Compressor Health Monitoring
Compressors are the highest-criticality machines on most process plants. Fizix detects valve leaks, bearing defects and surge precursors before they cause an unplanned shutdown or a safety incident.
What Fizix Detects on Your Compressors?
Each fault leaves a distinct signature across vibration, acoustic emission, magnetic flux or temperature. Fizix catches them weeks before failure — and tells you which smart multi-sensor device saw it.
Valve Leaks & Failures
Leaking suction/discharge valves detected by acoustic emission — nearly invisible to vibration analysis.
Bearing Failures
Main, rod and crosshead bearing defects with full defect-frequency analysis.
Piston Rod & Ring Wear
Wear in reciprocating rod packing and rings identified before it scores the cylinder.
Rotor Imbalance & Misalignment
Centrifugal rotor defects causing vibration and efficiency loss.
Surge & Stall Precursors
Early aerodynamic instability in centrifugal compressors detected before full surge.
Lubrication Failure
Acoustic emission detects oil starvation at bearing surfaces before damage occurs.
Structural Looseness
Foundation, coupling and skid looseness driving abnormal vibration levels.
Thermal Anomalies
Overheating from inter-stage cooling failure, blocked passages or overload.
Built for Where Compressors Live
The most critical compressors sit in hazardous, classified areas where standard electrical gear is banned — and their deadliest fault, a leaking valve, is nearly silent to vibration. Fizix answers both: acoustic emission that hears valve leaks, and an ATEX-certified sensor rated for the zone.
Leaking suction/discharge valves lose efficiency and build heat with little vibration — caught weeks early on acoustic emission.
Permanent install on gas compressors and flare blowers with no hot-work permits or safety-classification impact.
Standards-based alarm setpoints and severity levels for machine-protection compliance.
Compressors That Fail Take Everything With Them
Compressors are typically the highest-criticality rotating machines on a process plant. An unexpected failure shuts the whole line down — and in oil & gas or chemical facilities it creates serious safety risk.
Reciprocating compressors have valves that fail silently: a leaking valve loses efficiency and builds heat with little obvious vibration. Centrifugal compressors can surge catastrophically without warning. Both have bearing systems that degrade in ways only the right sensing catches.
Fizix addresses every failure mode: 80 kHz acoustic emission detects valve leaks and early lubrication failure; high-frequency vibration catches bearing defects and rotor instability; temperature identifies thermal faults. For classified areas, the ATEX-certified sensor is rated for Zone 1 and Zone 2.
COMPRESSOR TYPES SUPPORTED
One Platform, Value For Every Role
From the boardroom to the shop floor, compressor monitoring delivers something different — and useful — to everyone who keeps production running.
Plant & Reliability Leaders
Turn unplanned compressor failures into planned, budgeted work
A clear ROI and payback you can take to finance and the board
Fleet-wide visibility across every compressor — one plant or many
Lower safety exposure and fewer emergency interventions
Predictable spend, less capital tied up in spares
Operations & Production Teams
Keep the line running — no process interruption to install
A simple health score per compressor, readable without expertise
Alerts before a trip, so you shut down on your terms
Know which asset actually needs attention first
Web & mobile dashboards for the whole shift team
Maintenance & Reliability Engineers
Pinpoint the fault type and location on each compressor
Plan repairs into routine stops, not emergencies
Order the right spare at the right time — no over-stocking
Guided diagnostics without deep vibration expertise
Remote checks — fewer trips into hot, hazardous zones
Reactive Maintenance vs Fizix
Most plants still run compressors on calendar schedules and walk-around checks. Here's what changes when your compressors talk to you.
See What Fizix Could Save You
Move the sliders to match your compressor fleet. This is an indicative estimate — book a free consultation for a validated, site-specific business case.
Defaults reflect a typical compressor-heavy plant. Adjust to your own figures.
Based on Fizix reference outcomes: up to 50% less downtime, 35% lower maintenance cost, ~134 kg CO₂/day per 200 kWh motor. Indicative only.
From Smart Multi-Sensor Device to Insight
An end-to-end solution connecting your compressors to actionable intelligence in real time — installed in minutes, with no process interruption.
Mount in <15 min
ATEX-certified sensor installs on the frame, cylinder or bearing — no hot-work permit.
Hear the valves
80 kHz acoustic and vibration captured 24/7 across every stage.
Valve + surge + twin
Mate detects valve leaks, surge precursors and bearing faults, stage by stage.
Standards-based alerts
ISO 10816 / API 670 severity levels drive alarms your protection standards recognize.
How Fizix Protects Your Compressors?
Smart multi-sensor devices in the field capture four signals — analyzed on the cloud-based Fizix Mate platform.
Valve-Leak Detection
Leaking valves are nearly invisible to vibration but generate strong 80 kHz acoustic emission — detected weeks before energy loss and heat damage escalate.
Prevent Catastrophic Surge
Early aerodynamic instability in centrifugal units appears in vibration before full surge. Fizix alerts operators with time to act.
Efficiency Monitoring
Valve degradation, worn rings and bearing inefficiency all cut efficiency. Trending reveals the onset before energy cost and overheating rise.
Multi-Stage Support
A single installation can cover multiple compressor stages — each monitored independently with its own health indicators.
Standards Compliance
Mate displays ISO 10816 / API 670 severity levels, supporting compliance with machine-protection and alarm-setpoint standards.
Remote for Unmanned Sites
Offshore platforms, pipeline stations and gas-gathering facilities are monitored centrally, eliminating costly routine site visits.
What We Detect & Measure?
Fizix combines multiple measurement technologies to give complete compressor health visibility.
Acoustic Emission
Valve leaks and lubrication failure up to 80 kHz.
Vibration Analysis
Bearing, rotor and looseness faults up to 26.6 kHz.
ISO/API Severity
ISO 10816 / API 670 severity levels and setpoints.
Temperature
Inter-stage and bearing thermal fault detection.
RPM Estimation
Speed tracking for load-normalized trending.
Statistical Indices
RMS, Crest Factor, Kurtosis, Peak — on-device.
Fizix Smart Multi-Sensor Devices for Compressor Monitoring
Choose the right smart multi-sensor device for each compressor's criticality and environment.
Best for Critical Assets
Wired power for 24/7 continuous streaming. For high-criticality assets where any downtime is unacceptable.
Best for Important Assets
Battery-powered with up to 5-year life. ATEX-certified for hazardous areas. Wireless and quick to install.
Best for Balance-of-Plant
Bluetooth, compact and economical. Ideal for monitoring many assets across a facility cost-effectively.
Impact on Compressor Reliability
Typical outcomes reported across Fizix deployments. Actual results vary by asset condition and baseline.
Figures reflect "up to" improvements observed across Fizix installations and the 200 kWh reference calculation for CO₂. Company-wide figures (150M+ monitoring hours, 40,000+ connected machines, 18+ sectors) are as of 2025. Asset-specific results should be validated during a pilot.
Compressors fail quietly.
A single Fizix smart multi-sensor device captures 3-axis vibration, acoustic emission, magnetic flux and temperature. For compressors, acoustic emission is decisive — a leaking valve barely moves the vibration needle but rings clearly at 80 kHz.
Data streams to the AI-powered Mate platform, where a digital twin and fault library classify valve, bearing, surge and thermal faults against ISO 10816 / API 670 severity levels.
Request a Free Expert Consultation
Tell us about your compressors and what you want to protect. A Fizix specialist will get back to you within one business day to discuss your goals and outline a tailored path forward — with no obligation.
Free 1:1 consultation with a reliability expert
Assessment of your critical compressors
Tailored sensor & Mate platform recommendation
Optional pilot to prove ROI before scaling
Your Compressors Are Too Critical to Leave Unmonitored
One avoided compressor failure can save more than your entire monitoring investment. Talk to Fizix about protecting your most critical machines.
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