Transforming compressor maintenance through AI and digital innovation 

Digital services are reshaping compressor care with real-time data insights extending maintenance intervals. This reduces production interruptions, helping our customers to save costs.

A comprehensive portfolio for condition-based maintenance

Our broad portfolio of digital solutions now supports compressor operators in understanding machine behavior and planning maintenance with greater accuracy. Live operating data is collected, captured and translated into clear, condition-based guidance, extending MTBO and reducing production interruptions. Through intuitive dashboards, operators can follow compressor system conditions in an easily understandable manner. When a machine alarm is triggered, the system provides recommended next steps, and our technical support hot line is available 24/7 to help evaluate findings. Regular compressor health reports summarize condition trends, flag potential risks, and provide recommended actions for maintenance planning. 

UP! Detect pairs an independent data acquisition unit with high frequency vibration analysis. The collected data is securely transmitted and made accessible via the cloud. By identifying up to 90% of potential component failures at an early stage, the system helps operators avoid the kinds of issues that typically lead to unplanned downtime and extend the MTBO of critical components. As the system evolves, added pressure and proximity sensing will deepen diagnostics and sharpen failure detection further.

For operators needing full spectrum insights, PROGNOST-NT provides 360° condition monitoring with machine protection supported by the new Predictive Intelligence module. Using artificial intelligence, it estimates the remaining lifetime of critical components and indicates how long the machine can continue safe operation without anomalies. When thresholds are reached, PROGNOST^®-SILver ensures machine protection through contextual analysis and emergency shutdown capability.

UP! Insight provides the foundation: a cloud-based solution that captures process data directly from the compressor control system. By analyzing this data in real time, UP! Insight offers automated service recommendations that can shorten troubleshooting and response times by up to 75%.

Compressor reliability is especially critical in marine applications. Here, PROGNOST-NT has become a trusted system for operators seeking stability during long voyages. By combining real-time vibration, pressure, and temperature data with automated diagnostics, it enables early detection of wear in valves and packings (components responsible for most unplanned compressor downtime). Decades of service experience across LNG carriers and other marine applications feed into the system’s algorithms, allowing operators to prevent failures by recognizing subtle patterns well before they become critical. The Remaining Useful Life (RUL) and Projected Availability Span (PAS) algorithms provide clear fore sight into component health at cylinder level. This enables precise planning of maintenance during port calls rather than at sea. As marine operators face increasing pressure to maximize equipment uptime and operate more sustainably, PROGNOST-NT and its AI-augmented Predictive Intelligence module extend component lifetimes and reduce the risks of in-voyage failures. With automated analytics, secure cloud-enabled workflows, and expert validation through the Prediction Validation Service, the system turns compressor data into operational insights, helping ship owners to plan maintenance proactively and operate with greater efficiency and confidence across their fleets.

Across UP! Solutions and PROGNOST-NT, we apply advanced neural networks and deep learning models, including autoencoders, to detect anomalies, automate diagnostics, and predict component failures with accuracy. These models are trained on thousands of operating hours and validated with historical data from compressors in service worldwide, ensuring robustness across industries and machine types. The impact of AI is tangible: earlier failure detection, fewer unplanned shutdowns, and optimized maintenance planning. Customers benefit from extended component lifetimes, reduced operational costs, and improved availability, whether in a plant, gas terminal, or an LNG vessel at sea. Looking ahead, we are expanding these AI models to wards autonomous diagnostic workflows and cross-asset forecasting, enabling even smarter, more adaptive maintenance strategies.