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Leverage AI-infused APM to prevent unplanned downtime from shutting down the value chain

SCG Chemicals is one of the largest petrochemical companies in Thailand and a key industry player in Asia. The company's integrated operations include initial production of olefins and subsequent production of polyethylene, polypropylene and polyvinyl chloride.

With its closely integrated business, the company ran the risk that the failure of an individual piece of equipment could shut down the entire production chain with direct implications for financial performance. To address this risk, SCG Chemicals undertook a digital transformation initiative to leverage data to create an advanced asset performance management (APM) solution to monitor critical assets and predict failures toward the goal of zero plant downtime.

The company partnered with AVEVA to develop a digital reliability platform (DRP), a complete asset performance management solution to predict equipment health, monitor performance and enable advanced maintenance to eliminate unnecessary downtime. planned. Using a combination of on-premises and cloud-based applications, the solution integrates online and offline equipment data to visualize plant performance, improve workforce efficiency, and apply artificial intelligence (AI) for predictive maintenance and resolution.

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Goals

  • Build on integrated platform to provide integrated, real-time visibility of operations
  • Leverage smart analytics and cloud to drive decision support and streamline operations
  • Visualize operational information and KPIs to coordinate Asset Performance Management (APM)


Challenges

  • Drive greater real-time visibility of plant performance across team
  • Visualize data and track KPIs as well as leverage performance improvements from analytics-based decision support
  • Build a digital operating system that would realize the vision of zero unplanned downtime


Solutions 

  • AVEVA™ Predictive Analytics.
  • AVEVA™ Enterprise Data Management.
  • AVEVA™ System Platform.
  • AVEVA™ Mobile Operator.
  • AVEVA™ Enterprise Asset Management.
  • AVEVA™ Work Tasks.
  • AVEVA™ Insight.
  • AVEVA™ Asset Information Management.
  • AVEVA™ 3D Asset Visualization.
  • AVEVA™ E3D Design.
  • AVEVA™ Flex subscription program


Results

  • Plant reliability raised from 98% to 100%
  • ROI of 9x achieved within six months
  • Maintenance costs reduced, delivering savings of 40%
  • End-to-end visibility of plant operations
  • Trusted real-time data blended with analytics enables team to predict equipment health, monitor performance and drive optimizations more readily
  • Better understanding and tracking of performance through visualization of data and KPIs
  • Operational digital twin supports aim to dive zero unplanned downtime



“Our Digital Reliability Platform is an unprecedented step forward to ensure reliability for our business. AVEVA was the only company able to provide an end-to-end solution spanning engineering, operations, and maintenance. With the DRP, we have successfully brought together big data, AI, machine learning, and predictive analytics into a practical solution that will empower our workers and improve our performance. This is a great achievement and innovation for SCG Chemicals.”

Mr. Mongkol Hengrojanasophon, VP – Olefins Business & Operations SCG Chemicals




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