Predictive Operations Use Cases
Chemical Manufacturing
Benefits of Predictive Operations
Operational machine learning leverages underutilized operations data, and provides insights
that can significantly improve uptime, quality, performance, or safety.
20-50% reduction in maintenance planning time
15-25% increase in equipment uptime availability
10-15% improvement in product quality
Use Cases Across Industries
How can Falkonry help Chemical manufacturers?
Quality Assessment
Production Efficiency
Safety & Compliance
Predict batch quality
before final production
Predictive maintenance
of process compressor
to minimize downtime
Predict pre-trip conditions
in advance of compressor
trip to avoid unit shutdown
and flaring
Advance detection of
off-spec product to avoid
reprocessing costs
Quality Assessment
Batch and Process Manufacturing
Predict batch quality before final production
●
Problem: Variability in quality and yield of batch production
●
Cost: Material loss, production and disposal cost of low quality
batches
●
Solution: Discover patterns that predict final batch quality early in
the manufacturing process
●
Benefit: Avoid mixing low quality batches or scrap them early in the
process
Advance detection of off-spec product
Quality prediction
●
Problem: Product stream being off-spec
●
Cost: Reprocessing and inventory costs, yield degradation
●
Solution: LRS can identify off-spec events in advance and provide
early warnings
●
Benefit: Ensure product remains on-spec, waste reduction
Early warning of off-spec product
●
Chemical plants have multiple processing units
that manufacture products with required
specifications.
●
Some of the sensors/measurements that Falkonry
LRS monitors:
○ Process flows
○ Process temperatures
○ Process pressures
○ Intermediate unit stream properties (lab or
analyzer)
●
These sensors provide new data every minute.
Analyzer cycle times and lab sample draw
frequencies vary.
●
The customer is interested in early warning for a
product stream being off-spec.
●
Customer chose Falkonry LRS to identify early
warning conditions that operations can use to
correct conditions in the plant and ensure the
product remains on spec.
●
The objective is to use Falkonry’s early detection to
identify off-spec events in advance thereby
reducing reprocessing and inventory costs.
Applying Falkonry machine learning
Batch & Phase Indexed
Process Data
Recipe information
Process settings
Batch identification
Quality information
Machine telemetry data
- Temperatures
- Currents
- RPMs
- Torques
Batch & Phase Indexed
Machine Data
Predicted
Quality of
Batch
Advance warning of off-spec product
Early
detection of
off-spec
event
Actual off-spec events
Prediction: Predict “conditions” of the system
over time. Provides early warning.
Explanation Score: Identifies which signals
are most/least associated with a given
prediction.
*Signal names not shown
Production Efficiency
Predictive maintenance of process compressor
Early warning of compressor seal failure
●
Problem: Unplanned shutdown of process compressor
●
Cost: Lost production and concurrent high repair costs
●
Solution: Use Falkonry to monitor compressor health in real time
●
Benefit: Maintain planned production rates. Optimize downtime.
Predictive maintenance of process compressor
●
Chemical plants have multiple process compressor
units.
●
Some of the sensors/measurements that Falkonry
LRS monitors are:
○ Suction & discharge flows
○ Suction & discharge temperatures
○ Suction & discharge pressures
○ Recycle flow, valve position
○ Vibration (if available)
○ Load/Speed and Amperage
●
These sensors provide new data every minute.
●
The customer is interested in early warning for
scheduling the compressor for predictive
maintenance.
●
Customer chose Falkonry LRS to identify early
warning conditions that operations and
maintenance can use to proactively schedule an
optimal maintenance window and minimize
process downtime.
●
The objective using Falkonry’s early detection is to
minimize downtime and maximize compressor
life.
Predictive maintenance of process compressor
Without Falkonry
With Falkonry
Whitespace indicates either normal compressor operation or compressor downtime
Early detection
Advance warning
Compressor down for
unplanned maintenance
Falkonry identifies high seal degradation weeks in advance of detection by Ops
Safety and Compliance
Detecting pre-trip conditions for a process compressor
Proactive health monitoring for fixed equipment
●
Problem: Process related compressor trips leading to unsafe process
conditions and unplanned downtime
●
Cost: Unit trip, flaring, downtime and startup cost
●
Solution: Identify precursor conditions that lead to a compressor trip
●
Benefit: Maintain planned production rates and improve safety
Detecting pre-trip conditions for a process compressor
●
Process units have multiple compressors for
vapor handling and recovery.
●
Some of the sensors/measurements that
Falkonry LRS uses:
○ Suction & discharge pressure
○ Suction & discharge flow
○ Suction & discharge temperature
○ Vibration
○ Process measurements (Flow,
Temperature, Pressure)
●
These sensors provide new data every minute
●
The customer is interested in identifying
precursor conditions for process related
compressor trips.
●
Customer chose Falkonry LRS to identify
early warning conditions that operations
can use to avoid downtime & flaring events
and/or posture the unit for a graceful
shutdown.
●
The objective is to use Falkonry’s early
detection to avoid trips and flaring events
thereby reducing startup costs and fines.