BCI Yanbu

Empowering Predictive Maintenance through Smart Vibration Intelligence

🏭Client Overview

Basic Chemical Industries (BCI), a key player in Saudi Arabia’s industrial chemical sector, operates a high-capacity production facility in Yanbu.

🎯Challenge

BCI faced issues with two critical rotating assets (vertical process pump and centrifugal air blower), causing unexpected vibrations, mechanical fatigue, and process disruptions.

•Unexpected vibrations leading to mechanical fatigue
•Shortened equipment lifespan
•Disruption of process continuity and maintenance schedules

🧠Our Approach

Initiated a three-phase Smart Manufacturing engagement, including on-site diagnostics, IoT integration, and fault prediction modeling.

🔧Implementation Phases

1On-site Diagnostic & Digital Asset Survey

•Conducted plant walk-through and digital maturity baseline
•Interviewed operations, reliability, and maintenance staff
•Mapped asset criticality and failure history

2Vibration Intelligence with IoT Integration

•Deployed ADASH VA5 Pro smart data collectors with multi-channel sensors
•Ran full-spectrum vibration analysis on bearings, couplings, and shafts
•Used frequency domain (FFT) analysis and ML-based fault pattern libraries

3Fault Prediction and Action Modeling

•Applied ISO 10816-3 and ISO 14694 thresholds
•Used ML clustering models to project fault evolution and Remaining Useful Life (RUL)

🧠Technologies Used

ADASH VA5 Pro Smart Data CollectorsIoT Multi-Channel SensorsMachine Learning Fault Pattern LibrariesISO 10816-3 and ISO 14694 Standards

🚀Business Outcomes

Prevented catastrophic failure of the vertical pump

Reduced time-based maintenance costs through data-driven actions

Enabled shift to predictive maintenance

Established foundation for AI-based anomaly detection

🧰Smart Manufacturing Alignment

Enabled connected machines, digital twin modeling, ML-based fault prediction, and upskilled maintenance teams through vibration intelligence.