IIOT Development

IIOT for process intensive industry

Asset Monitoring and Predictive Maintenance: Industries constantly strive to diagnose and predict asset failure, protect workers (hazard exposure - chemical spill/ leak for e.g.,) and reduce NPT.

Managing emergency conditions Lack of effective and efficient maintenance strategy where plant operators and engineers have limited accessibility and visibility on the performance on asset especially pumps, pipes, boilers, reactor vessels, etc.,. Mechanical parts (mechanical seals, wear and tear of pumps, misalignment of shafts, failure of couplings and bearings, vibration and leaks etc ) and fluid handling systems (pumps, pipes, boilers, seals, reactor vessels) , high pressure and temperatures associated with an abundance of inflammable & toxic fluids, pose a huge risk leading to unplanned downtime, delayed production, and does not present an ideal working environment.

Benefits of IIoT Applications

• Reduced Unplanned Downtime: Proactive maintenance keeps machines running longer.
• Improved Worker Safety: Sensors and automation reduce the need for humans in hazardous environments.
• Lower Operating Costs: Optimized processes reduce waste and resource consumption.
• Data-Driven Decision Making: Real-time visibility enables better, faster business decisions.

Industry trend: IIoT in Oil and Gas Companies

• Oil and Gas is a vast industry that requires a lot of variables to be managed at once. IIoT implementation simplifies the process of monitoring these variables through sensor technology and advanced telemetry.
• The upstream, midstream, and downstream segments benefit from the seamless framework of IIoT, as it creates a connected ecosystem within the entire infrastructure, thereby improving supply chain, customer deliveries and schedules.

BC Solution - IIOT on cloud with AI/ML Data Analytics

• Real-time monitoring: BC IIOT solution offers real-time monitoring of equipment and operations, which allows for early detection of potential problems before they escalate into critical/ crisis issues. This feature enables to initiate preventive measures before any downtime or loss of production (NPT).
• Predictive maintenance: BC IIOT solution uses cloud based AI/ ML advanced predictive analytics by analysing data from sensors installed at oil & gas facilities enables analytics predict when equipment is likely to fail, and provides insights into root cause analysis. They help identify pre-failure conditions and initiate/ trigger maintenance schedules in advance to avoid major downtimes and ensure smooth operation and smarter utilization of assets. This feature is especially helpful in maintaining remote offshore facilities, which often lack visibility and rely on manual check-ups.. This feature allows for scheduled maintenance that can reduce downtime and improve asset longevity.
• Improved safety & Hazard Management: BC IIoT solution provides remote monitoring, the presence of flammable gases and toxic vapors in the atmosphere and help prevent gas leakage or oil spills. Accident prevention capabilities of IIoT also make drilling and extraction operations safer and reduce injury rates by enabling advanced workplace safety monitoring and instant danger alerts. BC IIOT solution, which enhances the safety of employees by enabling them to monitor operations from a safe distance. It also allows for a faster response to any potential safety incidents – oil spill, chemical leak, low/ inconsistent fluid levels/ flow etc., allowing zone confinement/ initiate standby process to avoid NPT.
• Better production planning: Our IIOT solution provides real-time data on production levels and can help with better production planning. This feature enables production optimisation, reduce costs & redundancy, and increase profitability.
• Scalability & Integration: Our IIOT solution is scalable and can integrate with existing systems and infrastructure

To summarize IIoT Benefits for Oil and Gas Industry: The Internet of Things (IIoT) is used in the oil and gas industry to collect, transfer, and analyze raw data in real time to get a clear picture of processes at the facilities, improve operational efficiency, reduce energy consumption, and drive profitability across three major segments:

• Upstream operators use it to enhance drilling and extraction management and reduce non-productive time.
• Midstream operators improve fleet management as well as pipeline and storage maintenance.
• Downstream businesses leverage IIoT for optimized oil and gas processing and distribution.

Real-time visibility

IIoT solutions provide real-time view into equipment performance and safety status, environmental conditions, and fleet operations, enabling oil and gas companies to continuously monitor their assets - fixed or mobile.

Predictive maintenance

They help identify pre-failure conditions and perform maintenance in advance to avoid major downtimes and ensure smooth operation and smarter utilization of assets. Employing IoT helps optimize maintenance schedules there to avoid unnecessary visits of technicians while ensuring maximum equipment health.

Other Markets/ Industries

• Pharma
• Food Processing
• Chemical plants
• Fertiliser

Field study

State of the art IIOT 4.0 based multi sensor data analytics engine on a cloud platform to provide performance in real time and advanced preventive maintenance diagnostics

• The present solution handles data from 78 sensors with 22 distinct sensor types placed at right places in a urban water supply system along with field validation and real time monitoring connected to cloud based data analytics engine for prognostics.

Result

15%	savings in energy costs
12%	savings in scheduled repairs
25%	reduction in overall maintenance costs
70%	reduction in unwarranted breakdowns

No unscheduled breakdown and maintenance
LCC reduction by 15-45%
Extended life of pumping station by 30-50%
Real time performance and operational information of pumpsets