Predictive maintenance projects in the oil and gas industry

The Abu Dhabi Nation­al Oil Com­pa­ny (ADNOC) select­ed Honeywell’s asset mon­i­tor­ing and pre­dic­tive ana­lyt­ics solu­tion to dri­ve improved asset and machin­ery man­age­ment across ADNOC’s upstream and down­stream oper­a­tions. Lever­ag­ing AI tech­nolo­gies like machine learn­ing and dig­i­tal twins, the plat­form is expect­ed to help gen­er­ate sig­nif­i­cant year­ly sav­ings through reduced unplanned main­te­nance, increased reli­a­bil­i­ty, uptime and safety.

The 10-year con­tract marks one of the largest pre­dic­tive main­te­nance projects in the Oil and Gas indus­try and is part of ADNOC’s flag­ship Cen­tral­ized Pre­dic­tive Ana­lyt­ics and Diag­nos­tics (CPAD) pro­gram. CPAD, which under­pins the company’s 2030 Strat­e­gy and Oil & Gas 4.0 ini­tia­tives, aims at trans­form­ing ADNOC’s oper­a­tions to max­i­mize val­ue from every bar­rel of oil, while deliv­er­ing the great­est pos­si­ble returns to the Unit­ed Arab Emirates.

“ADNOC con­tin­u­ous­ly dri­ves inno­va­tion and seeks new and advanced tech­nolo­gies that can enhance oper­a­tional effi­cien­cies and opti­mize per­for­mance,” said Dr. Alan Nel­son, chief tech­nol­o­gy offi­cer, ADNOC. “The pre­dic­tive main­te­nance project is sig­nif­i­cant in scale and in its appli­ca­tion of AI tech­nol­o­gy. Data on thou­sands of crit­i­cal assets will be host­ed on a plat­form where AI tech­niques will be applied to enable us to bet­ter under­stand the per­for­mance of our assets and to pre­dict short­falls in advance, there­by enabling us to max­i­mize oper­a­tional effi­cien­cies. Hon­ey­well was select­ed as our tech­nol­o­gy part­ner to pro­vide this state-of-the-art solu­tion after a high­ly com­pet­i­tive and rig­or­ous bid process.”

ADNOC will deploy Hon­ey­well Forge Asset Mon­i­tor and Pre­dic­tive Ana­lyt­ics solu­tions at its Panora­ma Com­mand Cen­ter in its Abu Dhabi head­quar­ters. Its Panora­ma Dig­i­tal Com­mand Cen­ter cur­rent­ly aggre­gates real-time infor­ma­tion across ADNOC’s busi­ness­es and uses smart ana­lyt­i­cal mod­els, AI and big data to gen­er­ate oper­a­tional insights and rec­om­mend new path­ways. The addi­tion of Honeywell’s solu­tions will enable the cen­tral mon­i­tor­ing of up to 2,500 crit­i­cal rotat­ing equip­ment across all ADNOC Group companies.

With con­tin­u­ous online equip­ment mon­i­tor­ing, aid­ed by dig­i­tal twin mod­els and machine learn­ing ana­lyt­ics, oper­a­tors and main­te­nance per­son­nel will be able to iden­ti­fy impend­ing machin­ery issues ear­li­er and shift from reac­tive and pre­ven­ta­tive main­te­nance prac­tices to a pre­dic­tive main­te­nance approach. Sophis­ti­cat­ed insights into equip­ment health will also allow ADNOC to eval­u­ate equip­ment over­haul exten­sion pro­grams, increase the avail­abil­i­ty of equip­ment and max­i­mize pro­duc­tion. Built on a scal­able enter­prise plat­form, the solu­tion will accel­er­ate time to val­ue by pro­vid­ing ADNOC engi­neers with a host of embed­ded data sci­ence and sim­u­la­tion tools.

“Hon­ey­well Forge Asset Mon­i­tor and Pre­dic­tive Ana­lyt­ics can deliv­er sig­nif­i­cant OPEX cost-sav­ings each year while opti­miz­ing CAPEX expen­di­ture,” said Que Dal­lara, pres­i­dent and chief exec­u­tive offi­cer of Hon­ey­well Con­nect­ed Enter­prise. “We look for­ward to ADNOC real­iz­ing these ben­e­fits after deploy­ing this lead­ing-edge tech­nol­o­gy. Our enter­prise-grade solu­tion pro­vides the intel­li­gence aug­men­ta­tion that busi­ness lead­ers rely on for quick and effi­cient deci­sion mak­ing. Lead­er­scan now focus their resources on inno­va­tion and achiev­ing opti­mal busi­ness outcomes.”

The pre­dic­tive main­te­nance project is one of many dig­i­tal trans­for­ma­tion ini­tia­tives by ADNOC to embed cut­ting-edge tech­nol­o­gy across its entire val­ue chain and deliv­er on its Oil & Gas 4.0 mis­sion to stay ahead of the world’s grow­ing demand for ener­gy. Oth­er dig­i­tal ini­tia­tives include its Panora­ma Dig­i­tal Com­mand Cen­ter; smart data ana­lyt­ics Thama­ma Sub­sur­face Col­lab­o­ra­tion Cen­ter; and the use of AI-assist­ed val­ue chain mod­el­ing, rock image pat­tern recog­ni­tion tech­nolo­gies, and blockchain-based hydro­car­bon account­ing, to name a few.

Hon­ey­well is an estab­lished leader in dig­i­tal trans­for­ma­tion across the Mid­dle East and glob­al­ly. Through Indus­tri­al Inter­net of Things (IIoT) based solu­tions, Hon­ey­well has enabled many of the region’s oil and gas projects to achieve improved per­for­mance and effi­cien­cy. The company’s solu­tions sup­port a vari­ety of long-term, nation­al devel­op­ment and eco­nom­ic diver­si­fi­ca­tion ini­tia­tives across the Mid­dle East and North Africa region.