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Asset Performance Management (APM) Software

SOCAR Türkiye Reduces Reactive Maintenance by 20% and Achieves Additional Efficiencies with APM

Introduction

SOCAR Türkiye is Türkiye’s largest integrated energy company and includes activities in the petrochemical, refining, natural gas, trade, transmission and distribution sectors.  

 

SOCAR Türkiye is the first and only refinery in the world selected for the Global Lighthouse Network of the World Economic Forum with its two sites, Petkim and STAR Refineries, accepted as the "Facility of the Future." STAR Refineries, which is one of the largest oil operations in the region, started operations in 2018 and produces petroleum products such as naphtha, diesel, jet fuel, and LPG. STAR Refineries, with a 6.7 billion USD investment cost and a storage capacity of 1.9 million m3, meets approximately 25% of the processed petroleum product needs in Turkey. Petkim, the petrochemical producer of SOCAR Türkiye, is Turkey's first and only integrated petrochemical producer with an annual gross production capacity of 3.6 million tons. 

 

Challenges

SOCAR Türkiye's goal is to achieve maximum value in areas such as Health, Safety and Environment (HSE), Process Safety, availability and reliability, asset output effectiveness, life cycle cost, innovation and improvement in refinery and petrochemical facilities integrated structure from the planned maturity level to the maturity level of excellence with a sustainable and continuous improvement approach to reach the level of best practices. The most significant difficulty SOCAR Türikye experienced in this process is the change in organizational culture and the use of new technology and software. They tried to create common values, beliefs, and behaviors among employees for organizational culture change, which was a lengthy process. SOCAR Türkiye organized trainings and workshops for adaptation to the new software with GE Vernova's support. 

Solutions and Final Outcome

Petkim and STAR Refineries harnessed the power of GE Vernova's Asset Performance Management (APM) suite, encompassing Asset Health, Reliability, Asset Strategy, and Integrity applications, to help  increase  safety, reliability, and efficiency of their operations.  Examples include:  

 

  • APM Strategy is used to generate a risk matrix and criticality analysis that allowed for the development of risk-based maintenance and inspection strategies. Within the APM Strategy application, SOCAR Türkiye leverages Asset Strategy Manager (ASM), Asset Criticality Analysis (ACA), and Reliability Centered Maintenance (RCM). 
  • APM Health is used for condition-based monitoring support for the assets across the operation.  
  • APM Reliability is provides automated Root Cause Analysis (RCA) along with queries to track bad actors, RAM Analyses on boilers to determine cost savings potential, Life Cycle Cost Analysis (LCC) to better optimize their programs, Product Loss Analysis (PLA) integrated with RCA to determine mechanical and operational availability, and SmartSignal predictive diagnostics that uses advanced pattern recognition to help their operation avoid unplanned downtime.  
  • Risked Based Inspection (RBI), Inspection Management (IM) and Thickness Monitoring (TM) within APM Integrity is used to support  fixed asset performance and also expand their coverage with Policy Design, Asset Health and Queries to generate their own analyses and thresholds.  

Demonstrated Results

With the support of GE Vernova’s APM in coordination with Stork advisory services, SOCAR Türkiye was able to generate the following results:  

  • Reduced reactive maintenance by 20% 
  • Reduced HSE incidents by 10% 
  • Reduced maintenance inventory costs by 7% 
  • Reduced total maintenance costs by 5% 

Increased employee productivity for maintenance and digital reporting by 10%

Client and Industry Satisfaction

“It was crucial for us to have a solid foundation during our Asset Management journey, and by developing our integrity and reliability strategies together with STORK utilizing GE Vernova’s Digital APM suite, we believe that we can improve and sustain our asset performance to attain maximum value of SOCAR Türkiye’s Refinery and Petrochemical facilities integrated structure”, said Özgür Can Akyüz, Asset Management Managing Director, SOCAR Türkiye Refinery and Petrochemicals Business Unit. 

 

“With GE Vernova Asset Performance Management (APM), we not only adopted a systematic improvement approach but also experienced a significant boost in decision-making speed and success after implementing. GE Vernova APM provided with real-time performance data, enabling them to quickly identify bottlenecks and potential issues within the system and proactively address them. As a result, GE Vernova was able to significantly improve the overall performance and availability of its system. Additionally, GE Vernova APM helped make data-driven decisions and better plan for the future needs of its system,” said Tamer Eldemir, Reliability manager SOCAR Türkiye Refinery and Petrochemicals Business Unit. 

 

Digital Roadmap of Asset Domain