Case Study

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O&G Producer Reduces Downtime by 20 Percent

Vibration monitoring system from Rockwell Automation reduces downtime

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  • Market demand increases needs for petroleum products, requiring accurate and timely distribution to retail outlets.


  • Seamless integration on a single EtherNet/IP network
  • Integrated solution ensures single vendor solution
  • Flexible measurement and parameter setting allows ease of operation and maintenance


  • Reduce risk of critical downtime by 20%
  • Reduce dependency on multiple vendors for support – and reduce downtime by 10%
  • Flexible and user friendly graphic user interface helps reduce operator training time and expense on new and multiple systems


A swelling middle class in India has created growing market demand for an increased consumption of petroleum products.

This oil and gas producer is one of India’s largest petroleum product manufacturers and distributors, with a processing capacity of 6.5 million metric tonne per annum (MMTPA). The plant must steadily keep petroleum products pumping through the station because any unplanned downtime can cause critical product shortages. Contributing to the ability to reach zero unplanned downtime is healthy equipment, like pumps, achieved through maintenance and monitoring.

The company’s pipeline supplies the interior areas of India. Seven pumping stations along that pipeline already used Rockwell Automation for several years with almost no downtime. The goal is to maintain and even improve that performance.


The biggest challenge for this customer is timely distribution and accurate pumping of products 24 hours a day, seven days a week. Any disruption could increase refinery inventory and leave retail units without adequate supply.

To maintain continuous flow, each pumping station uses three pumps: Two are at work at all times to maintain line pressure across the pipeline to the next terminal. The remaining pump is on standby in case one of the other pumps fails.

Oil pump operation is precise. Undetected or unreported wear and tear on the pump is not acceptable because even the slightest shift in pump operating parameters can cause damage. An aging Bentely Nevada 3500 system, installed years ago, did not function, and there was no ability to communicate with the station PLC to identify and rectify system faults.


To reduce the number of systems it needed to maintain, the customer preferred a single system (and a single system supplier) that worked with their control system, HMI and the machine monitoring system (MMS), and offered continuous and reliable support. Since continuous operation is required, this customer could not shut down the system for a switchover. The company requires seamless integration of this system, including the MMS, with existing systems.

Given the scope and complexity of the requirements, the customer wanted a supplier with proven skills, experience and support and selected Rockwell Automation for the company’s extensive experience in automation and global support.  With a local office and authorized distributor just five kilometers from the site, Rockwell Automation had the required expertise to manage the requirements of the project, from initial design through engineering, integration and implementation.

Effective solutions for the terminal included seamless integration on a single EtherNet/IP network with the flexibility to configure parameters using the existing graphic user interface. Separate training was not required so the new systems were easily accepted by the operations team.

Rockwell Automation Global Solutions implemented a vibration monitoring solution that:

  • Interfaces with existing systems to monitor vibration data of the pumps, and alert operators of any abnormal situations.
  • Allows operators/engineers to easily set parameters and provides trending, alarming, and exception handling.
  • Works with existing equipment, including probes and sensors, by ensuring compatibility.
  • Offers the plant manager complete and accurate information in real-time.

The solution is built on:   

  • Dynamix™ 1444 Condition Monitoring System using a common control system, ControlLogix® L72, with a common development environment to provide high performance in an easy-to-use environment. The system’s tight integration between the programming software, controller, and I/O modules reduced development time and cost at commissioning and during normal operation.  
  • Logix5000™ controllers and Add-on Instructions (AOI) to increase productivity and make troubleshooting easier.
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With this solution and the integration of various OEM control systems to enable plant wide visibility and real-time monitoring, Rockwell Automation helped this customer reduce the risk of critical equipment failure.

At the same time, the solution improved the ability of operators to monitor conditions and immediately address concerns before problems turn into downtime. The solution ensures that any abnormalities in the process conditions and deviation from the standard operating parameters will be immediately highlighted to avoid problems and improve reliability.

As a result of implementing the Rockwell Automation vibration monitoring system, the customer reduced the risk of downtime by 20 percent, and also reduced its dependency on multiple vendors. The flexible graphic user interface helped reduce operator training time and expense.

The next iteration of the solution could include the ability to create real-time dashboards for production and utility data.

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The results mentioned above are specific to this customer’s use of Rockwell Automation products and services in conjunction with other products. Specific results may vary for other customers.

Dynamix, ControlLogix and Logix5000 are trademarks of Rockwell Automation Inc.


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