Lube Oil Cooler Fault Detected During Routine Monitoring
An expanded monitoring round identified a partially broken belt tensioner before fan or compressor operation was disrupted
Oil & GasProducts used
Machine Sentry Fixed MSF2 Machine Sentry Mobile MSM2 Machine Sentry Next Generation Software
Working to Achieve
Enhancing asset reliability through proactive diagnostics and expanding monitoring scope based on field observations.
The Challenge
During a monthly inspection round at a North European compression platform, an unusual sound was detected near the Lube Oil Coolers, equipment not included in the standard measurement route. These coolers are essential for maintaining optimal operating conditions, and failure could compromise compressor performance and safety.
Our Approach
AVT Reliability® extended the scope of the inspection based on field observations. Using Machine Sentry® sensors, vibration data was collected from the accessible motor and surrounding framework. Remote analysis identified anomalies, prompting a targeted inspection. Although the coolers weren’t part of the original monitoring plan, their simplicity allowed for quick inclusion and data capture.
Our Findings
Despite limited access (only the e-motor was physically reachable), verification measurements were carried out on all six coolers.
Vibration analysis revealed abnormal readings, but the e-motor was ruled out as the source. Due to missing technical data on the fan, AVT advised a thorough visual inspection. This revealed a partially broken belt tensioner, which was removed. A follow-up baseline measurement confirmed restored condition. Further investigation showed the tensioner had been added due to excessive belt wear caused by frequent start/stop cycles and slippage.
The Solution
The faulty tensioner was removed, and the system returned to optimal condition. AVT advised installing soft starters or VSDs to reduce belt stress during startup. Additionally, MSF sensors were recommended for continuous monitoring of fan bearings to prevent recurrence.
Follow-Up
If left unresolved, the damaged tensioner could have led to belt failure, fan malfunction, and potential compressor shutdown resulting in costly downtime. The proactive approach prevented this and highlighted the value of expanding monitoring scope based on real-time observations
"This case shows how flexibility in monitoring and collaboration with the crew can uncover hidden risks and prevent future failures. "
Project Lead, AVT Reliability®
At a Glance
- INDUSTRY: Oil & Gas / Energy
- PROCESS: Gas compression and cooling
- EQUIPMENT: Lube Oil Coolers, Fan Assemblies
- PRODUCTS: Machine Sentry® sensors
- SERVICES: Remote diagnostics, vibration analysis
