Project Scope

Pakistan Petroleum is a state-owned oil and gas exploration and production company, operating one of the largest Oil & Gas facilities in the country.

FAIZAL was assigned to implement a Condition-Based Maintenance (CbM) system and a Preventive Maintenance Planner for the critical motors in the refinery.

Background

The electrical assets across various plants in the refinery are maintained by the Power & Utilities department, including HT (High Tension) and LT (Low Tension) motors from various manufacturers. Maintenance tracking was previously carried out using Excel sheets, which proved tedious and complex in the long run. Without visibility into the actual usage of motors, maintenance personnel performed motor maintenance cyclically, leading to over-greasing and under-greasing issues. This resulted in a high number of motor failures, causing increased unplanned plant shutdowns and production losses.

In the first phase, a Condition-Based Maintenance (CbM) system was implemented for 500 selected motors. This system featured a high-speed data gathering mechanism, calculated motor run-hours in real-time, and tracked greasing dates. An interactive dashboard provided a prioritized list of motors due for greasing.

In the second phase, a Preventive Maintenance Planner module was incorporated. This module tracked maintenance frequencies and last maintenance dates, presenting a prioritized list of motors for upcoming maintenance activities.

System Description

Using our EXOR Platform, a centralized motor management system was developed to collect critical motor parameters via OPCUA from the existing DCS (Distributed Control System) in the refinery. The built-in high-performance time-series database and low-code rule-flow module of the EXOR Platform were crucial for the solution.

Condition-Based Maintenance:

• Interactive dashboards and reports provide data visualization and deeper insights, giving the maintenance team visibility into each motor, enabling timely actions to save time and money.
• Web-based dashboards aggregate data from multiple sources, including run-hours, start count, motor metadata, maintenance schedules, and last maintenance dates.

Preventive Maintenance Planner:

• The Preventive Maintenance (PM) period varies based on multiple factors, typically 1 or 2 years.
• Weekly PM reports, including a prioritized list of motors to be maintained, are published, allowing maintenance personnel to plan in advance.
• Daily reports listing motors that have undergone PM maintenance are sent to the maintenance team via email.
• Maintenance personnel can add comments, attach photographs, and fill out checklists. Comparison of motor health (dust levels, leakage, cable condition, etc.) between maintenance activities is possible.

Result

• The maintenance team in the refinery can now schedule equipment maintenance based on the actual usage and condition of the motors, effectively saving time and money.
• Daily emails listing motors to be maintained make job allocation to technicians efficient and effective.
• Powerful dashboards with swift navigation provide insights into the equipment’s current status and forthcoming maintenance schedule.