1660318679714 1904pdmsaudiaramco

[Case history] Greenfield offers continuous monitoring of assets in real time

April 16, 2019
Predictive maintenance: Pedal to the metal

Run-to-failure is increasingly reserved for rare and unique circumstances. This trend started when increasingly capable condition inspection and monitoring tools shifted the asset management focus from “fix what’s broken” to “keep it from breaking down.” Today, unprecedented opportunities afforded by the industrial internet of things (IIoT) have further changed the playing field, and there are potential benefits yet to be realized.

For example, predictive maintenance (PdM), originally based on selected asset condition data, has grown to accommodate online, real-time streams of multiple types of condition data received via sensors and even drones. Some companies are applying machine learning (ML) to further refine their predictive analytics and prognostics.

The newest opportunity, prescriptive maintenance (RxM), is a multivariate approach that merges asset condition data with any combination of operating, environmental, process safety, engineering, supplier, or other related data to better diagnose conditions and prescribe specific options for corrective action. The advanced analytics, pattern recognition, modeling, ML, and artificial intelligence (AI) that empower RxM may help companies finally greatly curtail, if not eliminate, the need for reactive maintenance on critical equipment.

Saudi Aramco’s Jazan Refinery Complex is a greenfield megaproject expected to begin operations in 2019. Different tools are being used within the new site’s integrated manufacturing operations management system (imoms) to manage the end-to-end manufacturing business processes and monitor the health of different equipment types in real time, including rotating, instrumentation, and critical static equipment, says Eyad Buhulaiga, senior projects manager at Saudi Aramco.

The tools utilize mechanisms such as ML to predict equipment health anomalies at an early stage and to determine when the maintenance should be performed to avoid failure. Another mechanism ensures the assets are running within their optimum operating window, without unacceptable violations to equipment limitations.

Condition monitoring and predictive health tools built into Saudi Aramco’s integrated manufacturing operations management system (imoms) help ensure that assets are running within their optimum operating window, without unacceptable violations to equipment limitations.

“Continuous monitoring of the assets in real time, to ensure that they are operated with the least possible risks (as low as reasonably practicable, or ALARP), includes defining the asset integrity levels, safety critical elements, performance standards, assurance tasks, etc.,” says Buhulaiga. Any deviation of these parameters will be reported immediately in order to take the recommended measures. This will significantly enhance the PdM and RxM activities by injecting more data that is relevant to the asset, and hence, the activities will be focused on the items that require attention, he explains.

For instance, through the different tools and methodologies within imoms, a combustion liner failure in a turbine can be predicted three weeks in advance. This knowledge will lead to reduced or avoided damage to the critical equipment, improved process safety, and avoidance of unexpected shutdowns.

“Before implementation of PdM and RxM, it is important to identify the business goals, road map, and top-priority assets, where the relevant data is available,” recommends Buhulaiga. “Engage the right stakeholders to ensure smooth and sustained implementation and usability.”

About the Author

Sheila Kennedy | CMRP

Sheila Kennedy, CMRP, is a professional freelance writer specializing in industrial and technical topics. She established Additive Communications in 2003 to serve software, technology, and service providers in industries such as manufacturing and utilities, and became a contributing editor and Technology Toolbox columnist for Plant Services in 2004. Prior to Additive Communications, she had 11 years of experience implementing industrial information systems. Kennedy earned her B.S. at Purdue University and her MBA at the University of Phoenix. She can be reached at [email protected] or www.linkedin.com/in/kennedysheila.

Sponsored Recommendations

Arc Flash Prevention: What You Need to Know

March 28, 2024
Download to learn: how an arc flash forms and common causes, safety recommendations to help prevent arc flash exposure (including the use of lockout tagout and energy isolating...

Reduce engineering time by 50%

March 28, 2024
Learn how smart value chain applications are made possible by moving from manually-intensive CAD-based drafting packages to modern CAE software.

Filter Monitoring with Rittal's Blue e Air Conditioner

March 28, 2024
Steve Sullivan, Training Supervisor for Rittal North America, provides an overview of the filter monitoring capabilities of the Blue e line of industrial air conditioners.

Limitations of MERV Ratings for Dust Collector Filters

Feb. 23, 2024
It can be complicated and confusing to select the safest and most efficient dust collector filters for your facility. For the HVAC industry, MERV ratings are king. But MERV ratings...