What operational data is most underutilized today for predictive reliability and integrity management in petrochemical plants?
And what are the measures to make sure that the data is taken, used, and analyzed to switch reliability & integrity towards predictive mode?
Underutilized Operational Data
Re: Underutilized Operational Data
Just to start supporting your idea, petrochemical plants are sitting on massive amounts of operational data… but only a small fraction is actually converted into actionable predictive reliability or integrity intelligence.
Most sites still operate in a “reactive + preventive” mode:
Alarm happens → react
Equipment fails → investigate
Thickness drops below limit → repair
Vibration high → inspect
The real opportunity is identifying weak degradation signals months or years before functional failure.
I am not sure that is happening.
Now looking for such operational data;
- IOW deviations pickup
- Transient & upset data (leading indicator)
- Control valve behavior data
- Low level vibration
- Exchangers thermal performance trending
- PSV /flare system activation data
- Unexpected corrosion rates
- Operator log books & shift notes (early indications)
- Maintenance deferral analysis
- Temporary repair data analysis
Plants in todays time too struggle to be having a proactive approach towards issues.
Most sites still operate in a “reactive + preventive” mode:
Alarm happens → react
Equipment fails → investigate
Thickness drops below limit → repair
Vibration high → inspect
The real opportunity is identifying weak degradation signals months or years before functional failure.
I am not sure that is happening.
Now looking for such operational data;
- IOW deviations pickup
- Transient & upset data (leading indicator)
- Control valve behavior data
- Low level vibration
- Exchangers thermal performance trending
- PSV /flare system activation data
- Unexpected corrosion rates
- Operator log books & shift notes (early indications)
- Maintenance deferral analysis
- Temporary repair data analysis
Plants in todays time too struggle to be having a proactive approach towards issues.
Re: Underutilized Operational Data
IOW deviations pickup is required to be utilized by interfaces like inspection, integrity, and maintenance.
Similarly, for other cases like control valve behavior, low level vibration are maintenance related items.
So it is the responsibility of the interfaces to make sure all this data is correctly utilized.
Similarly, for other cases like control valve behavior, low level vibration are maintenance related items.
So it is the responsibility of the interfaces to make sure all this data is correctly utilized.
Re: Underutilized Operational Data
Some very meaningful set of data here.
I was thinking about operator log books & shift notes. Yes, early indications can be picked up from there.
PSV activation, I believe is one controlled, and measured set of data which at least at our place is very well reported, and analyzed.
Low level vibration, someone reports that?
I was thinking about operator log books & shift notes. Yes, early indications can be picked up from there.
PSV activation, I believe is one controlled, and measured set of data which at least at our place is very well reported, and analyzed.
Low level vibration, someone reports that?
sys1 wrote: 29 May 2026, 11:49 Just to start supporting your idea, petrochemical plants are sitting on massive amounts of operational data… but only a small fraction is actually converted into actionable predictive reliability or integrity intelligence.
Most sites still operate in a “reactive + preventive” mode:
Alarm happens → react
Equipment fails → investigate
Thickness drops below limit → repair
Vibration high → inspect
The real opportunity is identifying weak degradation signals months or years before functional failure.
I am not sure that is happening.
Now looking for such operational data;
- IOW deviations pickup
- Transient & upset data (leading indicator)
- Control valve behavior data
- Low level vibration
- Exchangers thermal performance trending
- PSV /flare system activation data
- Unexpected corrosion rates
- Operator log books & shift notes (early indications)
- Maintenance deferral analysis
- Temporary repair data analysis
Plants in todays time too struggle to be having a proactive approach towards issues.
Re: Underutilized Operational Data
Plants often ignore intermittent alarms, occasional vibration, rare excursions, nuisance trips, minor leaks.
But major failures usually begin as weak recurring signals.
Predictive organizations investigate weak signals early.
But major failures usually begin as weak recurring signals.
Predictive organizations investigate weak signals early.