In the era of Industry 4.0, industrial telemetry has become a mainstay for real-time monitoring of critical rotating equipment such as turbines and compressors. This technology makes it possible to collect, transmit and analyze key data on the operational status of machinery, improving energy efficiency, reducing unexpected failures and extending equipment life.
These machines are important in power generation, petrochemical production and large-scale manufacturing, requiring continuous and accurate monitoring to maintain performance and avoid failures. Telemetry provides real-time data on operating variables such as temperature, vibration, pressure and rotational speed, enabling predictive maintenance and efficiency optimization.
What is industrial telemetry?
Industrial telemetry refers to the remote measurement and transmission of data from equipment operating in various industrial conditions. It allows predictive maintenance teams to receive significant information without the need to be physically present on site, which speeds up diagnosis and early detection of faults. It is based on a network of sensors, transmitters and processing systems through which variables are analyzed in real time. Data can be visualized through SCADA systems, mobile applications or cloud platforms.
Industrial telemetry is a remote monitoring system that collects data from sensors installed on machinery or industrial processes, sending it to a central analysis station through wired or wireless networks. Data such as pressure, temperature, vibration, flow, position, among other physical and electrical parameters.
This technology is essential for predictive maintenance systems, real-time operational control in rotating equipment such as turbines and compressors.
Telemetry in industrial turbines
Telemetry applied to industrial turbines allows the collection and transmission of real-time operating data, such as temperature, pressure, vibrations and rotational speed. This technology is based on a network of sensors strategically located in the machinery, which send continuous information to remote monitoring systems. In this way, a detailed view of the turbine’s behavior during operation is obtained, which facilitates performance analysis and early detection of deviations or potential failures.
Turbines (gas, steam or hydraulic) are high-speed and high-power equipment, where small variations in operating conditions can cause severe damage. Telemetry allows on-line monitoring of variables such as: inlet and outlet temperatures, shaft speed, bearing vibrations, steam, or gas pressure.
In addition, the use of piezoelectric and optical sensors in turbines allows detecting imbalances, alignment problems and signs of cavitation, activating preventive alarms or stopping the equipment automatically to avoid considerable failures. Integration in industrial environments represents a key step towards efficiency, operational safety and digitization of power generation and conversion systems.
Telemetry in industrial compressors
Telemetry applied to the remote monitoring of industrial compressors, whether centrifugal, screw or piston, allows real-time supervision of critical parameters such as discharge pressure, operating temperature, lubrication system status and wear on components such as valves or rotors. This equipment, essential in industries such as petrochemical, food and energy, requires continuous monitoring to ensure efficiency and avoid unexpected failures that could affect production or compromise operational safety.
Through the use of intelligent sensors and advanced analytical algorithms, telemetry facilitates the early detection of anomalies and the identification of failure patterns. This information allows operational adjustments to be made and maintenance interventions to be planned proactively, without resorting to frequent manual inspections. As a result, compressor availability is increased, operating costs are reduced and equipment lifetime is extended in an increasingly automated and energy-efficient industrial environment.
Telemetry solutions for industrial control and monitoring
SCADA: Efficient monitoring for industrial processes
The Supervisory Control and Data Acquisition (SCADA) system is an essential tool in the era of automation and industrial digital transformation. Designed to collect, analyze and visualize data in real time, SCADA integrates hardware and software components to provide process monitoring and control in sectors such as oil and gas, energy, food, pharmaceuticals, water and advanced manufacturing.
Through sensors, PLCs/RTUs and HMI interfaces, it is possible to monitor operational failures, activate alarms and optimize energy resources. Its architecture converts operational data into strategic information, eliminating information silos and improving operational efficiency.
Implementing SCADA not only reduces costs and maintenance times, but also aligns production with sustainability objectives. Its value lies in facilitating decisions based on reliable data, extending the useful life of assets and boosting productivity in smart industrial environments.
Temperature sensors: key to safety
Temperature sensors are fundamental in industrial telemetry. They help prevent overheating damage to motors, bearings, mechanical seals and cooling systems.
Most common types:
- RTDs (Resistance Temperature Detectors)
- Thermocouples (Type J, K, T)
- Infrared (non-contact) sensors
In combination with telemetry, these sensors provide continuous data to monitor critical areas, preventing fires or losses due to unexpected shutdowns.
Piezoelectric sensors and mechanical vibration
Piezoelectric technology converts mechanical vibrations into electrical signals, allowing to:
- Monitor rotational imbalances
- Detect bearing failures
- Measure impact peaks in dynamic systems
These sensors are significant for the proper operation of compressors and turbines because they detect with high sensitivity even small irregularities, most of the time invisible to other types of sensors.
Benefits of telemetry in rotating equipment
The integration of telemetry systems in rotating equipment such as compressors, turbines and industrial pumps significantly improves predictive maintenance management. This technology allows the collection and analysis of operational data in real time, facilitating the continuous monitoring of critical variables such as vibration, temperature, pressure, and energy consumption.
Key benefits of this technology include:
- Early detection of faults: Sensors identify subtle deviations in equipment behavior, allowing intervention before major failures or unscheduled shutdowns occur.
- Maintenance optimization: Continuous data analysis allows scheduling interventions only when necessary, eliminating unnecessary maintenance and reducing corrective tasks.
- Extending equipment life: By operating within their optimal ranges, equipment suffers less premature wear and tear, prolonging their operation and delaying the need for replacement.
- Data-driven decision-making: Telemetry provides constant and reliable information, allowing maintenance managers to prioritize actions based on the actual condition of the equipment.
- Reduced operating costs: By preventing failures, reducing downtime and optimizing resources, telemetry helps to significantly reduce the costs associated with reactive maintenance.
Telemetry transforms traditional maintenance into a dynamic, intelligent and reliability-focused process. Its implementation not only improves productivity, but also turns predictive maintenance into a strategic ally for modern industry.
Conclusion
The integration of industrial telemetry with advanced sensors is changing the way industrial turbines and compressors are monitored and maintained. This approach optimizes equipment operation, protects strategic assets and improves industrial profitability. The transition to intelligent and connected platforms is no longer an option, but a necessity for industries seeking sustainability, competitiveness and operational excellence.
References
- Mechanical Solutions, Inc. (2025). Centrifugal compressor impeller strain measurement via FM telemetry: case study. Retrieved from https://www.mechsol.com/case-study/strain-measurement-of-a-centrifugal-compressor-impeller-via-fm-telemetry
- Meyer, A., & Brodbeck, B. (2020). Performance fault detection in wind turbines by dynamic reference state estimation. arXiv. Retrieved from https://arxiv.org/abs/2005.00370
