Powering Up Efficiency for one of the World's Largest Waste-to-Energy Plants

Our client, a leading waste-to-energy plant in the UAE with an annual treatment capacity of 1.9 million tonnes of municipal waste, generates 1.37 gigawatts of energy. Beyond energy production, the facility also recovers valuable metals for reuse, supporting the principles of a circular economy. The plant sought to enhance operational safety, reliability, and efficiency while optimizing asset performance and financial management. In response, Intertec implemented a comprehensive Enterprise Asset Management (EAM) solution that not only streamlined asset lifecycle management but also bolstered operational efficiency, cost control, and safety standards.

Business Problem

The client faced several business challenges, including:

Complex Organizational Structure: The plant’s joint venture between Hitachi and Besix created difficulties in managing various stakeholders and cost allocations.
Asset Hierarchy Complexity: A complicated asset hierarchy connected to multiple process systems made asset tracking and management difficult.
Integration Challenges: The need to exchange critical financial and HSE information with other systems posed a challenge for seamless operations.

How Intertec Helped

Intertec played a pivotal role in transforming the client’s asset management and operational processes by deploying a robust EAM system tailored to their needs. Our solution integrated work management, cost control, mobility, and collaboration tools to optimize operations and asset performance. Key implementations included:

Enhancing Asset Management:

Introduced a four-level asset hierarchy (Line, Section, Process, System) for better organization.
Barcoded all assets for easy tracking and visibility.
Managed asset positions with detailed elevation information for improved monitoring.

Streamlining Work Management:

Deployed a system for handling corrective, preventive, and condition-based maintenance requests.
Optimized maintenance scheduling with graphical work order planning.
Implemented process automation for planned shutdowns, improving resource allocation and reducing downtime.

Boosting Efficiency with Mobility:

Enabled mobile inspections and condition-based monitoring using checklists and barcodes.
Facilitated online and offline work execution, reducing paper-based tasks and enhancing O&M efficiency.

Seamless Integration:

Integrated EAM with Permit to Work (PTW) solutions for streamlined task management and approval workflows.
Created a unified platform, improving collaboration between finance, HSE, and operational teams.

Optimizing Inventory Management:

Managed the entire inventory lifecycle, from procurement to invoice matching, reducing manual work and errors.
Automated inventory processes and optimized long-term purchasing needs using blanket orders.

Improving Cost Management:

Automated cost tracking and integrated with the financial system, improving accuracy.
Implemented cost-code allocation based on transaction entities, ensuring flexibility and precision in operational expenses.

Business Outcomes Delivered

The implementation of the EAM system resulted in several key outcomes for the client:

Boosted Asset Data Accuracy & Transparency: With a unified, integrated platform, the client now has a single source of truth for asset information.
Improved Employee Productivity: Mobility features empowered the workforce with on-the-go asset management capabilities, reducing administrative burdens.
Process Automation & Optimization: Automated maintenance, inventory, and cost management processes enhanced employee productivity and operational efficiency.
Enhanced Decision-Making: Better analytics and reporting capabilities provided real-time insights, enabling informed decision-making across all departments.

Industry

Energy & Utilities

Company Size

~100 employees

Related Offerings

End-to-End Asset Management for Energy & Utility Provider

Powering Up Efficiency for one of the World's Largest Waste-to-Energy Plants

Business Problem

How Intertec Helped

Business Outcomes Delivered

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