Initially constructed in 1964, the Conda fertilizer manufacturing facility has undergone numerous shutdowns, restarts, and ownership acquisitions. In 2018, Itafos acquired the Conda assets and decided to review the facility’s asset reliability program. With over 9,000 active, maintainable assets and various changes in the manufacturing processes, environmental requirements, and management philosophies, manual, paper-based methods for gathering asset data were insufficient. Therefore, they needed to establish a digital asset management and reliability program to develop appropriate care plans.
Leveraging the capabilities of AssetWise, they identified highly critical assets, monitored failure modes, and created a consistent framework for asset maintenance within a single digital environment. The solution reduces the timeframe for asset data collection from days to minutes and provides automated notification of asset abnormalities so that immediate corrective action plans can be implemented. By digitalizing their asset reliability processes, they achieved complete control and understanding of all plant equipment, enabling safe and more sustainable operations.