Continuously monitor all the parameters of mechanical seals and generate auto alerts at a very early stage. SIMS captures details from instruments already installed on seal pots ; data entered in ODR by operator. Generates alerts based on defined alogrithms when the seal/seal system 's health starts deteriorating.
Seal health monitoring strategy
Recommendation closure
Alert generation based on deviations
Specialist analysis (Site Rotary team)
Recommendation generation
Inputs for model
Model preparation
Mechanical seal integrity monitoring platform
Recommendation management module
WO management module
IP21
Field - mounted instruments
Recommendation implementation and feedback to specialists
Seal data collection through ODR tool by FE
Figure 4 Seal health monitoring is configured in all the complex’s pumps, with 129 saves to date
observations and behavioural assessments is systematically analysed. Potential ‘bad actors’ are identified, enabling targeted programmes and campaigns. Continuous improvement initiatives have led to measurable year-on-year improvements in safety performance. • Production and energy efficiency : Syngas output has surged ahead, setting conditions have led to a substantial increase in syngas production. This surge not only reflects enhanced process stability but also demonstrates the effectiveness of targeted performance initiatives. The higher output sets a new internal benchmark for efficiency, throughput, and reliability, showcasing the facility’s capability to operate at improved conversion rates while maintaining product quality. This upward shift in performance also provides a stronger foundation for meeting downstream demand and supporting overall plant productivity. a new benchmark. Recent operational improvements and optimised process Captive energy usage has been significantly reduced, enhancing overall energy efficiency. Through strategic optimisation, better heat integration, and improved equipment performance, the facility has successfully lowered its captive energy consumption. Reducing internal energy demand not only decreases operational costs but also contributes
to a more sustainable energy footprint. These improvements allow more efficient utilisation of available resources, minimise energy losses, and support corporate goals related to sustainability and reduced emissions. The cumulative effect is a more resilient, energy-efficient operation with enhanced long-term reliability, and cost competitiveness. • Equipment reliability : Monitoring rotary equipment performance with the help of EED logics has reduced reliability concerns over the years. Continuous real-time monitoring of critical rotary equipment supported by advance EED logic has significantly strengthened equipment reliability. These enhanced diagnostic capabilities allow for early detection of abnormal vibrations, temperature shifts, load variations, or lubrication deficiencies. By identifying deviations at an early stage, operators can intervene proactively, preventing unplanned downtime and reducing the overall maintenance burden. Over time, this data- driven approach has translated into fewer recurring issues, longer equipment life cycles, and greater operational confidence. Stringent control in the process has reduced the static equipment failure caused by vibrations. Through improved process stability, tighter control parameters, and better dynamic balancing of operating conditions, the plant has substantially lowered the rate of
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