The Company
The client operates one of the world’s leading oil refineries. The client’s facilities have an operating capacity of 6 million tons of fuel annually, with a refinery yield rate of 81.6%.
The Challenge
The oil refinery experienced a fault in a reagent dosing pump station that caused one of its rectification units to go out of service for seven hours. The loss of function led to an under-production of 400 metric tons of various fuels—the equivalent of $250,000 in value. Upon conducting an internal incident analysis, GRT discovered several issues requiring attention.
Major requirements included:
- Preventing growing fault tendencies in aging refinery equipment
- Implementing a predictive monitoring system to anticipate and prevent breakdowns
- Ensuring consistent motor operations to optimize performance and product quality
The Solution
Aspects of the new implementation included:
- Early detection of faults and abnormal operating modes in critical electrical assets
- Reduced demand for routine maintenance of electric motors
- Flexible, optimized maintenance planning that aligns with the refinery’s production schedules
The Result
The PowerLink condition-based monitoring and preventative maintenance system ensure flexible maintenance planning, optimizing production, and fewer unplanned stops:
- Minimized the risk of unplanned shutdowns and disruptions to production processes
- Reduced workloads for maintenance staff
- Advised personnel for the replacement of the motor that would reduce active energy losses on 170 000 kW*h per year, thus reducing CO2 emissions by 47 tons per year
- Eliminated expenses on unnecessary regular maintenance of electric assets
- Ensured the protection of f a potential of reducing active energy losses in all the monitored motors combined of about 170 000 kW*h per year uel product quality
- Prevented faults in worn-out pump impellers and agitators within three months of operation