Route-Based Monitoring

Extend Monitoring for Every Asset

Expand coverage while unifying your data within a single system

Route-Based Monitoring

Most facilities have a small number of critical assets with continuous monitoring and a large population of balance-of-plant equipment with limited visibility. Traditional route-based programs often rely on disconnected tools, manual data handling, siloed analysis workflows – resulting in incomplete visibility and missed opportunities to detect early-stage issues.

InsightCM now supports route-based data collection, enabling technicians to gather condition data during scheduled inspection routes—and automatically integrate it into the same platform used for online monitoring.

No more disconnected systems. No more lost data.

Assets Monitored

Balance-of-Plant Equipment

Failure Modes Detected

Imbalance
Misalignment
Bearing defects
Mechanical looseness
Gear wear/eccentricity
Cavitation
Resonance or structural vibration
And more…

Customer Testimonials

"Safety wise, [Brush Condition Monitoring] is a great system. We're not changing our brushes as often and our guys don't have to stick their hands in the machines to change them. We're able to change the brushes on an as needed basis, instead of an arbitrary number of brushes each month. We're seeing some O&M savings as well. We're probably able to save about 1/3 of our O&M budget since our operators aren't having to go out and check on the brushes as often. Our operators really like the system."

John Wilcox
O&M Superintendent
AEP Dresden (OH)

"I used to spend about 50–70% of my time traveling to analyze issues. Now, with InsightCM, that's down to about 20%. It's also valuable to us and our customers to not have to wait 4–5 hours to start a 500MW unit. Everybody wins."

C.R.
Vibration Analyst
Midwest Power Plant

“We have nothing but great things to say about the Cutsforth brush systems here. Low costs, easy to maintain and no issues whatsoever.”

P.B.
Maintenance Superintendent
Midwest Power Plant

Route-Based Vibration Kit

Tools for defining routes, guiding data collection, and uploading the data are integrated into the InsightCM platform. The Route-Based Vibration Kit contains all of the hardware needed to get you started on route-based monitoring, including:

iPad with ruggedized case
Wireless piezo traixial accelerometer with magnetic mount
Laser Tachometer with magnetic mount
2 IEPE accelerometers
3-Channel wireless input
Breakaway accelerometer cables, chargers, and touch screen gloves

Talk with an Expert

How It Works

Plan Routes

Define assets, measurement points, and inspection types
Configure routes by area, system, or technician
Standardize data collection across sites

Collect Data

Follow pre-defined routes using portable devices
Ensure consistency with step-by-step instructions
Make multiple measurement types in a single route

Synchronize Data

Upload collected data into InsightCM
Automatically associate data with the correct asset and location
Eliminate manual data handling and siloed tools

Mobile Applications

The Cutsforth Route-Based Monitoring license includes three mobile applications for use on the monitoring Ipad:

InsightCM Route downloads routes you define in InsightCM, guides your technicians through the measurement process, and uploads the data to InsightCM. Use the included wireless vibration sensor or pre-installed sensors for hard-to-reach assets.
InsightCM Analyze enables advanced vibration analysis, including cross-channel phase analysis, bump tests, and other diagnostic tests to identify a wide range of mechanical fault conditions.
InsightCM Balance walks technicians through single- and two-plane shaft balancing with an intuitive, step-by-step workflow.