End-User: BPCL, India

Bharat Petroleum Corporation Limited (BPCL) is a state-owned oil and gas exploration and production business and it is one of the country’s largest Oil & Gas facilities,

Challenges & Background

BPCL Kochi refinery was about to implement a Condition-based Maintenance system that covers more than 1800 motors.  The P & U department’s job is to maintain electric assets installed in various plants throughout the refinery complex, which includes maintenance of various HT and LT motors. This part was difficult due to a lack of an effective preventive maintenance tracking system for those motors, which was only tracked using excel sheets. The existing method was tedious and complex as the maintenance team was over greasing and under greasing certain motors as they lacked visibility to their run hours. The first phase of the project was to implement a Condition-based Maintenance system for 1800 motors with an incorporated high-performance data gathering mechanism that could give the maintenance team an interactive dashboard which caused wasting their time and money on these motors. 

System Description

IIoTNext Platform is set up as a centralized Motor Management system for 1800 motors. The required parameters that are related to each motor are collected from existing DCS. The platform contains a built-in high-performance time-series historian for data storage. 

• The data visualization and deeper analysis are done using interactive dashboards and reports so that they will be able to understand the maintenance of each motor at a time and take proper procedures as required without wasting time and money.   

• Smart widgets are used to create dashboards that visualize data from several sources in the desired format, which includes metadata for each motor, running hours monitoring, and plant-wise motor maintenance management information. 

• The Platform collects and monitors the number of hours that a machine has been running, as well as plant-specific motor maintenance data so that they will be always up to date and cross-checked whenever required. 

Benefits 

• Maintenance personnel at BPCL. Kochi Refinery can now schedule equipment maintenance based on actual conditions, saving their time and money. 

• Daily emails with a list of equipment that needs maintenance make it simple to assign jobs to technicians which made their job simple of the complexity they were undergoing. 

• A powerful dashboard that gives customers insight into the equipment’s forthcoming schedule.