Cosmo Oil Enables Proactive Work Processes with GE Vernova APM & SmartSignal

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Customer Information

Introduction

Company

Cosmo Oil

Industry

Oil & Gas

Products

SmartSignal Predictive Analytics, Asset Performance Management

Cosmo Oil, Japan’s third-largest oil petroleum refining company, had a 10-year objective to expand condition-based maintenance capability at its refineries, enhancing maintenance effectiveness and efficiency. The company focused on critical rotating and static equipment and improving asset condition visibility for proactive maintenance actions. Cosmo Oil engineers share their use cases for Asset Performance Maintenance (APM) and SmartSignal software, as well as the business value and efficiency gained by migrating APM to the cloud.

The Challenge

Before introducing APM and SmartSignal, Cosmo Oil was dealing with challenges:
  • Managing data so that maintenance actions were easy to identify
  • Sharing information effectively across the refineries and enterprise
  • Onboarding early-career engineers to the operations environment
Overall, they needed to enable faster decision-making, more consistent work processes, and reduce reliance on senior expertise.

The Solution

To embed predictive maintenance across the facilities, they adopted SmartSignal for critical rotating equipment. The goal was to enable early detection of abnormal conditions and leverage APM to enhance their risk-based asset management strategies. To reduce manual work and dependence on individual expertise, they implemented APM Policy Designer to convert data inputs into advanced, automated maintenance planning. In addition, they implementedAsset Health Manager to automate data interpretation and corrosion risk assessment.

The Results

Cosmo Oil’s use of APM and SmartSignal has contributed to both quick operations wins and significant maintenance saves, building a business case for future expansion to additional assets and greater integration between APM and SmartSignal.

Results include:
  • 250% Return on Investment (ROI) achieved in about three years since APM and SmartSignal rollout, with a projection to increase to 257% by 2028.
  • Potential unplanned shutdowns averted, reducing reduced downtime. For example, SmartSignal detected an abnormal lubricating oil temperature, leading to early intervention and preventing bearing damage and an unplanned shutdown.
  • Operations shift from reactive to proactive maintenance. APM enables early detection of abnormal conditions, allowing for planned corrective actions and improving maintenance effectiveness and efficiency.
  • Improved equipment availability through proactive maintenance decisions and more effective management of static equipment.
  • Reduced Total Cost of Ownership (TCO) by 10%+ is a projected benefit from the migration to Cloud APM.
Cosmo Oil
25:13
Speakers:

Ryutaro Aida
Maintenance Inspection Group Leader, Cosmo Oil

Suguru Tachikawa
Maintenance Rotating Asset SME, Cosmo Oil