Baker Hughes Enhances Braskem Reliability with Cordant Asset Health

In petrochemical production, particularly in polymer and chemical manufacturing, compressors and turbines operate under continuous high-load conditions where unplanned downtime directly affects output and energy consumption. To improve asset reliability and energy efficiency across its Brazilian operations, Braskem implemented Baker Hughes’ Cordant™ Asset Health platform, built on System 1™, enabling predictive monitoring of critical rotating equipment.

Fourteen months after deployment, the project has generated more than USD 100,000 in return on investment, with additional value still under evaluation. The results demonstrate how advanced asset performance management and predictive maintenance technologies can reduce operational risk in energy-intensive industrial environments.

Predictive monitoring for critical rotating equipment
Braskem operates a complex asset base across multiple Brazilian sites, including centrifugal and screw compressors as well as turbines that are essential to continuous production. Traditional monitoring methods were not sufficient to detect early-stage anomalies before they evolved into performance losses or failures.

Cordant Asset Health integrates thermodynamic efficiency analytics, decision support tools and anomaly detection algorithms. These functions continuously evaluate operating parameters to identify deviations from normal performance patterns. The objective is to detect incipient faults, optimize energy use and reduce unplanned shutdowns.

Early detection during compressor startup
One documented case involved a butadiene centrifugal compressor during startup. The system identified early indications of surge conditions, enabling corrective action before the instability escalated. By detecting incipient surge at an early stage, the platform supported safer startup procedures and reduced mechanical stress on the compressor.

Instrument failure and vibration anomaly detection
In a separate application on a butadiene screw compressor, the combination of decision support and anomaly detection tools identified intermittent instrument failure. Early identification prevented potential downtime and avoided production losses.

Anomaly detection was also used to assess increasing vibration levels on another screw compressor. By identifying abnormal vibration trends before reaching alarm thresholds, maintenance teams were able to schedule interventions proactively rather than reactively.

Energy efficiency improvements in gas compression
On a charged gas compressor, thermodynamic efficiency analytics detected mini-flow malfunctions that negatively affected energy performance. By correcting these deviations, Braskem improved compressor efficiency and reduced unnecessary energy consumption.

In energy-intensive petrochemical plants, even small inefficiencies in compression systems can lead to significant operational costs. Continuous performance analytics therefore contribute directly to improved energy efficiency and lower lifecycle costs.

Measurable operational and financial impact
Within 14 months of implementation, the solution delivered over USD 100,000 in ROI. Of this amount, approximately USD 39,000 resulted from avoiding downtime and production losses at the butadiene plant.

Beyond direct financial savings, the implementation improved maintenance planning accuracy, reduced operational risk and enhanced asset reliability. By shifting from reactive to predictive maintenance, Braskem strengthened operational stability while supporting broader efficiency and sustainability objectives in its petrochemical operations.

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