Early, Automatic, Online Failure Detection In December 2007, the online monitoring system avoided a major and cost- intensive damage at one compressor. The permanent piston rod position monitoring detected a cracked respectively a virtually broken piston rod at the 1st stage. Prior to a complete rod failure, the machine had been automatically stopped and costly consequential damages have been avoided. The urea plant operates, besides others, two Thomassen reciprocating compressors in carbon dioxide (CO 2 ) service. Both compressors are equipped with PROGNOST®-NT since October 2001. In the last years, several machinery failures have been detected by the system such as rider ring wear, loosened components and valve problems. The machines are 4-throw, double-acting, 4- stage horizontal compre

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