The application of artificial intelligence in maintenance and repair: An inevitable trend in the gas and petrochemical industry

BSR organizes commendation and award ceremony for outstanding achievements in the 2020-2025 period and celebrates 50 million safe work hours

Science, Technology, and Innovation: A Path for Petrovietnam’s Fundamental Transformation

How AI is transforming maintenance and repair

Traditionally, maintenance and repair in the Gas and Petrochemical Industry have relied heavily on human experience and scheduled routines. However, this approach has several limitations: high costs from conducting maintenance regardless of equipment condition; risk of operational disruptions caused by unexpected failures; and limited predictive capability due to a lack of real-time data analysis.

The emergence of AI has fundamentally changed this approach. Machine learning algorithms can collect and analyze data from sensors installed on equipment, delivering accurate predictions of when maintenance is needed. This shift enables the oil and gas sector to move from time-based maintenance to predictive maintenance—an important step toward optimizing costs and boosting operational efficiency.

At Petrovietnam, several units have been pioneers in implementing AI for M&R, with encouraging results:

Dung Quat Refinery (operated by Binh Son Refining and Petrochemical JSC – BSR) has adopted AI in its operational data monitoring and analysis systems. This allows the plant to detect early signs of equipment abnormalities, significantly reducing the risk of unplanned shutdowns.

BSR employees in the central control room of Dung Quat Refinery

At Ca Mau Fertilizer Plant (PVCFC), AI is used in combination with equipment condition assessment models, allowing for accurate predictions of the lifespan of critical components. This facilitates more effective maintenance planning and extends equipment service life.

Operations at Ca Mau Fertilizer Plant

Meanwhile, Phu My Fertilizer Plant (PVFCCo) utilizes AI to analyze the performance of air compressors and high-pressure pumps—crucial components in the production process. As a result, operational efficiency has improved while energy consumption has been significantly reduced.

Experts and engineers at the Central Technology Department of Phu My Fertilizer Plant

Challenges and opportunities

Despite its advantages, the implementation of AI in maintenance and repair faces several challenges. First, the upfront investment is considerable, as integrating AI requires a strong data infrastructure—from IoT sensors to advanced analytics platforms. Second, there is a shortage of specialized personnel; traditional maintenance engineers must be trained to work effectively with AI technologies. Moreover, ensuring cybersecurity to protect operational data from potential cyber threats remains a critical concern.

However, the opportunities that AI brings are substantial. When properly implemented, AI can help save millions of USD in maintenance costs annually, while also enhancing safety and promoting long-term sustainability for Petrovietnam.

The adoption of AI in maintenance and repair is no longer a future trend—it has become a strategic necessity. Enterprises in the Gas and Petrochemical Industry must move quickly to seize this opportunity to improve operational efficiency, reduce costs, and ensure safety throughout production. In this digital era, AI is the key for Petrovietnam to stay aligned with global technological advancements.

PVN