Case Study: Early Detection and Prevention of Compressor Failure with Foundation Analytics
Overview.
In remote desert locations, maintaining the continuous operation of critical equipment like compressors is vital but challenging due to the site's isolation and difficulty of access. To ensure that their compressor remained online, a client in the energy sector deployed Intelligent Plant’s Foundation Analytics tool.
Within just three months, the analytics detected an unexpected and potentially catastrophic event. This early detection enabled the client to take swift action, preventing significant damage to the compressor and ensuring continued operation, even in an unmanned and hard-to-reach location.
Challenges.
Operating a compressor in a remote desert environment presents several unique challenges:
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Remote, Unmanned Location: The site is typically unmanned, making it difficult and time-consuming to respond to any operational issues.
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Environmental Extremes: While the desert location usually experiences high temperatures, unexpected environmental shifts can occur, potentially affecting the performance of critical equipment.
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Critical Importance of Continuous Operation: Any failure of the compressor could lead to significant operational downtime, compounded by the challenges of mobilising a team to a remote site.
Solution.
Intelligent Plant deployed Foundation Analytics to continuously monitor the compressor's performance, providing the client with a reliable means of detecting anomalies and ensuring the integrity of their operations.
Key Elements of the Solution:
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Remote Monitoring: Foundation Analytics was implemented to monitor key performance indicators, such as inlet temperature and pressure, without requiring a physical presence on-site.
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Anomaly Detection: The tool was designed to identify deviations from normal operating conditions in real-time, even in the absence of on-site personnel.
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Proactive Alerts: When an anomaly was detected, Foundation Analytics immediately alerted the client, enabling a rapid response to potential issues despite the site's remoteness.
Results and Impact.
Foundation Analytics proved its value by detecting a critical issue just three months after deployment:
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Unexpected Temperature Drop: Although the site is located in a warm desert, Foundation Analytics identified an abnormal drop in the compressor's inlet temperature to below 0°C. This sudden drop was highly unusual for the environment and posed significant risks to the equipment's metallurgical integrity.
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Potential for Severe Damage: The low inlet temperature indicated that the process was not functioning as expected, raising the risk of liquid dropout and cavitation within the compressor and its associated components. Such conditions could lead to severe damage if not promptly addressed.
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Rapid Response and Prevention: Despite the site being unmanned and difficult to access, the early detection allowed the client to dispatch a team quickly. The issue was identified and rectified before any major damage occurred, preventing a potentially catastrophic failure and ensuring the compressor remained operational.
Foundation Analytics provides clear alerts to users when there is a shift from normal operation
Conclusion.
The successful deployment of Foundation Analytics in a remote desert environment underscores the importance of advanced monitoring tools for ensuring the reliability of critical equipment. By providing real-time insights and early detection of anomalies, Foundation Analytics enabled the client to take preventive action, avoiding significant damage and costly downtime.
This case study highlights the effectiveness of Intelligent Plant’s solutions in maintaining operational integrity in challenging and remote locations. The client’s ability to quickly identify and address a critical issue demonstrates the value of continuous monitoring and the proactive management of assets, even in the most inaccessible environments.