From Weekly Checks to
Real-Time Reliability at
NESTE Singapore

From Manual Checks to Continuous Insights

In 2025, Neste and I-care partnered to pilot continuous vibration monitoring on hot oil pumps at the Singapore refinery. These pumps circulate heated thermal oil from the expansion drum through the fired heater and out to various production units. This thermal oil maintains the high process temperatures needed for efficient operation. Any unexpected pump failure could disrupt heat circulation, causing temperature drops in production units. It could also lead to localized overheating in the heater, risking thermal oil degradation, carbon buildup, or even equipment damage.

The pumps were already fitted with accelerometers that recorded amplitude changes during operation. However, there was no leading-indicator logic integrated into the instrumentation to identify potential failure events in advance. Condition monitoring was performed only once a week by Neste’s on-site contracted maintenance team, which meant any anomalies arising between inspections could go undetected.

Neste initiated this trial to address those blind spots. By installing continuous wireless vibration monitoring, the goal was to catch abnormal conditions early, generate leading indicators of potential failure modes, and provide actionable insights for better-informed technical decisions. The trial was also designed to demonstrate proof of value — showing how continuous monitoring could enhance reliability, reduce unplanned downtime risk, and support safer operation of these critical pumps.

Wireless Sensors Deliver Real-Time Clarity

I-care installed ATEX wireless vibration sensors and a gateway on the hot oil pump sets. The magnet-mounted sensors required no cabling and were installed quickly, without operational disruption. The gateway was positioned for optimal signal quality, overcoming potential obstructions from nearby steel structures.

Data streamed directly to I-care’s I-see platform, accessible to both Neste and I-care analysts. Every two weeks, I-care provided detailed vibration analysis and maintenance recommendations, turning raw data into actionable insights.

Data Correlation Uncovers a “Nice Catch”

During the trial, all pumps operated within normal vibration limits, confirming stable performance under normal operating conditions. The system also detected a period of increased vibration, later correlated with reduced pump flow in the process data. When flow increased, vibration levels dropped — a clear correlation Neste described as “a nice catch.” This insight confirmed the strong link between process parameters and vibration behaviour, providing a valuable reference for future troubleshooting and performance optimisation.

During the pilot, I-care also identified a wide noise floor on one of the pumps, indicating cavitation. Production data confirmed that this condition was intentional to meet operational needs, but the early detection proved the system’s ability to flag potential issues before they could escalate. Identifying such events in real time gives operators more control over operating decisions, reducing the likelihood of unexpected failures.

Overall, the pilot demonstrated how continuous wireless monitoring can turn raw vibration data into clear, actionable insights — enabling faster decision-making, improving maintenance planning, and strengthening asset reliability in one of the plant’s most critical systems.

Next Target: Reliability for Critical Mixers

Following the success of the hot oil pump project, Neste has identified other critical rotating assets for monitoring, including large side-entry tank agitators. These mixers are used to maintain product homogeneity, prevent sedimentation, and ensure consistent process quality in storage or process tanks. Their continuous operation is vital to product quality and process efficiency.

Common failure modes for agitators include bearing wear, shaft misalignment, gear or coupling damage, and blade imbalance due to product build-up or erosion. Such failures can lead to unplanned downtime, off-spec product, and in some cases, the need for full tank draining and cleaning — a costly and time-consuming process. In extreme cases, mechanical failure inside the tank can result in contamination or damage to the vessel itself.

By extending wireless vibration monitoring to these mixers, Neste aims to detect early signs of mechanical issues, plan interventions during scheduled maintenance windows, and avoid disruptive and expensive unplanned stoppages. This next step builds on the proven value of the pilot and further embeds predictive maintenance into Neste Singapore’s reliability strategy.