Client: Leading Oil and Gas Corporation
Products/Services/Core Business: Oil, Natural Gas, Petrochemicals
For many years, one of India’s leading oil and gas corporations relied on conventional approaches to ensuring the integrity and reliability of assets in the field. But as its infrastructure aged, the company wanted to improve asset availability and recognized a need to update and improve asset performance management with contemporary technologies like Internet of Things (IoT), big data, and predictive maintenance. The business objective was threefold: to improve Overall Equipment Efficiency (OEE) metrics, prevent outages, and protect the health and safety of workers. An additional objective was lowering the cost of asset management. The company engaged Wipro to create a new Asset Integrity Management System (AIMS), an integrated solution for comprehensive data collection and with the ability to leverage this data to make more proactive decisions.
The project began with design workshops and planning exercises to identify and articulate broad business requirements: higher asset availability and a better, more data-driven approach to managing and mitigating risk. Wipro also conducted risk-based inspection and reliability-centered maintenance studies to identify best practices in the industry. This effort paved the way to the more analytically rigorous, risk-based predictive maintenance approach of an AIMS and drove the creation of a strategic roadmap for implementation and execution.
A key part of collaborative solution development process was configuring and customizing new requirements into the existing asset management workflows. The team created functional and technical specifications and designed an appropriate architecture for the intake of real-time data (using sensors). This data is the key to predicting and ultimately preventing asset failures by using advanced AI/ML algorithms to continuously monitor and identify small deviations in real-time operating data.
Wipro also developed multiple dashboards – displaying key performance indicators, metrics, and scorecards – to generate real-time views of assets. These can be tailored to specific job functions and roles.
Implementation required standardizing asset management processes at two refineries and enabling the transition to the new AIMS. Ultimately, the AIMS was extended to two additional refineries.
With the successful deployment of the new risk-based Asset Integrity Management System, the oil and gas company has standardized and updated processes for asset reliability, mechanical integrity, asset strategy, and asset health. Expected benefits are substantial: a reduction in unplanned downtime by 50%, an increase in overall equipment effectiveness of 24%, an increase in percentage to planned to work to 90%, a reduction in annual maintenance costs of 10-15%, and a reduction in lost time injuries by 2%. The company expects the project to pay for itself within three years.