, training programs, and consultation services to help plant personnel understand the vibration monitoring process, interpret data accurately, and make informed maintenance decisions.


Overall, vibration monitoring in the water, wastewater and stormwater industries enables proactive maintenance, reduces downtime, increases equipment lifespan, and improves operational efficiency by identifying potential issues before they escalate into major failures.

It’s advisable to consult with vibration monitoring solution providers, such as Metrix Vibration or other reputable companies in the industry, to understand their specific offerings and how they align with the unique requirements of your industrial treatment plant.

In conclusion, vibration monitoring is a proactive approach to maintain the operational efficiency, safety, and environmental integrity of water, wastewater and stormwater treatment plants. It allows for early detection of equipment issues, optimized processes, and overall, more sustainable, and reliable plant operations.

Figure – Why Metrix for Vibration Monitoring

Contact Neal Systems here to request more information on how Metrix can suit your needs. 

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Job Note: Large Waste Water Treatment Plant Scada Upgrade

April 24, 2024 | Application NotesMunicipal: Water / Wastewater / Landfill


Waste Water Treatment Plant
Northeast, USA
Construction Costs: $250K

Large Waste Water Treatment Plant
Northeast, USA
Construction Costs: $350K

Services Provided

  • SCADA Systems

  • Remote I/O Racks & OIT’s

  • PAC Control System

  • Wireless Communication


  • Switches & Fiber Runs

  • Enclosures

  • Installation Services

scada upgrade job note
scada upgrade job note-2

SCADA upgrade for sludge tanks, DO tanks, chlorine control, hypo tanks, thickeners and digesters including all field devices, enclosures and communication systems.

Our customer had a SCADA system in place that monitored the boilers and the gas detection system. However, an excessive amount of time was spent collecting data from remote chart recorders and indicators.

The Iconics SCADA system was expanded four-fold in order to bring in many remote parts of the plant. Twenty-five new stainless steel enclosures were installed— each being connected back to the control

room with a mix of serial comms, ethernet radios,fiber cable and copper ethernet. This meant that five-hundred new I/O was added to the control room screens along with alarms for dozens of key plant parameters.

With the new SCADA system in place, the time spent driving to remote parts of the plant has been significantly reduced as was the speed with which problems could be identified.


New Removable Cable Option for Acculevel Submersible Level Transmitter

April 15, 2024 | Product News

The KELLER America Acculevel and Acculevel SDI submersible level transmitters are now available with an optional Removable Cable. This option allows for the instrument to be separated from the cable for ease of installation and/or maintenance. The instrument with this option is equipped with a rugged connector that mates with a removable cable assembly, which is sold separately. The watertight seal is formed with the use of dual O-rings on the instrument and double O-rings on the removable cable assembly.

See datasheets here! 

How to Choose the Right Seismic Sensor for Your Application

April 4, 2024 | Product News

Choosing the right seismic sensor for your application – accelerometer or velocity sensor

In this blog post, we are discussing seismic sensors, which typically means we’re talking about machines with rolling element bearings. For machines with fluid film bearings, we typically use proximity sensors that can be augmented with casing mounted seismic sensors. At Metrix, we differentiate seismic sensors and seismic transmitters by the output needed by the monitoring or protection system. If the customer needs a 4-20 mA output, then a seismic transmitter will be used. Here we will be focused on seismic sensors, which provide a voltage output to a monitoring system. The seismic sensor outputs are in terms of acceleration or velocity, depending upon the machinery application needed. If the machine speed is 60 Hz or less, a velocity sensor is typically used. A velocity sensor is used because the bearing related, and rotor related, malfunction frequencies have the best signal to noise ratio. If the machine speed is greater than 60 Hz, then an accelerometer is typically used because it provides a better signal to noise ratio.

A seismic vibration sensor is inertially referenced, meaning that, if the sensor is not shaking, then the sensor will not produce a vibration output. Another way to say this is if you shake the seismic sensor on the earth or on the moon with the same force and frequency, you’ll get the same output. Seismic sensors are used to measure the motion of a casing of a rotating or reciprocating machine. The casing motion is usually indicative of the condition of the machine.

Seismic Sensors: General Considerations

Velocity Sensors

There are three basic types of velocity sensors, electromechanical, piezoelectric, and MEMS. An electromechanical velocity sensor uses a moving coil in the presence of a magnetic field to generate a voltage proportional to velocity, or the movement of the casing to which the velocity sensor is connected to. The piezoelectric velocity sensor takes advantage of the piezoelectric crystal inside, similar to an accelerometer, along with an integration and amplification circuit that converts the acceleration signal into a velocity signal. The MEMS (Micro-Electrical Mechanical Systems) velocity sensor takes advantage of the change in capacitance between small metal plates measured at the micro-millimeter scale. All these sensors have their advantages and disadvantages.

Even though the electromechanical velocity sensor has moving parts, its chief advantage over other velocity sensors is its ability to handle very high temperatures up to 375° C (707° F) without having to worry about melting integrated circuits. You see these types of sensors used on machines with relatively light casings and heavy rotors in high temperature environments, typically gas turbines.

The piezoelectrical velocity sensor is frequently used because of its solid-state design and its wide frequency range, typically from 2 Hz to 2,000 Hz. The piezoelectric velocity sensor is usually limited to 120° C (248° F). This velocity sensor does a great job at monitoring rolling element bearing machines that operate at 60 Hz or less. They’re also useful in measuring casing vibration on fluid film bearing machines when high temperatures are not encountered.

A MEMS velocity sensor is usually used for balance of plant equipment where a triaxial velocity sensor may be useful. The MEMS sensor can have a wide frequency range from 10 Hz to 5,000 Hz and is usually limited to 120° C (248° F). It should be understood that vibration is a ratio of forces to stiffnesses. A triaxial velocity sensor placed on top of the machine will not have the same X, Y, and Z axis readings as a triaxial velocity sensor placed horizontally on the machine due to the change in mechanical stiffness between the horizontal and vertical directions. For this reason, a single axis MEMS sensor can often provide more value when mounted properly on the machine.

Accelerometer Sensors

An accelerometer is a transducer that converts mechanical acceleration into an electronic signal. This is usually measured with a piezoelectric or MEMS device. The seismic sensors made from a piezoelectric material which produces a charge output proportional to acceleration (pC/g). When housed together with an electronic charge amplifier and charge-to-voltage converter (mV/g), it is referred to as an “internally amplified” accelerometer. If, due to temperature, only the sensor is machine mounted, the remote electronics are referred to as a “charge amplifier” (although it usually also contains a charge-to-voltage convertor). The MEMS accelerometer measures the acceleration by measuring the capacitance change between two surfaces. The output of the MEMS accelerometer is amplified and scaled to provide the same output as standard piezoelectric accelerometers.

Accelerometer sensitivity is a specification of the ratio of the accelerometer’s mechanical input to electrical output typically specified at a 100-Hz reference frequency or, as in the case of accelerometer frequency response, as a function of a range of frequencies.

Accelerometer frequency response is a specification of the accelerometer sensitivity as a function of frequency. Most accelerometers use the industry standard scale factor of 100mV/g or 10.2mV/m/s2. Accelerometers can have scale factors that range from 10 to 500 mV/g depending upon the sensitivity required. As the sensitivity increases, the frequency range increases. Typical frequency ranges for industry standard accelerometers are usually from 2Hz to 10kHz. Oftentimes the accuracy of the sensor is better at lower frequencies, like 2Hz to 5kHz, the accuracy may be +/- 5%. Whereas, from 2Hz to 10 kHz, the accuracy may be +/- 10%.


The above general guidelines should be helpful in determining whether to use a velocity sensor or accelerometer. One needs to consider the vibration frequencies of interest, the signal to noise ratio of a given sensor to the expected output, the environmental conditions, and mounting considerations. To learn more about this topic, also read our companion whitepaper titled “Accelerometers Versus Velocity Sensors – What’s the Difference?

All the advancements in sensors have been focused on precision, building in measurements on small scales that can give operators a better understanding of the trends that are taking place in their operations. Metrix sensors have been improved upon over the years to provide insight to identify how machinery vibration is changing over time, so you can schedule repairs and maintenance long before you must shut the machine down. For more information, please contact Neal Systems.


Application Note: Monitoring Methane at a Landfill

March 15, 2024 | Application NotesMunicipal: Water / Wastewater / Landfill

Flare System Retrofit A Turnkey Solution


Outdated Control System for Flare Operation

A landfill customer was in need of a new control system for their flare operation— a secondary disposal path for methane. Their current system was 20 years old, outdated, and remained dormant for 4 years.

Their old panel had an obsolete circular chart recorder. Since their system was down for 4 years, NSI worked with them through the process of identifying potential roadblocks and old units that needed to be replaced.

before interior


Neal Systems redesigned and retrofitted their old system with custom screens and newer technology, creating a cleaner, EPA compliant, operator interface.

NSI retrofitted and rewired their current panel with Foxboro Scadapack 474 RTU and Eurotherm Nanodac for recording and PID loop control. The Scadapack 474 is ruggedized and able to operate in harsh environments, which makes it the perfect solution for outdoor operations.

exterior after
interior after


With Neal Systems’ solution, the landfill’s methane flare is operable and compliant with EPA regulations and recording requirements. The new solution provides the customer with reduced operator involvement in startup and operation. They can simply turn it on and forget about it. Our customer now has a viable secondary disposal path for methane in the event that their generators are unavailable.


Custom panel creation

Field Installation/Modification

Custom Engineering drawings

Integration with existing field devices

Trained staff and provided back-end support

Solutions Delivered

Cleaner/more intuitive and capable operator interface 

Easier data recording and storage

Custom screens for flare operation and maintenance Worked with customer to revive dormant system

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