Objective Allow optimized inspection, repair, and workload planning by providing asset maintenance, performance & location/tracking information
Technologies Laser Scanning, Digital Twin, 3-D Modeling, Antea Web, Edgeline Systems
Partners CBT, Hewlett Packard Enterprise, Antea
‘The Eureka moment for me for our IIoT implementation was when I realized that with a handheld device we could get readings on the condition of a particular asset, like a particular pump, which would tell whoever was looking at the handheld device, that the asset, that pump is going to fail in a week, it’s going to fail in a day, it’s going to fail in an hour, it was like the proverbial light bulbs going off above all our team’s head.’
~Doug Smith, CEO of Texmark Chemicals, Inc.
In a chemical plant environment if a system goes down it can cost millions of dollars and even loss of life. When Texmark Chemical reached out to HPE, CBT and the RotF partners they described an industry struggling with outdated equipment, no centralization of data, and manual processes that were dependent on the tribal knowledge of a generation of employees nearing retirement. The RotF partners proposed a Solution that would centralize the data intelligence around all the plant’s assets.
Asset Integrity Management allows for optimized inspection, repair, and workload planning by providing asset maintenance, performance & location/tracking information.
Asset Integrity Management centralizes and distributes data to keeps systems running and reduce cost– enabling decision making both real-time and long-term, expediting maintenance procedures and emergency response, and empowering proactive maintenance planning.
Asset Integrity Use Case and ROI– Mechanical Integrity (MI)
Mechanical Integrity (MI) encompasses the activities necessary to ensure that equipment/assets are designed, fabricated, installed, operated and maintained. That means required inspection of different plant assets, and monitoring things like corrosion and the overall condition of the plant. At Texmark, the MI initiative was largely driven by a pending increase in insurance deductible for the plant, and the process they went through with their insurance company to develop a program for compliance using IIoT technology.
It started four years ago when Texmark’s insurance carrier was demanding a more formalized approach from Texmark for their MI process. So Texmark spent the first year putting a framework together with some simple tracking on spreadsheets to show the insurer. The insurer told them ‘this is good, it’s a start but we still need a more formalized MI program’. Another year went by, and Texmark shared additional information with their insurer, but the insurer still needed more information and doubled Texmark’s deductible. As Doug Smith, CEO of Texmark recalled, ‘that really got our attention!’
Using Asset Integrity Management technology, Texmark created a digital twin of their plant using 3-D laser imaging, and then implemented Antea Web that allowed them to start ingesting all of the different records, paper files, computer files, and put them into a digital library which included inspection data.
When the insurer came back they were so impressed that they reduced Texmark’s deductible back to what it originally was.
‘We knew we needed IIoT technology to advance our operations and keep us ahead of the competition. What we got from the RotF partners exceeded our expectations because our team was involved and engaged from the beginning, and not just at the executive level. Our employees understood that this wasn’t another smoke and mirrors technology project with no substance that was being forced on them. The team came up with the use cases, worked with the RotF partners, and the technology made it real.’
~Linda Salinas, VP of Operations, Texmark Chemicals, Inc.
Inspection & Quality Control | Predictive Maintenance | Risk Analysis | Emergency Response | Preventative Maintenance
Benefits and Value
- Enables immediate and long-term decision making
- Expedites maintenance procedures/emergency response
- Empowers proactive and responsive maintenance planning
- Reduces costs
Return on Investment
- 75% reduction in time to identify equipment malfunction/degradation
Formerly, workers had to manually locate unstructured, paper files (asset’s P&IDs, inspection reports, asset drawings, etc). Now, workers can log in to Antea Web, retrieve documents digitally, obtain a 3-D rotational view of assets and obtain risk-based inspection graphs.