Industrial monitoring has traditionally relied on manual and time-based methods, but as new technologies emerge, it’s clear that repeating the same process is no longer optimal. The classic quote from Einstein, “Insanity is doing the same thing over and over and expecting different results,” perfectly captures this sentiment. In today’s environment, relying on human-driven industrial monitoring is becoming increasingly untenable due to the challenges of hiring, training, retaining, and ensuring consistent performance across shifts.
Consumer and commercial markets are continuously investing in new technologies and methods to stay competitive. From anytime-anywhere access to home security and appliances to commercial fleet logistics and supply-chain anomaly detection, these markets are embracing automation. Industrial companies must follow suit and invest in similar technologies to transition from human-centered monitoring to automated solutions.
While some industrial companies enhance their monitoring within an existing framework that focuses on identifying "what went wrong and by how much," there’s a more proactive approach available: early detection. Early detection aims to find out "what is starting to go wrong and how to fix it in advance."
Early detection leverages high-fidelity sensors, automated data quality checks, and intelligent algorithms to identify early anomalies and adapt to the operating environment. This approach remains firmly anchored in first principles, operational methods, and operator requirements, rather than relying on predictions.
Early detection is an often automated process that monitors the condition of equipment in real-time and detects anomalies as defined by the user, and alerts plant operators to any perceived problem. It enables expert users to trust that potential problems are caught in real-time, before they cause equipment or operational failures.
The advantages of such an automated system are easy to see. The first and biggest advantage comes from downtime avoidance. The impacts of downtime can be extreme. According to a Global survey commissioned by ABB in 2023, unplanned or unscheduled downtime in the Oil & Gas industry costs approximately $144,452.28 per hour. Early detection can prevent many of these downtime hours, without the inefficiencies inherent to scheduled maintenance, such as unnecessary remote site visits and premature part replacements.
Scheduled maintenance involves regular inspection, repair and replacement. While this process is effective, it requires a truck roll, a certified engineer, and time spent - even when no repair is necessary. In contrast, real-time anomaly detection employs intelligent sensors to continuously monitor equipment and only alert operations when conditions actually demand attention. This approach eliminates the inefficiencies of scheduled maintenance and ensures timely interventions.
In Oil & Gas facilities, the leading causes of downtime are emissions and corrosion. With sensors programmed for real-time anomaly detection, emissions and corrosion can be caught early and that’s how analytics enters the equation.
A dataset is defined according to parameters that determine what kinds of anomalies should trigger alerts. The sensor data is then processed through an algorithm in real-time. When the inspection parameters are met, such as a pipe reaching certain thresholds, a truck roll can be scheduled, often on a more efficient timetable. Preventing unseen pipe corrosion and minimizing emissions are key to reducing downtime in oil and gas operations. Sensors can be strategically placed near mission-critical areas such as process units, fencelines, remote pipelines, alkylation units, fluid catalytic cracking units, and other process piping and equipment. This placement targets areas with a high risk of emissions or corrosion, enabling early detection and repair.
While downtime prevention is the biggest business case for early detection versus scheduled or preventative maintenance, it’s not the only factor involved in reaching operational excellence. Early detection offers many other advantages. These include improved equipment lifetime, better safety rates for facilities, and reduced environmental impact.
Automated anomaly detection systems result in fewer accidents and employee injuries, as full equipment failures are much less likely with real-time monitoring. This also helps prevent and reduce environmental impact because even tiny leaks can be detected before dangerous materials enter the ecosystem, significantly reducing the chance of major incidents. The benefits to any company known to have safer plants and facilities are substantial.
Equipment itself lasts longer when its actual conditions are constantly monitored and known to the experts in charge. Spare parts aren’t used unnecessarily because the calendar says it’s time for replacement. Instead, parts are only replaced when they reach predetermined levels of corrosion or deterioration. This approach saves money at scale in both equipment costs and employee hours.
When implementing any new system, it's crucial to address the operational challenges of workflow integration. Sensors need to be strategically placed, algorithms must be trained on relevant data sets, and the operations team must be equipped with the knowledge to use the new system effectively.
These concerns can temporarily slow productivity, if not addressed properly. That’s why it’s often best to partner with a trusted solutions provider that not only claims to have the capability to implement an early detection solution but also has operational real-time anomaly detection systems in the field. A partner’s experience should be evident and proven across various environments, particularly with your industry’s unique challenges.
In process industries such as oil and gas, petrochemical, and chemical sectors, shifting from scheduled maintenance to early detection is a logical step toward true operational excellence, especially when handling volatile or hazardous materials. This transition not only drives efficiency, but also ensures cost savings, enhances employee safety, and minimizes environmental impact.
Contact us to learn how mPACT2WO can help you achieve operational excellence.