AI Assistant · MNT

Predictive Maintenance

Prevent failure before it happens

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For you as · Team Leader · Nawaf Al-Mutairi
You have decisions waiting in Predictive Maintenance. Approving unlocks value from the KWD 92M pool today.
KOC business value P-06 · Operational Excellence P-01 · Sustainable Capacity· Uptime Cost / bbl KWD 92M annualised value
The problem today

Rotating equipment failures cause 60% of unplanned deferment; USD 300M AI-PdM programme underway.

What Bayan does

Predicts failures 9–30 days out and schedules the shortest, cheapest outage window.

Path to KOC 2040
Operational Excellence88%
847 days LTI-free · 99.4% uptime → Top-quartile HSE + uptime
Sustainable Capacity60%
2.41 MMbbl/d (2.90 capacity) → 4.00 MMbbl/d by 2040

Reliability & maintenance scorecard

Industry-standard upstream KPIs · targets · peer benchmarks
76
Reliability health
MTBF up 11% YoY on rotating equipment; PM compliance holds above 95%. Bad-actor list down from 42 to 27 assets. Maximo backlog still 6 weeks — automation queue recommends triage.
MTBF (rotating)
Mean time between failures
on target
4180hrs
tgt4000hrs+180.0
IOC top-quartile4600hrs-420.0
Above target — vibration analytics catching bearings early.
MTTR
Mean time to repair
on target
6.4hrs
tgt7hrs+0.6
IOC top-quartile5.5hrs-0.9
On track; parts availability is the constraint.
PM compliance
Preventive maintenance compliance
on target
95.8%
tgt95%+0.8
IOC top-quartile97%-1.2
Just above target — schedule adherence at GC-24 slipping.
Backlog (wks)
Maintenance backlog
off target
6.1wks
tgt4wks-2.1
IOC top-quartile3.5wks-2.6
Amber — parts lead-time driving the gap.
OEE
Overall equipment effectiveness
on target
82%
tgt80%+2.0
IOC top-quartile85%-3.0
Above target; availability and quality strong, performance the gap.
Bad actors
Bad-actor assets (>3 failures)
on target
27
tgt30+3.0
IOC top-quartile20-7.0
Below target — 15 assets exited list this quarter.

Going good

On plan right now
  • Schedule outage · Compressor C-12
    Prevents unplanned trip ($2.4M deferment). · 01:00
  • Failures prevented YTD: 284
    +18
  • MTBF · ESP fleet: +22%
    on plan

Needs attention

Early warnings — not decisions yet
  • Order spare seals · PMP-204
    Failure probability 0.41 within 30d, lead time 22d.
  • AGRU-C12 bearing 4x harmonic rising — RUL 9 days · pull-forward maintenance window to avoid emergency flare event.
  • ESP-BG-441 motor signature matches 14 prior failures — replace within 14 days, SLB Hi-Ex stocked in Ahmadi yard.
External signals
  • OEM (Solar Turbines)· 3d agohigh
    Service bulletin SB-2026-14: bearing wear on Titan 130 units at >48k op-hours
    ↳ GTR-9 crosses 48k hours next month — pull inspection forward, protect the outage window.
  • ILI Vendor (ROSEN)· 1d agomed
    New MFL algorithm reduces false positives on <3mm pit depth by 28%
    ↳ Rerun 2025 ILI on 36" trunk — cheaper than mobilising a new inspection.

Needs your decision

Approval goes to the audit ledger
Action Center
  • Re-route load · GTR-9
    Vibration trending up; temperature delta +6°C.
    Buys 14 days to plan outage.09:00· 78%
  • Combine work orders · Sabriya pad
    5 small jobs fit one isolation window.
    Saves 18 maintenance hours.13:00· 86%

Automation

1 active rules
Recently auto-handled
  • Auto-delegate10:46 PM
    Routed PMP-204 spares work-pack to Planner
    RUL 9d < 14d threshold
Rules ready to run now
  • Auto-delegateRoute work-pack to Planner when RUL < 14d