Oil & Gas Remote Asset Monitoring Solutions
Smarter Engine Monitoring & Asset Performance Analytics for the Oil & Gas Industry
Monico Monitoring empowers oil & gas operators to maximize uptime, reduce costly failures, and maintain full visibility across remote and distributed assets. From midstream gas compression to rig power monitoring and frac truck integration, our IP 66 and IP67 hazardous location rated, pre-configured gateways deliver reliable data access and control across your entire operation.
Purpose-built for the harsh conditions of oilfield environments, Monico systems support a wide range of industrial protocols, engine controllers, and SCADA architectures, with direct data integration to most leading IoT platforms — delivering actionable insights that enhance reliability, performance, and operational awareness.
For multi-device operators, Monico’s device management platform provides centralized visibility, device health monitoring, configuration management, and remote firmware updates across entire fleets, simplifying oversight and reducing maintenance effort.
With Monico Gateways, oil & gas teams can:
- Continuously monitor engine and compressor performance in real time
- Log high-resolution data for diagnostics, condition-based maintenance, and failure analysis
- Minimize field visits through secure remote access, diagnostics, and analysis
- Receive automated notifications — including shutdown alerts, critical alarms, and performance events — via email or SMS
- Seamlessly integrate with PLCs, SCADA, and automation systems through supported protocols including Modbus, OPC, J1939, and other industrial standards
- Access and decode standard and OEM-defined J1939 parameters for enhanced engine data visibility
From offshore and land-based drilling rigs to remote compressor stations and frac operations, Monico delivers field-proven, integration-ready data acquisition and monitoring solutions that scale from edge to cloud — empowering operators to enhance uptime, visibility, and overall asset performance.
mGuard® CompressorWatch
Your Compressor’s Early Warning System
Avoid costly shutdowns and unplanned service.
mGuard® CompressorWatch is Monico’s proprietary, cloud-hosted analytics application purpose-built for industrial compressor reliability. Developed by Monico subject matter experts using AVEVA™ PI System technology and deployed on Microsoft Azure, CompressorWatch applies rules-based analytics for condition-based maintenance. Operating exclusively on the MonicoLive™ platform, it continuously analyzes real-time compressor data, offering automated analytics that assist operators with actionable recommendations — enabling proactive maintenance action before failures occur.
Compression and Natural Gas Monitoring Systems
One of the most common applications for Monico Gateways is in natural gas compression systems used throughout midstream gathering and pipeline operations. The majority of these units utilize natural gas-fueled reciprocating engines driving reciprocating compressors. Monico Gateways not only monitor the engines directly—without the need for intermediary devices—but can also provide engine data to the compressor controller as well as collect data from the compressor controller, delivering a unified view of real-time, time-stamped engine and compressor data.
Key Capabilities:
- Bidirectional Communication: Gateway pushes engine data to the compressor controller and reads compressor data back—enabling seamless coordination between engine and compression logic.
- SCADA-Ready Interface: Provides a unified interface to seamlessly present consolidated engine and compressor data to SCADA or PLC-based control systems.
- Real-Time Logging: Capture high-resolution performance data for preventive maintenance, condition-based diagnostics, and failure analysis.
- Virtual HMI Access: Access live data—including fault codes—over a secure LAN connection, reducing reliance on on-site displays or manual checks.
- Automated Alerts & Shutdown Notifications: Configure alarms and shutdown alerts via email or SMS for faster response and reduced downtime.
- Freeze Frame Diagnostics: Leverage onboard data logging to perform snapshot analysis of abnormal operating events.
- Proactive Maintenance & Failure Prevention: Enable preventive intervention by identifying anomalies before they lead to costly downtime or component damage.
- Asset Tracking & Management Optimization: Use logged performance data to inform long-term asset planning, lifecycle management, and resource allocation.
- Remote Station Monitoring: Safely manage unmanned or hard-to-reach sites while reducing unnecessary travel and truck rolls.
Why Monico Gateways for Natural Gas Compression?
Since launching in 2007, Monico has deployed over 5,000 Gateways in natural gas compressor applications globally. Our systems offer unmatched protocol support—communicating directly with engine controllers, compressor control systems, PLCs, and SCADA platforms—all from a single device.
Our flexible architecture enables:
- Unified Data Handling: A single Gateway pulls engine and station data, integrates with the compressor controller, and provides a single SCADA-facing interface.
- Reduced Latency: Eliminate unnecessary hops in the data path, increasing speed and reliability over legacy serial networks.
- Scalable Configurations: From basic integration to advanced logging with Gateway PLUS™, we support fleet-wide standardization.
The mCore® SDR flagship gateway integrates engines, compressors, station-level PLCs, and SCADA into a single high-speed interface, pushing engine/compressor data to the PLC while pulling station data (flow, pressures, etc.) for a unified upstream feed. With advanced edge processing and sub-second performance, mCore® SDR eliminates multiple devices and serial bottlenecks—delivering dramatically faster speed for new deployments. Supported legacy Monico gateways remain reliable for existing installations.
Every mCore® SDR includes real-time data logging (up to 200 Hz) and synchronized time-stamping as standard features. While serial SCADA networks limit true real-time collection to slow polling for long-term trending, mCore® SDR captures engine, compressor, and station data—like suction pressures—in one integrated, time-aligned file for powerful failure analysis. Customers on legacy Monico gateways can enable PLUS logging via firmware updates or upgrade to mCore® SDR for next-gen edge analytics and storage
Case Study: Real-Time Logging Prevents Recurring Failures
A midstream operator experiencing frequent cylinder liner failures—costing $14,000 per incident—found no root cause through SCADA polling every 2–3 minutes. Monico installed a Gateway PLUS™ that captured 60 engine and 20 compressor parameters every three seconds, storing 200 daily log files in a rotating memory buffer.
The result? Real-time data revealed intermittent coolant spikes linked to the failures—insights traditional SCADA missed. The operator rolled out Gateway PLUS™ units across their 100+ engine fleet, significantly reducing failures and improving reliability.
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The Role of Monitoring in Industrial Automation
Offshore and Onshore Drilling Applications
Reliable Engine Monitoring for Critical Rig Power
Drilling rigs are one of Monico’s most established applications, with generator engines that often lack integration with rig automation systems. Most gensets provide only basic local monitoring—leaving operators blind to performance, fuel usage, and emerging faults.
Monico Gateways deliver real-time engine visibility, reduce blackout risk, and support fuel and maintenance optimization. Our proven success in this demanding environment comes from rugged hardware, deep integration expertise, and trusted support.
Key Capabilities:
- Rig Power Efficiency: Monitor genset performance and electrical load balance to prevent rig blackouts and downtime.
- Event Logging & Diagnostics: Capture engine diagnostics and system events for fast root cause analysis and long-term reliability planning.
- Fuel Economy Optimization: Track fuel consumption by engine to develop strategies that reduce cost and emissions.
- Predictive Maintenance: Log engine hours and operational events to drive preventive maintenance and reduce unplanned outages.
- Virtual HMIs: Access live data—including fault codes—over LAN for each engine, improving situational awareness.
- Automated Notifications: Configure SMS and email alerts for shutdowns, alarms, or performance thresholds.
Proven Success in Rig Automation
Monico Gateways are now standard equipment on many newbuild drilling rigs and retrofitted on over 150 legacy rigs for a major contractor. With over 1,500 Gateways installed across the North American onshore drilling market, our systems integrate generator engine data into rig automation platforms or SCADA systems for real-time and historical insight.
One major contractor reported that engine integration using Monico Gateways virtually eliminated rig blackouts and significantly reduced fuel costs—proof of the power of integrated monitoring and control.
Engineered for Harsh Electrical Environments
Drilling rigs pose extreme challenges for data communications. Powerhouses house variable frequency drives (VFDs) and high-current wiring that generate significant electrical noise. Monico’s experience in this environment ensures reliable operation with best-in-class noise mitigation strategies, including:
- Isolated repeaters to prevent electrical interference on comm lines
- Proper grounding and drain wire management for engine and cable shielding
- Multi-protocol support across ports:
- (2) RS-232
- (1) RS-485
- (1) Ethernet port supporting 4 protocols simultaneously
- Dedicated genset interface with options for I/O expansion (analog & digital)
- Direct integration with Allen-Bradley, GE Fanuc, Siemens, Omron, and Woodward control systems
This robust architecture enables seamless integration of generator data into rig-wide automation systems while ensuring reliable communication—even under the most demanding conditions.
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Remote Monitoring for Oil & Gas Completions
Frac operations place intense demands on engines and transmissions. Monico Gateways are widely used in frac truck monitoring systems to provide real-time visibility, advanced control inputs, and reliable protection for critical equipment.
Integrated Control for High-Pressure Applications
Our J1939 Gateways support control commands for torque converter lockup, engine start/stop (normal and emergency), and engine speed regulation. Monico’s ability to interface simultaneously with Modbus, Allen-Bradley, GE Fanuc, Siemens, and Omron PLCs makes us a proven solution for complex frac operations involving multiple control layers.
Proprietary PGN Support Sets Us Apart
Frac fleets often rely on OEM-specific features communicated through proprietary J1939 PGNs. Monico’s deep expertise in implementing these protocols enables advanced control strategies, including safety-critical features like Caterpillar®’s Kickout to Neutral—which automatically shifts transmissions to neutral when pressure thresholds are exceeded, protecting pumps and engines from costly damage.
In these high-pressure, high-risk environments, Monico’s systems help operators reduce failure points, extend asset life, and maintain control over mission-critical frac operations.
Why Monico
Key Advantages for Oil & Gas Operators
Full control of your data
Your operational data stays in your hands—securely collected, stored, and transmitted without vendor lock-in or third-party access restrictions. You own the insights, the history, and the decision-making power, because in this industry, actionable intelligence and operational independence are critical.
Preconfigured for the field – no custom coding
Monico solutions are engineered for deployment in harsh, high-stakes environments—without requiring in-house developers or custom integration work. Each Gateway ships preconfigured for your specific engines, compressors, or frac equipment, enabling rapid deployment and faster ROI.
Built for real-world operators
Designed with field teams and operations managers in mind, our interface makes it easy to visualize engine performance, monitor alarms, and pull diagnostics—whether you’re at a central control center or remote compressor station. No steep learning curve, just intuitive, actionable data.
OEM-agnostic with broad protocol compatibility
Oil and gas fleets run on mixed equipment—from CAT® to Waukesha®, Siemens to Allen-Bradley. Monico Gateways are built to work across them all, with out-of-the-box support for Modbus, J1939 (including proprietary PGNs), Allen-Bradley, GE Fanuc, Siemens, Omron, and more. We simplify integration, even across legacy systems.
FAQs
Frequently Asked Questions
What types of oil & gas operations benefit from Monico Monitoring?
Monico’s solutions are used across midstream, drilling, and frac operations—monitoring natural gas compressors, engine-driven generators, and frac truck systems. Our products are ideal for applications where real-time data and remote monitoring can prevent downtime and reduce maintenance costs.
What industrial protocols do Monico systems support in oil & gas environments?
Monico Gateways support a wide array of protocols including Modbus TCP/RTU, J1939, BACnet, SNMP, and many proprietary PGNs. This flexibility ensures that data from engines, compressors, and ancillary devices can be accurately collected and transmitted across even the most challenging networks.
Can Monico systems support remote monitoring of unmanned oil & gas stations?
Yes. Our Gateways are designed to work in remote or unmanned installations, offering virtual HMI access via LAN or Internet. This remote capability enables continuous oversight of compressor performance and engine activity without the need for frequent on-site visits.
How do Monico Gateways integrate with existing SCADA systems?
Our Gateways are pre-configured to serve as a unified interface between engine data, compressor controllers, and your SCADA or building automation system. They support a variety of protocols—such as Modbus, Allen-Bradley, Siemens, and GE—allowing seamless integration with existing systems without costly modifications.
How can Monico Monitoring reduce downtime and equipment failure?
By providing real-time data logging, freeze frame diagnostics, and proactive alarm notifications (via email or SMS), our systems enable operators to identify anomalies early. This allows for preventive maintenance and rapid troubleshooting, significantly reducing the likelihood of catastrophic failures and unscheduled outages.
What are the benefits of integrating both engine and compressor data into one system?
Integrating data from both engines and compressor controllers creates a holistic view of your operations. This unified interface not only simplifies troubleshooting and maintenance but also helps optimize performance, improve fuel economy, and enhance overall asset management.
