Showing 1 - 23 of 23
Alarm Management and Triage

Industrial plants have many level 3 and 4 alarms from DCS and SCADA systems. Operators often don’t respond to these lower level alarms due to the large number. These alarms can be leading indicators of potential operational or equipment failures.

Solution

Aggregate and group level 3 and level 4 alarms and make them available to reliability and process engineers to review. Create recommendation rules for alarms that are leading indicators of potential failures.

Benefits

Gain visibility into critical leading indicator data. Improve the remaining useful life of older equipment.

Boiler Feed Water Pumps

Thermal power plants can experience large generation losses due to boiler feed water pumps. Downtime of the BFW pumps are mostly due to high levels vibrations and passing of recirculation valves, resulting in low discharge.

Solution

Continuously monitor vibration and thermography data to trigger recommendations based on plant specific business rules. These recommendations include tribology data (oil samples) with an AI bot that can be trained to create new recommendations in future.

Benefits

Reduce BFW downtime due to failures and optimize recommendation thresholds with the AI bot.

Casting Guidance

It is important to maintain a consistent iron/slag inventory inside a blast furnace for stable operation, especially to avoid iron/slag level beyond certain limit that may lead to serious hearth chill situations.

Solution

An engineering solutions partner developed a casting guidance model for iron and steels plants. It uses real-time blast furnace information to advise on taphole and other parameters that estimate current iron/slag level. It predicts trends based on future furnace operation and cast schedules.

Benefits

Stabilize furnace operation and hot metal supply downstream. Better management of the furnace pressure drop by maintaining a consistent dry hearth condition. Essential for reaching the maximum furnace output.

CHPP Throughput Loss Monitoring

Coal washeries can account for 20 – 30% mass loss through the process of mineral matter from coal and this impacts washery yield. CHPP and General Managers only find out about losses through weekly reports.

Solution

Continuously monitor and calculate wash plant losses during each shift. Alert the CHPP manager if wash plant losses exceed a certain threshold per shift and alert the site GM if losses go above a specific daily threshold to make recommendations to operations.

Benefits

CHPP managers and site GMs have real-time visibility into losses. Reduce losses per shift by at least 20%.

Cooling Tower Fin Fan Monitoring

Steel manufacturers experience a high frequency of cooling tower fin fan failures. This results in longer production cycles. Drive gearboxes are often the main cause of downtime.

Solution

Receive alarm and corresponding event data from the OEM equipment and then create work orders in the EAM based on recommendation rules.

Benefits

Reduce fin fan failures by creating work orders in the EAM system.

Cyclone/Slurry Pump Monitoring

Mining operators experience large losses due to unplanned downtime of the cyclone pumps in processing plants.  Efficiency losses due to impeller wear and unplanned downtime to replace worn impellers impact processing plant performance.

Solution

Condition monitoring with recommendations on amperage thresholds, density variations, and flow rate changes. XMPro predicts impeller wear and creates recommendations for the reliability engineering team to investigate performance when the predicted impeller wear is greater than 60%.

Benefits

Reduce lost product tonnes per month and improve maintenance planning.

Demand Planning to Reduce Stockholding in Stores

Retailers with hundreds of stores have a high frequency of “stock outs” on popular items while carrying unnecessarily high quantities of slow-moving stock. Store managers restock based on replenishment rather than demand.

Solution

Continuously monitor store POS and execute a demand planning algorithm. A store manager receives a recommendation on reorder quantities, taking predicted demand into account and an AI bot validates the reorder actions by the manager.

Benefits

Reduce in-store stockholding and increase revenue due to reduced stock outs.
Improve customer experience.

Demin Water Monitoring for Boiler Tube Corrosion

Thermal power plants experience large generation losses due to boiler tube leaks. A failure of the demineralized water deaerators that heat feedwater and reduce oxygen is a major cause of boiler tube erosion/corrosion.

Solution

Monitor the demin water deaerators that remove the oxygen that lead to pit corrosion on the boiler tubes. Operations are not always aware of the impact of deaeration on the tubes and often ignore these DCS alerts.

Benefits

Reduce losses due to boiler tube leaks. Improve collaboration between reliability engineering and operations.

Golden Batch Monitoring

Chemical industry plants experience large variations on product batches in batch cycle time, raw material usage, and product quality. Their process engineers established a “golden batch” profile that could be applied retrospectively on completed batches to identify potential quality issues.

Solution

Monitor batches in real-time to the “golden batch” profile. Provide recommendations on raw material feed rate. These recommendations are created by expert users that create and maintain the business rules.

Benefits

Improve product quality.

Improve First Pass Yield (FPY)

Manufacturer want to improve the First Pass Yield rate through better understanding and control of key upstream process parameters. Every 1% increase in FPY delivers large cost savings at current volume levels, with higher savings as volume increases.

Solution

Combine information from raw material inventory, real-time SCADA, a gauge profiler, and a vision inspection system to identify upstream process issues that will impact quality downstream. Provide a real-time eventboard for process engineers to identify and change process parameters.

Benefits

Improved product quality through integrated process view.

Induced Draft (ID) Fan Monitoring

Thermal power plants experience large generation losses due ID fan downtime from high levels of vibration. Bearing lubrication system failures are often the main cause of ID Fan downtime.

Solution

Monitor the gear pumps used for the ID fan bearing lubrication system. Tribology sample information is combined with pump operating data to predict abrasion wear and recommend prescriptive maintenance actions with an improvement feedback loop.

Benefits

Reduce ID fan downtime due to improved bearing lubrication monitoring.

Long Conveyor Monitoring

Mining operators with extensive underground operations experience significant borer downtime due to fluid coupling issues on long conveyor drives. Borer downtime results in direct revenue losses – product tonnes.

Solution

Predict fluid drive failures based on engineering model calculations. Create event alerts based on criticality and provide reliability engineers with data such to prioritize maintenance on the drives.

Benefits

Reduce borer downtime which leads to increased production and revenue.

Monitor and Reduce Energy Consumption

Energy costs account for a significant portion of total operational costs at food manufacturers and provides an opportunity for reducing costs and improving competitiveness.

Solution

Continuously monitor various variable speed drives (VSD) and other electric motor drives to identify bad actors. Recommendations provide guidance on process and maintenance actions to reduce energy usage.

Benefits

Continuous monitoring of various drives can identify electro-mechanical issues. Identify operational process issues that lead to higher energy use.

Monitor Process Health to Reduce Cash-to-Cash Cycle

Discrete manufacturers identify increases in their cash-to-cash cycle through procurement processes, stockholding and production planning processes.

Solution

Continuously monitor the process health metrics in the cash-to-cash cycle. Leading KPIs alert operational managers of processes or stockholding that negatively impact the cash-to cash-cycle.

Benefits

Reduced cash-to-cash cycle.

Monitor Storm Water Reservoirs For Flood Prevention

Residential areas in metropolitan cities regularly suffer flooding during long rain spells. The stormwater reservoirs are often near full when the rain starts as the services team work on a fixed route and not on the most urgent based on levels and weather forecasts.

Solution

XMPro is used to monitor the storm water reservoirs (sumps) continuously and combine level information with weather prediction information to create dynamic truck rolls. It also measures water quality to determine if there is any industrial runoff into stormwater systems (similar to tailings in mining scenarios)

Benefits

Reduce the frequency of residential flooding. Improve safety by warning service crews of potentially hazardous conditions.

Oil Well Maintenance Planning

Inspection and maintenance crews are often dispatched to live oil wells that are dangerous to crew. Stale data in planning systems leads to major safety and cost implications.

Solution

Optimize production and regulatory inspection planning with a proprietary scheduling algorithm. XMPRO monitors SCADA data in real-time to determine if there is flow from the well before enabling the release of a work order for a crew to be dispatched.

Benefits

Reduce truck rolls and weekly maintenance schedule planning time.

Oil Well RTP Monitoring

Oil wells are shut in and cooled down before operations crews can perform maintenance and inspections. But crews often forget to return a well to production (RTP) once maintenance is completed.

Solution

Monitor operations systems to determine when the well can put back in production. Once this status change occurs, monitor flow in the flow meters from the well and notify operations managers of wells that are not returned to production.

Benefits

Return wells to production faster and reduce production losses.

Pipe Scaling Prediction for Roller Cooling

Scaling in pipeline affects product quality for steel rolling manufacturers. Pipelines must be cut during shutdowns for inspection. It also causes cavitation in cooling pumps.

Solution

Continuously run a predictive model that uses real-time operational data to predict the scaling in the roller cooling circuit.

Benefits

Increased product quality and a reduced scrap rate due to inconsistent roller cooling. Extended remaining useful life for pumps.

Predict Heat Exchanger Fouling

Heat exchanger fouling at polyethylene process manufacturers mean that batch cycles get longer and that results in lower plant yield. Heat exchangers foul over time with usage and process engineers do U coefficient monitoring calculations intermittently in Excel.

Solution

Perform U coefficient calculations weekly and run a predictive model to determine when the heat exchanger performance will be below the required process requirements. Recommendations with business rules close the loop on maintenance actions.

Benefits

More than 9 months notification before a failure event. Eliminate unplanned maintenance on heat exchangers.

Pumping Station OEE

Water utilities can experience a catastrophic engine room failure and subsequently other upstream and down streams equipment can also be damaged.

Solution

Provide an OEE style monitoring solution to provide insights on overall health of the equipment in the primary, secondary and tertiary water treatment stages.

Benefits

Provide insight and foresight to maintenance and reliability engineers to schedule work of upcoming short duration shutdowns.

Real-time Balanced Business Scorecard (BBS)

Executive teams use a BBS model to monitor and track strategic initiatives across all business areas. The current approach is manual with lag that can extend to a quarter. This does not give the executives time to influence business initiatives in a timely manner.

Solution

Collect and aggregate real-time data from business systems and processes to update a dynamic BBS that gives the executive team the ability to introduce business actions that positively impact performance and the resulting BBS.

Benefits

Executive teams have real-time insight into business performance and the ability to respond while they can still influence outcomes.

Real-time Safety Monitoring

Industrial accidents often happen as a result of the condition or state of equipment or when the environment is not suited for maintenance and operations tasks. Workers are often put in harm’s way unknowingly.

Solution

XMPRO partnered with a leading industrial safety, inspection, and certification organization to monitor equipment and environments in real-time to improve safety standards and advise operations and maintenance planners of potentially hazardous conditions and human proximity.

Benefits

Reduce safety incidents and risk.

Short Term Inventory Planning

Different inventory planning managers, with access to the same ERP data, achieve different customer and inventory outcomes. This means that customers experience different service levels and DIFOT outcomes.

Solution

Create an operational near real-time view of inventory and open sales orders. Using the corporate algorithms, the system offers a series of recommendations for any shortage. The planner’s choice is then automatically actioned into the ERP system.

Benefits

Consistent approach to fulfilling any shortages in the supply chain. Consistent approach to meeting customer DIFOT requirements. Improved inventory and customer SLA ratios.