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Asset Performance Prediction Solution employed to Increase Uptime of an Offgas Compressor at a Major Petrochemical Group in India

Business Objective

To increase Uptime of an Offgas Compressor and derive more value from existing expensive assets at a Major Petrochemical Group in India A large Petrochemical Group in India turned to Lummus Digital for solving the various problems associated with its Offgas Compressors and wanted to increase their uptime. By doing so, the Petrochemical Group wanted to derive more value out of their existing expensive assets, improve on reliability, efficiency, and minimize the costs associated with the running of their equipment. The business objective included:
  • Frequent failure of Offgas Compressors leading to unplanned downtime and production loss
  • Costly and time-consuming maintenance activities
  • Hard to identify root cause of the problem – whether process or equipment

Key Solution

  • Anomaly Detection: Using supervised and unsupervised machine learning, anomalies are detected along with other contributing factors that are responsible for the anomalous behavior of the equipment
  • Root Cause Identification: Perform root cause analysis of the contributing factors that lead up to the equipment part/ system and generate corresponding alerts. Further, controlled variable in a data driven Failure Mode and Effect Analysis (FMEA) of equipment and application of Data Science are utilized to ascertain the same.
  • Predicting Failures Ahead of Occurrence: By using deep learning Long Short-Term Memory (LSTM) of the networks, prediction of anomalies and remaining time to failure of equipment is made possible.
  • Best Optimal Solution Recommendation: Conducting ‘What-if analysis’ for failure mitigation/repair management results in recommending the most appropriate solution.

Business Impacts & Outcomes

  • By predicting an early compressor failure, way ahead of its occurrence, the Solution helped the Petrochemical Group steer clear of unplanned shutdown and avoid production loss amounting to an Avg. $1.2 Million per year
  • Reduction in maintenance costs : Avg. $0.25 million per year
  • Reduced cost of safety incidents
  • Improved life of equipment as well as reduced labor and spare parts opex

Lummus Digital is a joint venture bringing together the capabilities and expertise of Lummus Technology and TCG Digital. Collectively owned by The Chatterjee Group, both companies lead their respective fields.

Lummus Technology is the global leader in the development and the implementation of process technologies for the petrochemical, refining and gas processing industry that make modern life possible. TCG Digital accelerates enterprise digital transformation with big data, artificial intelligence and hyper-contemporary technologies, delivering value across the operational spectrum.

With their combined strengths, Lummus Digital brings tremendous value to our customers through digital solutions at scale. Beyond simply software, Lummus Digital monitors, predicts and optimizes for ultimate performance, and goes further with root-cause detection and improvement scenarios.

Our solutions typical result in ROI of 50% or more in less than six months.