TechnipFMC (Energy & Petrochemical)
Unifying isolated SCADA islands to predict compressor & pump failures before downtime.
Operational Context & Background
Operating gas compression stations, boilers, and heat exchangers across multiple facilities requires real-time health monitoring. Isolated control islands prevented central reliability engineering teams from spotting early degradation.
The Core Challenge
Critical offshore and refinery telemetry was trapped inside isolated SCADA islands, resulting in reactive repairs, high maintenance costs, and unplanned gas compressor trips.
Identified Plant Floor Gaps:
- ✕Telemetry trapped inside legacy proprietary SCADA packages with zero cross-site visibility.
- ✕Turbine and pump maintenance was reactive, occurring after high-vibration alarms tripped production.
- ✕Environmental compliance logging required manual data extraction from local historians.
Calypsion Solution & Deployment
Connected multi-protocol telemetry using LinkEdge protocol gateways into LinkVision analytics with automated anomaly detection, vibration FFT tracking, and predictive equipment health indexing.
Deployment Milestones:
- 01Deployed LinkEdge edge nodes to tap serial RS-485, Modbus TCP, and DNP3 SCADA loops non-intrusively.
- 02Streamed sub-second telemetry into the central LinkVision cloud telemetry dashboard.
- 03Applied machine learning trend models for bearing wear, heat exchanger delta-T, and pump head pressure.
- 04Configured automated SMS/email condition-based alerts prior to high-alarm trips.
Verified Plant Outcome
Reduced unplanned equipment downtime by 22%, lowered monitoring costs by 30%, and extended asset utilization across critical processing loops by 18%.
"The failures were always visible in the data — we just couldn't see across the assets in time. Now the warning comes days ahead, on one screen, and our controllers never changed."
— Reliability Lead, TechnipFMC / Energy OperationsFrequently Asked Technical Questions
What is predictive maintenance in oil and gas?
Predictive maintenance uses real-time sensor and controller data plus analytics to forecast equipment failure before it happens, so maintenance is scheduled by condition rather than by calendar.
How does an industrial protocol gateway connect legacy oil and gas assets?
A protocol gateway such as Calypsion LinkEdge auto-detects and normalizes industrial protocols like Modbus, OPC-UA, Ethernet/IP, DNP3 and MTConnect, unifying mixed-vendor SCADA and PLCs into one stream.
How much can IIoT reduce unplanned downtime for energy assets?
Industrial IoT with predictive analytics typically reduces unplanned downtime by 20-30%. In this deployment, unplanned breakdowns fell 22%, monitoring cost dropped 30%, and asset utilization rose 18%.
Does adding IIoT compromise OT security or control?
No. Calypsion's gateway reads from existing controllers non-intrusively and analytics are advisory only — safety and control logic never leave the PLC or SCADA system.
Evaluating us for a similar plant deployment?
We can arrange a technical walkthrough under NDA with live telemetry sample data from similar operational lines.