Flutura Powering Industrial IOT for Leading Shale Equipment Manufacturer

About Client

The customer is one of the world’s largest designers and manufacturers (OEM) of specialized equipment for the hydrocarbon and heavy engineering industries. They also provide aftermarket parts and services to their customers. Some of the high-end equipment they provide include Fracturing Pumps, Chemical Additive Units, Acidizing Units, etc.

Business Problem

Hydrocarbon producers are heavily dependent on OEMs to minimize asset failures and downtime. Daily losses of millions occur at Shale Fields when there is any critical equipment failure, and complex mechanical assets such as Fracturing Pumps are prone to frequent failures.

Operational Efficiency is another key problem hydrocarbon producers face, especially given the state of the industry today, and are depending on the OEM’s to help them with. Operational assets that are not optimally utilized lead to high fuel expenditure.

Though there was an opportunity to help their customers with these two critical issues and retain competitiveness in an industry that was being rapidly commoditized, our customer, the OEM, did not have the means to manage assets at such a massive scale.

How Cerebra Solved the Problem

Cerebra IOT Prognostics/Diagnostics platform ingested signals from a variety of frontline industrial assets in real time like - Acidizing units, Fracking pumps, chemical additive units, blenders, large generators,. The specific signals analyzed include Pressure signals , Oil temperature signals, horsepower signals, rpm signals, discharge pressure signals to: find Anomalies to Potential Fault Modes, predict Failures & Maintenance Requirement, Forecast Spares requirement, and Optimize Asset Performance & Utilization.

Scale

20,500 Assets - 1.5 Million Signals - Thousands of Sensors streaming data at a second level - Event logs including Trips & Alarms

Benefits to the Business

Cerebra, Flutura’s Machine Intelligence Platform, created a new revenue stream for our customer by enabling them to provide digital services to their customers such as:

• Failure Prediction leading to Reduced Downtime, Scheduled and Breakdown Maintenance Cost
• Asset Performance Monitoring & Benchmarking leading Increased Asset Performance & Utilization
• Timely Spare Refurbishment leading to Increased Cross-selling & Up selling Opportunities