Facilities with industrial ovens, furnaces, and boilers must safely operate, troubleshoot, and maintain the equipment. This requires a high level of knowledge and expertise, which is becoming scarcer due to the retirement of older workers and the higher turnover rate of younger staff.
Connected Internet-of-Things (IoT) technology and cloud-based resources are being used to help overcome the lack of experienced workers while also helping to save time, improve safety and extend equipment life.
IoT and advanced artificial intelligence (AI) technologies are being leveraged for predictive maintenance. You can evaluate the equipment (as opposed to the process) in real-time, compare against historical data, and make maintenance recommendations before failure occurs.
Drones are being used to more easily inspect the condition of elevated piping and exhaust stacks. Actionable intelligence can be gathered on valve and piping leaks and damper and relief valve operation.
AI software, in conjunction with machine vision, can automate subjective quality assurance assessments. Typically, a digital twin of the machine is created and used to make the analysis and provide detailed equipment files. Augmented reality glasses then allow a maintenance worker to operate in a complete hands-free and paperless manner.
Parts can be ordered, warranties checked and labor scheduled all online. This connected environment also enables outcome-based maintenance, which uses key performance indicators rather than adherence to fixed schedules.
Start-up and shut-down are the most dangerous parts of the operation large thermal process equipment. National Fire Protection Association standards suggest the use of performance-based risk reduction safety instrumented system (SIS) Level 2 hardware and software controls. SIS-2 equipment takes a process to a safe state when predetermined conditions are violated.
With the help of advanced connected technologies, your operations and maintenance staff can keep your equipment running safely and effectively.