Insight
AI Valve Diagnostics Prevent Costly Shutdowns and Extend Equipment Life
Reducing unnecessary maintenance, increasing safety, and improving uptime by proactively identifying valve issues—before they impact production.
Anticipate control valve failures before they progressed to major operational disruptions. Optimize maintenance by identifying and scheduling repairs only when truly necessary.
Advanced Valve Diagnostics
Created AI models that analyzed historical valve performance, sensor data, and operational parameters.
Early Warning System
Implemented alerts to flag performance anomalies, leakage trends, and wear indicators.
Cross-Site Implementation
Deployed the solution across multiple plants, each with varying valve models and operating conditions.
Operator Interface
Provided user-friendly dashboards displaying valve health scores and recommended interventions.
Achieved Results
01
Early alerts enabled proactive interventions, cutting unplanned outages by nearly half.
02
Fewer emergency repairs and lower production losses translated into tangible ROI.
03
Stable compressor performance improved overall plant throughput.
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Aggregated insights allowed management to prioritize maintenance resources effectively.
The Real-World Challenge That Drove Our AI Breakthrough
Our journey began with a real-world need—something no off-the-shelf solution could fix. This complexity pushed us to design a tailored AI model capable of adapting to unpredictable variables in dynamic environments.
Varied compressor makes and models, with sensor data in multiple formats.
Staff accustomed to reactive maintenance practices initially questioned the AI-driven approach.
Ensuring the platform integrated seamlessly with existing SCADA systems.
Approaches
Unified disparate data sources in a secure cloud environment.
Fine-tuned models for each compressor's unique operating profile.
Launched pilot implementations at select sites, then rolled out company-wide after successful validation.
Incorporated field feedback to continually improve model accuracy and reduce false positives.
Benefits & Outcomes
01
Transitioned from a “fix-it-when-it-breaks” mentality to a predictive approach.
02
Compressors ran more efficiently, driving productivity gains.
03
AI insights fostered teamwork among maintenance, engineering, and operations.
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