Predictive Maintenance Techniques: Optimizing Chemical Plant Management

Chemical plants operate under demanding conditions, often managing hazardous chemicals and processes while adhering to strict regulatory compliance. This complex landscape poses numerous maintenance challenges, where timely intervention is crucial to prevent potential disasters. By integrating predictive maintenance techniques, these plants can proactively address issues, ensuring safety, compliance, and operational efficiency.

Predictive Maintenance Techniques

Emergence of Predictive Maintenance

Chemical industries follow their own maintenance regimes, often plagued with inefficiencies or fail to address the critical asset maintenance challenges. In this context, a new maintenance technique – predictive maintenance is slowly seeping its way into the chemical industry landscape, providing measurable outcomes and unparalleled efficiency in asset maintenance.

A mobile enterprise asset management (EAM) solution that leverages innovative technologies like barcode scanning, IoT and GPS can foster good predictive maintenance strategies in a chemical industry. In this blog, we’ll explore the main hurdles maintenance workers face in chemical plants and highlight how the utilization of predictive maintenance techniques through a mobile EAM solution can enhance maintenance management practices.

Key Challenges in Chemical Plant Maintenance

1. Downtime Costs

According to a report by McKinsey & Company, unplanned downtime in the chemical industry can cost up to $20 billion annually worldwide. This downtime not only disrupts production schedules but also leads to revenue losses and increased maintenance expenses.

2. Aging Infrastructure

Many chemical plants operate with aging infrastructure, which poses significant challenges in terms of reliability and maintenance. Equipment degradation over time increases the risk of failures, necessitating frequent inspections and replacements.

3. Safety Concerns

Safety remains a paramount concern in chemical plants due to the hazardous nature of materials and processes involved. Ensuring the integrity of critical assets is crucial to preventing accidents and mitigating risks to personnel and the environment.

4. Reactive Maintenance Practices

Traditional reactive maintenance approaches, where repairs are performed only after equipment failure, are no longer sufficient in today’s competitive landscape. Reactive maintenance not only leads to higher costs but also compromises operational efficiency and reliability.

Mobile EAM’s Predictive Maintenance Techniques Boosts Plant Efficiency

Predictive Maintenance Techniques are gaining a lot of traction in fostering effective maintenance programs, which is all about effectively leveraging and analyzing the data. Some of the common predictive maintenance techniques that play a major role in effective plant maintenance are as follows:

1. Real-time Monitoring

This is one of the important predictive maintenance techniques that is widely used in plant maintenance. A mobile EAM solution equipped with IoT sensors enable real-time monitoring of equipment health and performance parameters. By collecting and analyzing data such as temperature, vibration, and pressure, maintenance personnel can identify early signs of deterioration and proactively schedule maintenance activities.

2. Predictive Analytics

Leveraging predictive analytics algorithms, a mobile EAM solution can forecast equipment failures with a high degree of accuracy. By analyzing historical data and identifying patterns indicative of impending failures, maintenance teams can take preemptive actions to prevent unplanned downtime and optimize asset performance.

3. Remote Diagnostics

A mobile EAM solution equipped with remote diagnostic capabilities empower maintenance personnel to troubleshoot issues and perform diagnostics remotely. This not only reduces the need for onsite visits but also enables quicker response times in addressing equipment faults, thereby minimizing downtime.

4. Enhanced Asset Tracking

A mobile EAM solution offers robust asset tracking functionalities, allowing maintenance teams to accurately track the location, status, and maintenance history of each asset in real time. This visibility enables better resource allocation, inventory management, and scheduling of preventive maintenance tasks.

In the above backdrop, Propel Apps, a digital transformation company has developed an innovative, state-of-the-art Oracle mobile EAM solution that transforms the way you manage and maintain assets. With several cutting-edge features including barcode scanning, GPS functionality and offline support, it lets maintenance personnel to digitize their maintenance operations, while completely eliminating manual, paper-based processes.

Leveraging the power of predictive maintenance techniques using our Propel Apps’ EAM solution, your organization can always foster effective maintenance programs to keep your equipment in good health. To know more about how Propel Apps’ EAM solution and how it can revolutionize your plant maintenance operations, schedule a call with us today.


Predictive maintenance techniques have emerged as a game-changer for chemical plant operations, offering a proactive approach to asset management and maintenance. By leveraging mobile solutions equipped with advanced analytics and remote monitoring capabilities, maintenance personnel can overcome key challenges such as unplanned downtime, aging infrastructure, and safety concerns. With the adoption of good predictive maintenance techniques, chemical plants can enhance asset reliability, optimize operational efficiency, and ultimately drive greater profitability in an increasingly competitive industry landscape. Request a demo.

Request a Demo