Digital Twins Maximize Asset Performance and Improve Equipment Uptime for US-based Process Manufacturer

Client

Our Client is a leading US-based Midstream O&G firm with 60+ gas processing plants acrossthe region.

Business Challenges

• Lack of central real-time visibility prevented operations SMEs from monitoring and managing equipment operations centrally
• Critical assets at most sites monitored and managed manually - based on time-based maintenance; lack of real-time data prevented the operator from modernizing their maintenance strategies
• Missed opportunities for cross-plant optimization - ability to redirect gasto plants with additional capacity, when critical assets are down in one plant
• Sought to reduce miles driven by field techniciansto perform standard inspection and maintenance activities

Solution Highlights

• Instrumentation of legacy equipment and aggregation of real-time data as per asset hierarchy into enterprise historian
• Detailed visualization of critical equipment operating parameters such as pressure, temperature and energy consumption to enable SMEsto analyze and recommend operations changes
• Integrated view of operations across sites into an Integrated Collaboration Center enabled SMEsto drive optimization across plants
• Digital Twins and AI/MLAlgorithmsto enable predictive maintenance

Outcomes Delivered

1. Integrated Operations: Enabled central visibility of plant operations allowing stakeholders to collaborate effectively to manage performance in and across plants.
2. Remote monitoring of equipment health and performance reduced miles driven to inspect and manage them.
3. Comparison of real-time data with simulated data to drive asset, unit, plant and cross-plant optimization opportunities
4. Ability to transition from time-based to condition and risk-based predictive maintenance strategies.

Business Benefits

• 12% Increase in equipment uptime
• 20% Reduction in maintenance cost
• 75% Reduction in miles-driven for maintenance