Predictive Maintenance · Compressor
Compressor outages. Weeks of advance warning.
A mid-size gathering compressor outage backs up 20-50 wells and costs $300K-1M+ in deferred production. Vibration ML on per-unit baselines catches bearing wear 1-4 weeks early. Valve-pattern detection flags valve issues 5-21 days before efficiency drops. One avoided outage pays for the annual license.
Four compressor signatures.
Signature
Bearing wear
ML detects
Vibration creeping above per-unit historical envelope
Root cause
Wear, alignment, sand carry-over
Action
Schedule overhaul at 7-21 day window; not after bearing failure
Signature
Valve issues
ML detects
Suction/discharge pressure ratio drifting + valve-pattern change
Root cause
Valve seat wear, broken plates, fouling
Action
Schedule valve work at next planned outage
Signature
Oil temperature creep
ML detects
Oil temp creeping above historical envelope
Root cause
Cooler fouling, low oil level, internal leakage
Action
Investigate cooler first; mechanical work only if cooler ruled out
Signature
Fouling
ML detects
Efficiency declining at constant operating point
Root cause
Internal deposits, valve fouling, intercooler fouling
Action
Schedule wash at planned outage; project end-of-life if recurring
Continue the cluster
Compressor PM is one piece. The platform covers the full stack.
Other equipment classes
Predictive maintenance
Midstream + gathering
Where compressors matter most
Frequently asked
What gathering / facility engineers ask.
What compressor failures does WorkSync detect?
Bearing wear (vibration), valve issues (suction/discharge ratio drift), oil-temp creep, valve-pattern signature changes, fouling.
Cost of outage?
Unplanned outage $50-500K (gathering vs main-line). Downstream production deferred $20-200K/day for routed wells.
Lead time?
Vibration: 1-4 weeks. Valve pattern: 5-21 days. Oil temp: 3-14 days. Fouling: 1-3 months.
Compressor brands?
Caterpillar Solar Turbines, Ariel, Cooper Cameron, Atlas Copco, Howden, Sundyne. Any with vibration + temp + pressure telemetry.
Gathering vs main-line?
Same signatures, different impact math. Gathering outage backs up multiple wells. Main-line outage forces shut-ins + commercial penalty.
ROI?
One mid-size gathering compressor outage caught 14 days early saves $300K-1M+. Annual license pays for itself on a single deferred outage.
See compressor ML on your units.
4-week pilot at no license cost. We baseline your compressor fleet by Day 7.