Predictive Maintenance Automation: Transforming Petrochemical Operations
The Challenge
Frequent unexpected equipment failures caused costly downtime and safety risks at a leading Saudi petrochemical plant.
- 7.2 days of unplanned downtime per quarter
- $3.5M daily production loss
- High emergency maintenance and safety incident rates
Our Approach
EliteSquad.ai deployed an AI-driven predictive maintenance system integrating with existing SCADA, DCS, and SAP systems.
- Unified data via custom APIs on Azure
- Machine learning for early fault detection
- Automated alerts and SAP work orders
- Real-time dashboard for equipment health and planning
Key Outcomes
30% reduction in infrastructure and operations.
20% lower maintenance costs
40% fewer safety incidents
$15M saved from prevented compressor failure
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