Rotating Equipment Condition Monitoring Maintenance & Fault Prediction using Wireless Sensors Problem An industrial conglomerate faced challenges with their existing maintenance practices for rotating equipment, particularly screw compressors and their motors. Despite regular preventive maintenance processes and periodic vibration analyses, the company experienced a year-over-year increase in equipment failures. The delays in procuring components for […]
Real-Time Optimization of Refinery FCC Problem Optimizing plant performance is crucial to maximize output and achieve optimum profit, yield, production, and energy consumption without significant capital investments. However, many plants operate based on outdated design conditions and set points, leading to suboptimal performance. Additionally, the implementation of Advanced Process Control (APC) does not always result […]
Predictive Maintenance for Rotating Equipment (Compressor – MAB) Problem The main air blower (MAB) in the Fluid Catalytic Cracking (FCC) unit of a refinery is a critical centrifugal compressor that provides air necessary for combustion in the regenerator. The smooth functioning of the MAB is essential for the overall performance of the FCC unit. Unplanned […]
Heat Exchangers Fouling Prediction and Cleaning Schedule Optimization Problem The refining and chemical industries face a significant challenge with heat exchanger fouling, where deposits of impurities accumulate on heat exchanger surfaces over time. This fouling reduces heat transfer efficiency, leading to several issues: Approach To address the challenges of heat exchanger fouling and optimize the […]
EOR Optimization and Polymer Injection Reduction for Upstream Oil & Gas Operator Problem The upstream oil and gas operator uses Polymer Enhanced Oil Recovery (EOR) to improve the sweep efficiency of existing water flood systems. Polymer injection involves increasing the viscosity of injected water with polymers to improve sweep efficiency. However, maintaining the right viscosity […]
Real-Time Calculation of Asset Health based on Corroded Area Percentage Problem Operating plants and facilities generate a massive amount of data from various systems like DCS (Distributed Control Systems), historians, SCADA (Supervisory Control and Data Acquisition), and APM (Asset Performance Management). However, operators often struggle to gain meaningful insights from this data due to its […]
Real-Time Calculation of Asset Health based on Corroded Area Percentage Problem Asset management in industries like manufacturing, oil and gas, and infrastructure often involves monitoring and inspecting assets for signs of corrosion, which can lead to significant safety risks and operational inefficiencies if left unaddressed. Traditional manual inspection methods are time-consuming, costly, and may not […]