Maximizing Reliability Through Connected Insights
Industrial remote monitoring gives operations and maintenance teams greater visibility into compressors and other rotating equipment between routine inspections and service visits. By collecting operating data from compatible controllers, sensors, gateways, and connected devices, remote monitoring systems can help facilities identify changing conditions, review equipment performance, and respond to developing problems.
Relevant Solutions helps customers evaluate remote monitoring options based on their installed equipment, controller capabilities, communication requirements, maintenance program, and operational priorities.
Depending on the equipment, the appropriate solution may include a manufacturer-specific platform, ProCura IoT Asset Management, or another controller-based monitoring option.
Improve Equipment Visibility Between Site Visits
Industrial equipment conditions can change between scheduled inspections. Temperatures may increase, operating pressures may shift, alarms may become more frequent, or maintenance intervals may approach without being immediately visible to personnel responsible for the equipment.
Remote monitoring can provide access to available operating data through an online dashboard or connected control system. Depending on the equipment and platform, monitored information may include:
- Equipment operating status
- Run hours and load conditions
- Pressure and temperature readings
- Fault codes and active alarms
- Maintenance intervals
- Equipment performance trends
- Energy or power-related data
- Historical operating information
The available data depends on the equipment manufacturer, model, controller, sensors, network connection, and monitoring platform. Relevant Solutions can review the installed system and help determine which information can be collected and how it can support maintenance decisions.
Remote Monitoring Capabilities
A remote monitoring system should provide information that maintenance and operations teams can use without adding unnecessary complexity. The capabilities available will depend on the connected equipment, controller, sensors, communication method, and selected monitoring platform.
Equipment Status and Operating Data
Remote monitoring provides maintenance and operations personnel with access to current equipment information without requiring someone to be physically present at the machine.
This can be especially useful for equipment installed in remote areas, facilities with limited maintenance staffing, or operations managing multiple equipment locations.
Alerts and Notifications
Compatible systems can notify designated personnel when alarms, fault codes, or abnormal operating conditions are detected. Notifications may be delivered through email, text message, an online portal, or an existing control system, depending on the selected platform.
Alerts help bring attention to developing conditions, but they should be configured around the equipment and application. Too many unnecessary alerts can make it difficult to identify the conditions that require immediate attention.
Historical Trends and Performance Review
Historical data can help maintenance teams compare current operation with previous equipment performance. Reviewing trends may help identify recurring alarms, changing operating conditions, unusual load patterns, or gradual performance deterioration.
Trend information can also provide useful context when troubleshooting equipment. Instead of relying only on the condition observed during a service visit, technicians may be able to review how the equipment was operating before the problem occurred.
Maintenance Planning
Operating hours, maintenance intervals, alarm history, and equipment condition data can support more informed maintenance planning. Remote monitoring may help facilities schedule service before a minor issue becomes more disruptive, prepare required parts in advance, and coordinate maintenance around production requirements.
Remote data should support, rather than replace, preventive maintenance, physical inspections, oil or fluid analysis, vibration testing, and other condition-assessment practices.
Equipment That May Be Monitored
Remote monitoring can be applied to a range of compressors and rotating equipment when compatible operating data is available. The recommended approach should reflect the asset type, process importance, failure risk, and level of visibility the facility needs.
Industrial Air Compressors
Air compressor remote monitoring can provide visibility into compressor status, pressures, temperatures, run hours, loading conditions, alarms, and maintenance requirements when those data points are available through the installed controller.
Monitoring can be applied to an individual compressor or incorporated into a broader compressed air system strategy. The appropriate scope depends on the compressor type, controller, system configuration, and operational goals.
Blower and Vacuum Systems
Compatible blower and vacuum equipment may also support remote collection of operating conditions, fault information, and performance data. Monitoring can be particularly valuable when equipment operates continuously or supports processes where an unexpected shutdown could interrupt production.
Pumps and Other Rotating Assets
Pumps and other rotating equipment may be monitored using existing controllers or additional sensors for parameters such as vibration, temperature, pressure, motor condition, or operating status. Compatibility and the practical value of the collected data should be evaluated for each application.
Remote Monitoring Platform Options
Remote monitoring is not limited to one platform. The right solution depends on the manufacturer, equipment age, controller capabilities, communication infrastructure, cybersecurity requirements, and information the facility needs to collect.
Relevant Solutions can help evaluate whether an existing controller already provides the necessary functionality or whether an additional gateway, sensor package, or monitoring platform should be considered.
ProCura IoT Asset Management
ProCura IoT Asset Management remains available for selected industrial monitoring applications. The platform can collect information from compatible equipment and present operating data, notifications, analytics, and reports through an online portal. ProCura may be considered when a facility needs a broader monitoring approach that is not limited to one compressor manufacturer. Equipment compatibility, required hardware, available data points, communication methods, and implementation scope should be confirmed before selecting the platform.
Controller-Based Monitoring Options
Many modern compressors and rotating equipment packages include controllers capable of recording operating information, displaying alarm histories, or communicating with external monitoring systems. Depending on the equipment, controller-based monitoring may provide the required visibility without introducing a separate asset-management platform. Relevant Solutions can review controller capabilities, available communication protocols, connectivity requirements, and the desired monitoring scope.
Gardner Denver iConn
For Gardner Denver compressors equipped for the platform, iConn provides another remote-monitoring path with secure cloud-based data collection, real-time fault notifications, machine-performance insights, and preventive maintenance reminders. Relevant Solutions can help determine whether ProCura, Gardner Denver iConn, or another controller-based option is the appropriate fit for the installed equipment.
Turning Remote Data Into Maintenance Action
Remote monitoring is most valuable when the collected information supports a defined maintenance and response process. Receiving an alert is only the first step. Maintenance personnel must still understand the condition, determine its urgency, and decide what corrective action is appropriate.
Relevant Solutions can help customers use available monitoring information to:
- Review compressor and rotating equipment alarms
- Evaluate operating and performance trends
- Identify equipment requiring further inspection
- Plan preventive or corrective maintenance
- Prepare replacement parts and consumables
- Document recurring operating problems
- Confirm equipment performance following service
- Develop longer-term equipment reliability plans
Gardner Denver and Champion compressor owners can also use Relevant Solutions for service, preventive maintenance, parts, and operating follow-up within applicable coverage areas. Select compressor parts and monitoring-related products may be available through Shop Relevant as inventory is added.
Selecting a Remote Monitoring Solution
Before recommending a remote monitoring approach, Relevant Solutions considers the equipment and the way it is used. Important evaluation factors may include:
- Equipment manufacturer, model, and age
- Existing controller and communication capabilities
- Available sensors and operating data
- Critical alarms and notification requirements
- Internet, cellular, or facility network availability
- Cybersecurity and access requirements
- Number and location of monitored assets
- Maintenance responsibilities and response procedures
- Reporting and historical data requirements
- Future equipment or system expansion plans
This evaluation helps determine whether the facility should use ProCura, Gardner Denver iConn, an equipment controller, or another available monitoring method.
Remote Monitoring as Part of Equipment Reliability
Remote monitoring can provide earlier visibility into changing equipment conditions, but it does not prevent every failure or eliminate the need for qualified maintenance personnel. Sensors, controllers, communication devices, and monitoring platforms must also be installed, configured, and maintained correctly.
A complete equipment reliability program may combine remote monitoring with routine inspections, preventive maintenance, predictive diagnostics, operating reviews, parts planning, and emergency service support.
Relevant Solutions works with industrial facilities to identify a practical monitoring scope based on the equipment, operating risk, maintenance resources, and available technology.
Discuss Your Remote Monitoring Requirements
The first step is understanding the installed equipment, the available controller data, and the conditions your team needs to monitor. Relevant Solutions can review your compressor or rotating equipment system and help identify an appropriate remote monitoring approach.
Contact our team at Relevant Solutions to discuss ProCura, Gardner Denver iConn, controller-based monitoring, equipment service, preventive maintenance, or replacement parts.
Remote Monitoring Frequently Asked Questions
Can Existing Compressors Be Monitored Remotely?
Does Remote Monitoring Replace Preventive Maintenance?
No. Remote monitoring provides additional equipment visibility, but scheduled inspections, consumable changes, testing, and other preventive maintenance activities are still required.
Which Remote Monitoring Platform Should We Use?
The appropriate platform depends on the installed equipment and the information the facility needs. Relevant Solutions can help compare ProCura, Gardner Denver iConn, and other compatible controller-based options.