All case studies
Condition monitoring in a zone-rated environment
Midstream gas operator · 2 terminals · 60 rotating assets · 12 months
Measured outcomes
- -38%
- Unplanned shutdown hours
- 6 wks
- Average fault lead time
- -27%
- Manual inspection rounds
- 0
- Hazardous-area exceptions
Starting point
Rotating equipment was checked on a quarterly route with handheld analysers. Between rounds, developing bearing faults were invisible, and hazardous-area rules limited what could be installed.
“We now plan interventions during scheduled windows instead of reacting to trips.”
What we deployed
- Ex-certified wireless vibration and temperature sensors on critical assets
- Intrinsically safe gateways with segregated OT network design
- Anomaly models trained per asset class with engineer-reviewed thresholds
- Integration into the existing maintenance planning workflow
What changed
- Bearing and misalignment faults caught weeks before failure
- Fewer man-hours spent inside hazardous areas for routine data collection
- Maintenance shifted from fixed intervals to asset condition
Client names are withheld under commercial confidentiality; figures are drawn from post-deployment reviews agreed with each client.
