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Use Case Early Detection of Critical Equipment Failures

Major Hainan-based refinery project focussed on 3 major initiatives:

1. Digital Transformation

Connecting 2481 critical motors to the PHM system

2. Intelligent O&M including:
  • Expert diagnostic
  • Health evaluation
  • Onsite inspection
  • Integrated maintenance
3. Nearby Service

Setting up of the Digital Service Centre

Project outcomes:
  • 2 early detections of potential failure of operations critical equipment.
  • Significant reduction in labour cost for physical inspections (proprietary data)
By Focusing on:
  • On-line / remote monitoring of equipment
  • Intelligent equipment fault diagnosis
  • Dedicated service center

Use Case Reducing Operational Cost by > 30%

Located in the Tibetan plateau the largest copper mine has many operational challenges; a lack of trained technicians and a harsh environment are just two.

Project outcomes:
  • >30 % reduction in operational costs
  • >80 % reduction in downtime
  • >90% improvement on fault diagnostic
By Focusing on:
  • On-line / remote monitoring of equipment
  • Intelligent equipment fault diagnosis
  • Upgrading of aging equipment
  • Spare parts strategy

Use Case Preventing Significant Downtime Cost

USE CASE: ROLLER BEARING

In Dec 2022 and Jan 2023 the PHM system at an O&G firm in China detected damage to the inner ring of a roller bearing. The system gave enough time to plan the maintenance works for March of 2023. The 4 main indicators of the predicted failure were:

Project outcomes:
  • Close detection of fault allowed timely repair and prevention of downtime.
  • Reduction in Maintenance Costs
  • Timely repair prevented likely injury
By Focusing on:
  • On-line / remote monitoring of equipment
  • Intelligent equipment fault diagnosis

Use Case In-House Demo Setup

USE CASE: ROLLER BEARING FAILURE + UNEVEN MOUNTING

In Dec 2022 and Jan 2023 the PHM system at an O&G firm in China detected damage to the inner ring of a roller bearing. The system gave enough time to plan the maintenance works for March of 2023. The 4 main indicators of the predicted failure were:

Demo setup includes:
  • a motor, centrifugal pump and water line.
  • Two (2) separate faults can be introduced to test the diagnostic system.
Demo outcomes:
  • PHM identifies faulty bearing.
  • PHM identifies uneven base.

Natural (resonant) frequencies arising from ball bearing with internal fault (right)

Natural (resonant) frequency arising from uneven mounting

Faulty bearings

Uneven base

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Workshop Brook-TM: 15 Kwong Min Road, Singapore 628718

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