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 (illustrative industry figures). 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 (modeled lead times). That is the value of a single catch.
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
The work it triggers
When compressor flags
Frequently asked
What gathering / facility engineers ask.
What compressor failures does WorkSync detect?
Bearing wear (vibration trending), valve issues (suction-to-discharge ratio drift), oil temperature creep, valve-pattern signature changes, and fouling (efficiency drop at a constant operating point).
What does a compressor outage cost?
Illustrative industry figures: an unplanned compressor outage runs $50-500K depending on scale, small gathering unit versus main line. Downstream production is deferred in proportion, often $20-200K/day for the wells routed through it.
What is the lead time versus fixed SCADA thresholds?
Modeled lead times, which vary by signal density and history depth: vibration 1-4 weeks, valve pattern 5-21 days, oil temperature 3-14 days, fouling 1-3 months.
Which compressors does it cover?
Any reciprocating, screw, or centrifugal unit with vibration, temperature, and pressure telemetry. Coverage follows the available tags rather than the nameplate, so a mixed fleet models the same way.
How does it work for gathering versus main line?
Same signatures, different impact math. A gathering compressor outage backs up multiple wells (production deferral). A main-line outage often forces operator-side shut-ins (commercial penalty plus deferral).
What is the ROI math?
Illustrative industry math: one mid-size gathering compressor outage caught 14 days early avoids $300K-1M+ of deferred production depending on the wells routed through it. That is the value of a single catch.
See compressor ML on your units.
4-week pilot on the stack you already own. Pick one station. Day 7 we baseline your compressor fleet. Day 28 you decide, under the Impact Guarantee: we charge when your number moves.