End-User

Bharat Petroleum Corporation Limited (BPCL) is a state-owned oil and gas exploration and production company and it has one of the largest Oil & Gas facilities in the country.

CONSYST’s assignment in BPCL Kochi refinery was to implement a Condition-based Maintenance system and a Preventive Maintenance Planner for the critical motors in the refinery.

Background

The electrical assets in various plants in the refinery are maintained by the Power & Utilities department. The responsibility includes maintenance of HT and LT motors of varying makes. The maintenance tracking was carried out using excel sheets, which turned out to be tedious and complex to manage, in the long run. In the absence of visibility to the actual usage of motors, the maintenance personnels carried out motor maintenance in a cyclic manner, which often resulted in over-greasing and under-greasing motors. In turn, this resulted in a high number of motor failures, which caused an increase in unplanned plant shutdowns and production losses.

In the first phase, a Condition-based Maintenance system was implemented for a selected 1800 motors. This system had a highspeed data gathering mechanism, calculated motor run-hours on the fly, and kept track of greasing dates. The interactive dashboard provided a list of motors due for greasing, in the order of priority.

In the second phase, a Preventive Maintenance Planner module was incorporated into the system. This module kept track of maintenance frequencies and last maintenance dates, to present a prioritized list of motors for upcoming maintenance activity.

System Description

Using our IIoTNext Platform, a centralized motor management system was developed, which collected critical motor parameters via OPCUA from the existing DCS in the refinery. The built-in high-performance timeseries database, and low-code rule-flow module of IIoTNext Platform, played a crucial role in the solution.

Condition based Maintenance:

• Interactive dashboards and reports provide data visualization and deeper insights which gave maintenance team visibility into each motor, which helped them to save time and money, by taking actions at the right time.
• Web-based dashboards, which fetches and aggregates data from multiple sources, which includes run-hours, start count, & motor metadata, maintenance schedules, last maintained dates etc.

Preventive Maintenance Planner:

• A Preventive Maintenance period of a motor will vary motor to motor based on multiple factors. The typical period is 1 year or 2 years.
• Weekly PM reports, which include a prioritized list of motors to be maintained, are published. This enabled maintenance personnel to plan for the maintenance activity in advance.
• Daily Reports, which include the list of motors which have undergone the PM Maintenance, is sent to maintenance team through email.
• The maintenance personnel can add comments, attach photographs, and fill out checklists. Comparison of motor health (dust levels, leakage, cable condition etc.) between the maintenance activities is possible.

Result

• The maintenance team at BPCL Kochi Refinery can now schedule equipment maintenance based on actual usage and condition of the motors, effectively saving time and money.
• Daily emails with a list of motors to be maintained make job allocation to technicians efficient and effective.
• Powerful dashboards with swift navigation give the customer an insight into the equipment’s current status and forthcoming maintenance schedule.