Seeing is Believing !

Reduce Downtime with Predictive Analytics

Posted: July 16, 2019

Asset Performance

Seeing is Believing !

When executing a Digital Transformation strategy, the introduction of new technology and new ways of working can make many people uneasy. Everybody believes they should be going digital, but they don’t necessarily know how to do it. The benefits of implemented solutions may not be tangible at first sight, and the best approach to implement a project is not always clear. It becomes difficult then to justify an investment without proven results. Which is the right direction? What is the right first step?

The First Step

Asset Predictive Analytics is an important piece of any companies Digital Transformation strategy. More and more, it´s becoming the first step in a digital journey because it´s possible to ensure big results before acquisition, if you have the right technology and approach.

The terms “Artificial Intelligence (AI)”, “Machine Learning”, and “Pattern Recognition” are used everywhere, but what does it mean in real life operations? To truly understand that, you need a solution that is:

  • Easy to use, so you don't need to be a computer scientist to navigate
  • Gives you access to how the model is handling your data. No black box!
  • Flexible that allows you to explore your information in different ways to get insights about the best way to operate your plant

Creating Effective Maintenance Strategies

The development of the Maintenance Strategy is part of an ongoing journey towards continuous maintenance improvement involving the collaboration of people, processes and assets through digital technology. It doesn’t happen all at once but instead gains speed and velocity over time as people, processes and assets are digitally fused together to eventually bridge the operations technology and information technology gap. Start small in your strategy and adoption, but start now to maintain or improve your competitive level and market position.

A comprehensive Maintenance Strategy combines enterprise data capture with asset management, prescriptive analytics and risk-based management. Work orders can be automatically generated to relieve maintenance issues. Analytics capabilities continue to evolve from predictive to prescriptive, i.e. from what will happen to what should be done.

Read the Chemical Processing article now: Maintenance Strategies in the Era of IIoT

A True Story: COVESTRO

To advance their predictive maintenance strategy, Covestro evaluated AVEVA’s Predictive Analytics solution, PRiSM, in the most effective way. They proved the benefits during the pilot phase by running offline models with information from real past cases.

In their evaluation, Covestro selected two incidents that caused significant impact in terms of production and/or overall results to the company’s bottom line. The first case was a large motor failure that caused the trip of a 3-stage compressor from a supplier. The trip stopped the supply of a critical feedstock that could not be replaced, leading Covestro plant to shut down. Thermal and mechanical models were developed using historical data, and they trained the models for a 1 year period. The mechanical model was rigorous enough to demonstrate that the failure could be predicted at least 8 months before it happened. If they had AVEVA Predictive Analytics application at the time, they would have enough time to identify the problem, plan the maintenance activities, and avoid the feedstock supply interruption.

In the second case, Covestro demonstrated how AVEVA’s Predictive Analytics solution could be used to predict failures based on very subtle indications; proving machine learning really works. One of the Covestro plants shut down for two weeks because of major corrosion damage. A heat exchanger operating with solvent and water had an internal leakage. Because this solvent reacts with water generating a corrosive compound, the corrosion spread to different equipment leading the plant to shutdown. The Covestro team was skeptical in this case because they didn´t have all the measurements they thought they would need to build a rigorous model. Based on the correlations made by AVEVA’s solution, it was possible to calculate the important variables to predict the leakage. The model results demonstrated that the leakage could be identified about 10 days before the plant shutdown, avoiding the major damage caused in many units and reducing the overall downtime.

Another large Industrial Gases customer has quantified their savings from the detection of equipment failures before they occur and the ability to prevent unscheduled system downtime at more than of $500+K.

Clear Results and Insights

In both cases, the AVEVA Predictive Analytics solution benefits were clear proving the losses they could avoid related to the described incidents were significant. As well, Covestro had access to how the models worked (opened calculations), so the technical team had insights about how to use machine learning to solve different problems.

Watch the webinar where Jane Arnold, Head of Global Process Control Technology at Covestro, shares the aforementioned case studies and how this is part of Covestro’s largerDigital Transformation strategy. For more insights about Maintenance Strategy in the Era of IIoT, read the Chemical Processing article now: Maintenance Strategies in the Era of IIoT

 

author
Written By
Fernanda Martins

Fernanda Martins is the Global Marketing Manager for the Oil & Gas Downstream and Chemicals industries at AVEVA, holding a B.Sc. in Chemical Engineering from the Universidade de São Paulo. In her almost 20 years experience, she has helped companies to adopt and explore a variety of transformational technologies in areas like process engineering, optimization, workforce empowerment and enhanced operations and maintenance.

See how APM 4.0 drives measurable and immediate results to your bottom line. Get Connected

Related Blog Posts

Stay in the know: Keep up to date on the latest happenings around the industry.

Asset Performance
Artificial Intelligence: Friend of Foe?

Leveraging Artificial Intelligence to capture as much value as possible

Oil and Gas
Maximize Oil and Gas Pipeline Efficiency with Integrated Digital Twins

How pipeline companies lean towards digital transformation to improve operational efficiency with AVEVA while enhancing the safety measures

Asset Performance
Industry 4.0 starts with Asset Performance Management 4.0

The realization of Industry 4.0 requires a move to Asset Performance Management 4.0

Asset Performance
5 Key Takeaways from Decades of Successful Asset Management

While many companies recognize the potential of improving their APM strategy, we find that many simply do not know where to start

Asset Performance
Maximize the value of your Historian data using Predictive Analytics

Predictive Asset Analytics is one of the most promising technologies to derive tangible business value from existing historian data.

Asset Performance
5 Ways to Get More From Your Existing Water and Wastewater Assets Now

Minimize risk and maximize performance of assets in your water and wastewater operations with a digital, proactive maintenance and reliability approach that ...

Asset Performance
Visualize Asset Performance Management

Visual APM connects multiple sources and formats of asset and operations data to view digital twins of equipment, machinery and processes using navigable 2D ...

Asset Performance
Seeing is Believing !

Asset Predictive Analytics is an important piece of any companies Digital Transformation strategy

Food and Beverage, CPG
How Making Your Machine Learn Patterns and Infer from Data can Change the Manufacturing Shop Floor

Analytics and Artificial Intelligence-driven processes, supported by Machine Learning, will revolutionize the manufacturing shop floor.

Asset Performance
Key success factors for adopting condition-based and predictive maintenance

Industrial organizations can no longer afford to operate in a reactive environment, it’s critical to reduce downtime, failure and production loss. We ...

Asset Performance
Pushing A Data Driven Future with Predictive Asset Analytics

Digital transformation in chemical manufacturing is occurring at a rapid pace. Watch this video to learn how Covestro is implementing predictive asset ...

Asset Performance
Continuous Online Monitoring as the Foundation of a Condition-Based Maintenance Strategy

The shift from Time-Based Maintenance towards Condition-Based Maintenance (CBM) in Power highlights the importance of detecting potential failure at the ...

Asset Performance
How To Drive Real Results With An APM Strategy

When executed effectively, asset performance management can enable dramatic improvements in a company’s ability to achieve overall corporate objectives. A well ...

Asset Performance
Digital Work Culture

For smart utilities to successfully adopt digital transformation they must embrace new autonomous assets and adopt a new way of performing work. Predictive ...

Asset Performance
Predictive Analytics Pilots That Work

Implementing new technology is inherent in digital transformation. But qualifying new technology like predictive analytics and implementing it into production ...

Asset Performance
What’s really holding back your digital transformation? Technology or people?

Roy Hill, Enel, Southern Company weigh in on whether it is the readiness of the technology, or the workforce itself, that was most challenging in applying ...

Food and Beverage, CPG
Improve Food and Beverage and Consumer Packaged Goods Operational Efficiency with Predictive Analytics and Augmented Reality

To exceed reliability, safety and performance goals, food and beverage and consumer packaged goods manufacturers are implementing AR/VR, Mobility and Analytics ...

Asset Performance
Asset Performance Moving Beyond Just Reliability Because of Industry 4.0

The good news is that organizations don’t need to take on a massive redesign or make huge investments to achieve value from pursuing APM 4.0.

Asset Performance
In Mining Industry 4.0 Translates to APM 4.0

Mining, metals, and minerals companies are asset-intensive businesses and have long focused on asset performance management (APM) as a core competency. As ...

Asset Performance
Profitability Management is Possible - Thanks to Digital Transformation

The key to being successful with APM 4.0 is to take a systems perspective. Instead of looking at just the asset look across the entire value stream of the ...

Oil and Gas
How Closed-loop Operations Enable Digital Transformation of Oil and Gas Fields

Today, the advancement in technology – cloud platform, analytics and computing power – is revolutionising the way how companies can leverage big data and ...

Asset Performance
Increase Asset Availability, Reliability and Performance with APM 4.0

Industry 4.0 and the Industrial Internet of Things (IIoT) are bringing the asset to the forefront of the business. This is the future of APM – APM 4.0.

Oil and Gas
How Pipeline Operators are Working to Improve their Asset Reliability

Asset reliability is a key component of an overall asset performance management strategy. And it plays a big part in helping midstream oil and gas operators ...

Oil and Gas
Maximizing Midstream Profits with OT IT Convergence

Historically midstream oil and gas organizations have kept two critical functions within their businesses almost entirely separate – IT and OT. One of the ...

Asset Performance
How does predictive analytics fit in a pipeline operator's maintenance strategy?

As midstream companies progress through their digital transformation journey, opportunity is being uncovered on how to better use their data to drive ...

Chemicals
Freud was Right: Accidents are Avoidable

As IIoT/Industrie 4.0 continues to enable smarter equipment that creates increasing amounts of data, chemical companies are faced with both the challenges and ...

Asset Performance
3 Easy APM Use Cases

I’ve talked a lot about the value of Enterprise APM, the components necessary to implement it and the benefits it brings, but I haven't discussed the best use ...

Chemicals
Chemical Companies Deliver Outstanding Customer Experiences Through Digital Transformation

Leading chemical companies are turning to digital transformation and asset performance management to augment and overhaul their traditional industrial and ...

Chemicals
5 Benefits of Digital Transformation in Chemical Manufacturing

Chemical manufacturing is an ever increasingly competitive industry with margins shrinking every day. Here are the top five opportunities for digital ...

Chemicals
Augmented Reality in the Chemical Industry

Let’s take a step back and try to understand the real value proposition of augmented reality and address how and where it’s actually an applicable technology ...

Asset Performance
Researching APM Providers Part 1: Look for Proven Results

The APM industry has so much hype around IIoT, digital transformation, Industry 4.0 etc., that it's important to focus on concrete results achieved. When ...

Asset Performance
Researching APM Providers Part 2: Long-term Roadmap and Vision

This series will cover three things you should look for in your APM provider. The first blog in the series, “look for proven results” posted last week. Read ...

Asset Performance
Researching APM Providers Part 3: Open, Agnostic System

This is the last blog in a three part series on the three things you should look for in your APM provider. Read more.

Oil and Gas
How Advanced Analytics improve Margins at Natural Gas Processing plants?

mproved fracking technology in oil and gas fields is creating an unprecedented boom in natural gas production, exerting tremendous pressure on natural gas ...

Oil and Gas
Digitizing the Mobile Workforce

The front-line opportunities to improve plant reliability, safety, and profitability are infinite. Value lies in digitizing the mobile workforce.

Asset Performance
3 Ways to Maximize Return on Assets with Risk-Based Maintenance

Here are three steps companies can take to implement a risk-based maintenance strategy to maximize their economic return on assets.

Asset Performance
3 Steps to Optimizing Your APM Strategy

Implementing any APM strategy is a journey, and APM Assessments are a critical tool enabling companies to evaluate and select the optimal strategy.

Asset Performance
Utilities Squeeze Assets with Predictive Analytics

Utilities must embrace new technology, such as predictive analytics, to increase reliability, enhance performance, cut costs, and reduce asset failure.

Asset Performance
Empower People with the IIoT to Improve Asset Performance and Reliability

While machine-machine communication is an important component of IIoT, it's just as important that solutions empower people to make informed decisions.

Asset Performance
How You Can Optimize Your Maintenance Today with the IoT

Operators are being pushed to reduce maintenance costs, extend asset lifecycle and increase performance - digital transformation can provide the answer.

Food and Beverage, CPG
Three Ways to Improve Agricultural Efficiency and Sustainability with Digital Transformation

Digital transformation can offer significant benefits in agriculture by optimizing the value chain to feed the world more efficiently and sustainably.

Food and Beverage, CPG
How F&B Companies Can Improve Uptime with Predictive Maintenance

Predictive maintenance is enables Food and Beverage manufacturers to improve uptime and production, enabling them to remain competitive in today's market.

Food and Beverage, CPG
Drive Operational Excellence with Digital Transformation

Food and beverage manufacturers can drive operational excellence across the value chain by implementing digital transformation.

Food and Beverage, CPG
Three Ways to Extract Value from IIoT in Food and Beverage

Learn how food and beverage manufacturers can leverage the IIoT to increase asset utilization, improve OEE and lower costs.

Oil and Gas
How Big Data and Analytics increase Production Asset Uptime in Oil Fields?

Oil companies must continue to make investments in improving operational efficiencies to sustain and improve their profitability.

Chemicals
Cracking the Code

An insider’s view on America’s turbulent Steel Market.

Asset Performance
Digital Transformation of People – Risk Prevention

With digital transformation of people established as the next big thing, the question is, what will the implications be for businesses? There are two main ...

Chemicals
Congratulations, it’s Twins! How to get the Most from Your Digital Twin in the Design Phase

A digital twin is a complete 360° digital representation of a physical asset, i.e., a pump, motor, turbine, or an entire plant. By creating digital twins of ...

Chemicals
Improve Reliability in Chemical Manufacturing with Predictive Asset Analytics

Predictive asset analytics enable chemical manufacturers to catch problems before they occur. This means companies can optimize their MRO inventory by ...

Asset Performance
EAM Crystal Reports Training

Enterprise Asset Management Crystal Reports training in our Burlington, Ontario office.

Asset Performance
It is OUR data not MY data

There is a lot of interest in advanced analytics to inform better decisions and make additional revenue.

previous next

Sign up for our newsletter and get all the latest information straight from the source.