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Early warning saves engine plant from critical downtime

By:

SKYLER

The Challenge

Just 7 days after install, a major fault was detected in a critical air compressor at an engine plant. Real-time monitoring flagged foundation cracks before they led to costly downtime.

Six 500 HP air compressors, critical to plant operations, had sensors added on March 1. Initial health assessment began by comparing overall vibration levels and patterns across all compressors. Within 7 days, one compressor was flagged for elevated velocity RMS vibration levels around 0.7 IPS.

engine-plant-air-compressor
engine-plant-air-compressor_chart-1

The spectral pattern indicated a dominant motor shaft speed peak and a sinusoidal time waveform, both signs of structural looseness. A report was generated and sent to the customer.

Inspection revealed significant cracks in the concrete base beneath the compressor foot. A full rebuild of the compressor base was planned for the next outage. Until the rebuild, fault progression is monitored by Skyler algorithms and certified vibration analysts.

Inspection revealed significant cracks in the concrete base beneath the compressor foot.

A full rebuild of the
compressor base was planned for the next outage.

Until the rebuild, fault progression is monitored by Skyler algorithms and certified vibration analysts.

on-the-ground-monitoring-2

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