Remote Monitoring used for Improving Ethylene Plant Performance for a Major Petrochemical Group in India.

Case Studies

Remote Monitoring used for Improving Ethylene Plant Performance for a Major Petrochemical Group in India.

Business Objective

To remotely monitor real-time health performance of Ethylene Plant of a Major Petrochemical Group in India A large Petrochemical Group in India approached Lummus Digital with the following agenda pertaining to the real-time health performance of their Ethylene Plants. The business objective included:

To remotely monitor, track, and improve plant health and asset performance
To facilitate an effective, accurate and efficient approach on real-time basis to:
- Detect issues associated with equipment, operations, and processes
- Identify and troubleshoot the cause of issues
- Recommend corrective actions

Key Solution

Build a virtual plant as a digital replica of the real plant – the Digital Twin
Enable an online remote monitoring application to monitor plant health and performance in real-time using key KPIs, equipment condition and parameters operating range, which helps in faster troubleshooting and diagnosis
Utilize state-of-the-art AI platform, tcg mcube, for fast and accurate data driven and rule-based root cause analysis. Further, it empowers the application for intelligent alerting to identify failure signatures.
Carry out Unit Performance monitoring and improvement using what-if – Production, Conversion, Yields, Quality, Utility consumption through Intuitive real-time dashboards, having unit specific KPIs designed by Lummus process and technology experts. Detailed monitoring applies to all the systems within the plant – feedstock, cracking, storage, polymerization, bagging, utilities etc.
Real-time alerts and instant reporting of bad health of plant/asset parts or those operating at off-limit parameters. Identifies the root cause and recommends corrective actions, thus, enabling the operator to take quick and valuable plant floor level informed- decisions.

Business Impacts & Outcomes