Case Study: Saras boosts uptime and cuts maintenance costs with Aspen Technology (Aspen Mtell)

Prescriptive Maintenance Software Helps Saras Improve Business Performance and Drive Operational Excellence

Saras, owner of the most complex refinery in the Mediterranean with 300,000 BPD capacity and a 575 MW IGCC power plant, sought to improve uptime and cut maintenance costs as part of a broader digitization program. To meet this challenge they selected Aspen Technology and its Aspen Mtell prescriptive maintenance software to pilot predictive maintenance on critical compressors, pumps and valves.

Aspen Technology deployed Aspen Mtell agents within weeks, mining 52 million sensor values to learn failure signatures and predict issues with high accuracy (91%) and long lead times (examples: pump and valve failures predicted 24–45 days in advance). The solution delivered no false positives, is scalable refinery-wide, and is expected to reduce unplanned shutdowns by up to 10 days, increase revenue 1–3%, and lower maintenance and operating expenses by roughly 1–5%.

Saras

Alessandro Zucca

Digital Platform Manager, Operations and Assets