Dow Reliability Program Pays Off
Dow Chemical engineers in Deer Park Texas are using HART technology as part of a reliability improvement program to monitor critical control valves connected to asset management software for diagnostics, failure analysis, and preventative/predictive condition-based maintenance. Using the intelligent device information significantly reduced costs and improved plant operations as it enabled the transition from reactive to proactive maintenance.
MILLIONS OF $$ IN EBIT SAVINGS!!!
HART technology has helped reduce production downtime related to control valve failures. Through their reliability program, the plant has realized a 67% improvement in downtime reduction over a three year period. Along with performing valve overhauls, they use the HART signal to monitor real time valve conditions which has helped with identifying problems before they could cause unplanned events. Combined with several improvement initiatives, this reliability effort has yielded significant financial savings totaling millions of dollars to the bottom line.
HART Communication helped Dow Chemical realize benefits and savings throughout plant operations:
- Changed the plant culture with regard to valve maintenance, diagnostics and troubleshooting
- Identified root cause of the problem; short term solution to fix the problem; long term strategy to prevent it from happening again
- Recognized need for an equipment maintenance strategy and work processes so that the work could continue automatically based on established and new practices.
- Took two approaches for condition-based management – AMS and the data historian – instituting corrective action based on real-time data to prioritize and optimize maintenance resources.
For Dow, HART Communication is a digital gateway that provides access to a new world of hidden potential. By using the existing HART tools and resources they already had and engaging multiple levels of management and other staff, they were able to change the process and the culture for lasting benefits throughout the operation.
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