Sector / 05 · Energy and Utilities
Three minutes from anomaly to action.
Energy plants do not fail in straight lines. They fail when a vibration spike, an overdue oil sample, and a thermal drift converge over weeks. Cortrova watches six sensor streams and all fourteen OSHA PSM elements at once, catching the convergence before the catastrophe - and writing the work order before anyone files a ticket.
The challenge
- !Failures converge over weeks - a vibration spike, an overdue oil sample, and a thermal drift - but standalone monitors each see only their own threshold
- !A single unplanned outage on a critical pump or compressor burns hours of production and tens of thousands of dollars before parts are even staged
- !Tracking all fourteen PSM elements across operating procedures, mechanical integrity, MOC, and PHA lives in disconnected binders and spreadsheets
- !Annual EPA reporting across Air, Water, Waste, and TRI becomes a six-week scramble to reconstruct evidence at deadline
- !Lockout/tagout and permit-to-work are tracked off-system, so the compliance trail is rebuilt by hand after the fact
How Cortrova answers
- ✓The Predictive Convergence Engine fuses vibration, thermal, oil analysis, ultrasonic, motor current signature, and acoustic emission into one model - it alerts when several sensors drift together in a known failure pattern, not when one crosses a line
- ✓When risk is confirmed, Cortrova writes the work order automatically, stages parts, and dispatches the crew - minutes from anomaly to action instead of hours
- ✓All fourteen OSHA PSM elements under 29 CFR 1910.119 map directly to platform modules, with the convergence engine watching for the cross-element risk patterns standalone systems miss
- ✓EPA Air, Water, Waste, and Reporting obligations ship as native coverage with the recordkeeping and threshold monitoring that turns annual reporting into a one-click export
- ✓LOTO and permit-to-work are issued in-platform per OSHA 1910.147, so the compliance trail is captured as work happens
Predictive maintenance
Six sensor types. One AI prediction.
Each sensor stream feeds the same anomaly engine. Vibration, thermal, oil, ultrasonic, motor current, and acoustic data all converge in one model. The AI does not just alert on a single sensor crossing a threshold - it alerts when several sensors drift together in a known failure pattern.
Vibration
RMS and sigma-deviation tracking against per-asset baselines flags bearing and gearbox degradation on pumps, fans, and compressors.
Oil analysis
Sample cadence and ISO particle-count trends are monitored; an overdue sample becomes a risk factor the engine correlates against vibration.
Thermal
Thermal drift on motors, bearings, and steam systems feeds the convergence model alongside mechanical signals.
Ultrasonic & acoustic
Steam-trap leak detection and pressure-vessel acoustic emission monitoring catch failure modes that vibration alone misses.
Motor current signature
Current-signature analysis surfaces electrical and load anomalies that precede mechanical failure.
Automatic work order
On confirmed convergence, a high-priority work order is created, parts are staged, and the crew is dispatched - no ticket required.
Process safety
Fourteen elements. One platform.
OSHA PSM under 29 CFR 1910.119 specifies fourteen elements for highly hazardous chemical processes. Each one maps to a Cortrova module. The Predictive Convergence Engine watches all fourteen for the cross-element risk patterns standalone systems miss.
Employee Participation
Process Safety Information
Process Hazard Analysis (PHA)
Operating Procedures
Training
Contractors
Pre-Startup Safety Review
Mechanical Integrity
Hot Work Permit
Management of Change (MOC)
Incident Investigation
Emergency Planning and Response
Compliance Audits
Trade Secrets
Environmental compliance
Four programs. One module.
The EPA programs that matter to energy operators split cleanly into four columns: Air, Water, Waste, and Reporting. Cortrova ships native coverage of each, including the recordkeeping and threshold monitoring that makes annual reporting a one-click export instead of a six-week scramble.
Air - Title V
Permit-deviation tracking, NSPS and NESHAP limit monitoring, GHG inventory, and stack-testing schedules with auto-reminders.
Water - NPDES
Discharge monitoring with monthly DMR auto-export, stormwater SWPPP, pretreatment sampling, and SPCC plan audits.
Waste - RCRA
Generator-status tracking, e-Manifest integration, 90-day storage clocks, universal-waste tracking, and biennial report generation.
Reporting - EPCRA / TRI
Tier II chemical inventory, TRI Form R, Section 313 reporting, and state and local rollups.
How it works
Adopting energy & utilities.
07:14 - Detect
Pump 04 vibration crosses 2.4 sigma, 1.8 mm/s RMS above baseline. The anomaly is logged against the asset's history.
07:16 - Correlate
The engine finds the oil sample is 47 days overdue against a 30-day target and matches the combined signature to past failures.
07:18 - Act
Work order WO-7142 is created automatically at high priority, with parts staged for the bearing replacement.
07:32 - Permit
The crew is dispatched and a lockout/tagout permit is issued per OSHA 1910.147 before any work begins.
07:55 - Resolve
Bearing replaced, vibration normalized, monitoring cycle reset - a multi-hour outage avoided in under an hour.
Compliance frameworks
Built in, not bolted on.
FAQ
Questions, answered.
How does the Predictive Convergence Engine differ from standard condition monitoring?
Standard monitoring alerts when one sensor crosses a threshold. Cortrova fuses vibration, thermal, oil analysis, ultrasonic, motor current signature, and acoustic emission into a single model and alerts when several signals drift together in a known failure pattern. An overdue oil sample paired with a vibration spike and thermal drift is the kind of cross-domain convergence a standalone system never sees - and it is exactly what precedes a catastrophic failure.
What happens automatically when the engine confirms a risk?
On confirmed convergence, Cortrova creates a high-priority work order, stages the required parts, and dispatches the crew - typically within about three minutes of the first anomaly. When the job touches energized or rotating equipment, a lockout/tagout permit is issued in-platform per OSHA 1910.147, so the safety and compliance trail is captured as the work happens rather than rebuilt afterward.
How does Cortrova handle OSHA Process Safety Management?
All fourteen PSM elements under 29 CFR 1910.119 - from Process Hazard Analysis and Mechanical Integrity to Management of Change and Compliance Audits - map directly to Cortrova modules. The convergence engine watches across those elements for the risk patterns that emerge between them, so PSM stays continuously audit-ready instead of being assembled at review time.
Can Cortrova produce our EPA regulatory reports?
Yes. Cortrova ships native coverage of the four EPA program areas that matter to energy operators - Air (Title V, NSPS, NESHAP, GHG), Water (NPDES with monthly DMR export, SWPPP, SPCC), Waste (RCRA generator status, e-Manifest, 90-day clocks, biennial report), and Reporting (EPCRA Tier II and TRI Form R). The recordkeeping and threshold monitoring run continuously, so annual reporting becomes a one-click export instead of a six-week scramble.
Can Cortrova run in a secure or isolated plant environment?
Yes. Cortrova deploys in the cloud, on-premises, or fully air-gapped, so it fits operators that keep control and historian networks isolated. The same predictive, PSM, and EPA capabilities run inside the plant boundary, with role-based access and a complete audit trail.
In the field
What energy & utilities teams run.
Catch converging pump, compressor, and gearbox failures weeks before they take a line down
Avoid multi-hour unplanned outages and the production loss that comes with them
Keep all fourteen OSHA PSM elements continuously audit-ready, not reconstructed at review time
Turn annual EPA Air, Water, Waste, and TRI reporting into a one-click export
Issue and log LOTO and permit-to-work in-platform with a complete compliance trail
Get started
Built for energy & utilities.
We'll tailor a demo to your environment and constraints.