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Energy verified Verified Outcome TRL 9

AI-Driven Valve Predictive Maintenance

domain Client: Oil Refinery / LNG handshake Provider: C3 AI schedule Deploy: 2019-Present
93 Impact
Enterprise Ready
Evidence Score: 5/10
Strength: High

Executive Summary

ANALYST: COI RESEARCH

Application of machine learning to predict failure in thousands of control valves across global assets, moving from scheduled maintenance to predictive intervention.

rate_review Analyst Verdict

"Scale implementation of AI. Many do pilots; Shell did a global rollout. Valves are a common single-point-of-failure. The AI catches subtle anomalies (sticking, hunting) that humans monitoring SCADA screens miss, preventing unplanned shutdowns."

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Full Audit Report Available Includes Risk Register, Technical Specs & Compliance Data.

warning The Challenge

A typical refinery has thousands of control valves. If one fails, it can shut down a whole unit or cause a safety incident. Maintenance was based on 'time' (fix every 3 years) which is inefficient, or 'failure' (fix when broken) which is costly. Engineers could not manually analyze the data streams from 10,000+ valves.

psychology The Solution

Deployed the C3 AI Predictive Maintenance application. It ingests data from the plant historian (pressure, flow, valve position). The model learns the 'normal' behavior for each valve. It flags anomalies like 'valve hunting' (oscillation) weeks before failure. Alerts are triaged to local reliability engineers to schedule repairs during planned windows.

settings_suggest Technical & Deployment Specs

Integrations
OSIsoft PI
Deployment Model
SaaS
Data Classification
Operational Data
Estimated TCO / ROI
Subscription
POC Summary (2018 to 2019)

"Pilot in Pernis Refinery."

shield Risk Register & Mitigation

Risk Factor Severity Mitigation Strategy
Alert Fatigue Medium Model tuning/retraining.
Data Quality High Sensor calibration checks.

trending_up Impact Trajectory

Audited value realization curve

5-10% reduction in overall maintenance costs Verified Outcome
Primary KPIEarly detection of 65+ valve failures in single asset
Audit CycleScaled to 10,000+ valves globally

policy Compliance & Gov

  • Standards: Safety Critical Systems
  • Maturity (TRL): 9
  • Evidence Score: 5/10
  • Data Class: Operational Data

folder_shared Verified Assets

description
Verified Case Study
PDF • Version 1
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Technical Audit
PDF • Audited
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The "Blind Verification" Protocol

How we verified these outcomes for Oil Refinery / LNG without exposing sensitive IP or identities.

Private
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1. Raw Evidence

Audit ID: #PRIV-694
Evidence: Direct SQL Logs
Public
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2. Verified Asset

Outcome: Verified
Ref ID: #COI-694

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