Industrial AI

In this episode, Mr. Dibyendu De, reliability centric maintenance pioneer and heavy engineering specialist, reflects on the 40-year history of an evolving discipline. Mr. De believes AI can have tremendous impact asset reliability, if we can get the mix of human judgement and computational brute force right.

🎧 Available on:

on Youtube: https://youtu.be/g0qeXcnZNa8

on Spotify: https://open.spotify.com/episode/02sbJkN2M8P9dBeuEzrGxF?si=eI09I5_cQYCayf1MJOzJrw

on Apple Podcast: https://podcasts.apple.com/us/podcast/reliability-pioneer-shares-lessons-learned-over-long/id1879488349?i=1000798332504

HSE veteran Doha Mattar talks about how her discipline is at crossroads. The HSE function is being asked to go beyond compliance. Also, AI offers a chance to do everything better. But to do what its being asked to do, HSE has to transform.

🎧 Available on:

on Youtube: https://youtu.be/g_RAkChLGjA

on Spotify: https://open.spotify.com/episode/5UAbvRPOycTLmp03onFoQd?si=qjMEcmi0TN2KONhD27pYQA

on Apple Podcast: https://podcasts.apple.com/us/podcast/hse-at-crossroads-ai-beyond-compliance/id1879488349?i=1000783755786

The Maximl podcast series was privileged to host Frank Engli, P.Eng. globally renowned turnaround expert. Asking Frank, the questions we are all curious about was Pankaj, Maximl's founder & CEO.

Due to the situation in the Middle East, refineries located in jurisdictions where crude is plentiful are reluctant to pause production for TA. There’s an opportunity to make margins. Refineries in jurisdictions that are supply constrained have anobligation to serve the local economy & are in many cases running at afraction of full capacity.

Those chasing margins must deal with the elephant in the room at some point. The TA cannot be deferred forever. The first task is to communicate said risks to management. Second, in North America, while crude supply is not an issue, the nature of crude is changing, necessitating changes to production. The decision therefore will have to incorporate several variables.

For the crude constrained, the risks play out differently. While running at a fraction of capacity, reliability pros think this a good time to execute a TAR. However, few non-OPEC countries have large reserves. The pressure to keep the products flowing is high. Regulatory authorities too are easing a bit, with reports of self-certification replacing external inspections for high pressure equipment.

But even then, the risks levels won’t be tenable forever. For every refinery, clearly the approach to TAR needs to change.

Frank agrees with Winston Churchill’s quip that a crisis shouldn’t be wasted. He therefore proposes a fundamental change in thinking vis-a-vis TAR.

It’s important for leaders to not think in terms of executing the perfect TA & treat the need for TA as gospel truth. Instead, it’s time to take a step back & relook atthe ask:

“A maintenance team is tasked with enabling the desired level of production, operating at reasonable levels of breakdown & safety risks while minimizing annualized maintenance costs over the long term using different models, such as on-stream maintenance & TAR, while not being dogmatic about the efficacy of any one model.” 

The above reframing of the maintenance leader’s job yields a few guidelines:

·       The TA calendar should be risk-based & not schedule-based.

·       The goal is not the perfect TA, but maintenance in its entirety, the cost of ongoing maintenance plus the turnaround annualized.

·       Important to ask whether a TA is necessary, or the interventions can be done on stream. Technologies, such as drones, vision AI, & non-destructive testing, make maintenance without confined space entry tenable.

·       The goal is to extend the time between TA & shorten individual TA. The scope needs to be rationalized. Frank offered metaphor. Formula One crews change tyres in two seconds while civilians take 20 minutes. It’s about reaching a certain level of excellence.

🎧 Available on:

on Youtube: https://youtu.be/4Nh1XgOLK5s

on Spotify:  https://open.spotify.com/episode/16hIS1Ax4YqCgim76NoDbX?si=gr5mV4k7TiCRRZ6fgn4mPw

on Apple Podcast: https://podcasts.apple.com/us/podcast/turnaround-reckoning-old-habits-new-tools-the-race/id1879488349?i=1000775646780

In this episode, industry experts explore the realities behind managing complex shutdowns and turnarounds, from early strategic planning in the boardroom to high-pressure execution on the ground. The conversation highlights how turnaround success is shaped long before execution begins, emphasizing detailed planning, clear decision frameworks, and alignment between business priorities such as duration, cost, and production impact.

Through practical experiences and real operational insights, the discussion examines the intense nature of turnaround execution, where rapid decisions, cross-functional collaboration, and strong coordination between internal teams and service partners become critical. The speakers also address the inherent unpredictability of shutdown work, including emergent discoveries during execution, and how evolving technologies, data, and AI-driven approaches are helping reduce uncertainty and improve outcomes.

Listeners will gain perspective on:

• The strategic and tactical lifecycle of shutdowns and turnarounds

• The pressures and mindset required during execution phases

• Balancing safety, cost, schedule, and operational risk

• The role of technology, data, and AI in improving planning and predictability

• Lessons learned from real-world turnaround leadership experience

This episode offers valuable insights for plant leaders, maintenance professionals, turnaround planners, and anyone interested in how AI and modern practices are reshaping complex industrial operations.

🎧 Available on:

on Youtube: https://youtu.be/vCboIEhdkBo

on Spotify: https://open.spotify.com/episode/6FphBaptAfXLSzjI9HCOBv?si=5ZgnAVidRvGwEOi3qik_OQ&nd=1&dlsi=0c99b9a4e5d94b8d

on Apple Podcast: https://podcasts.apple.com/us/podcast/ai-changing-shutdown-turnarounds/id1879488349?i=1000751009768