Predictive reactor effluent air cooler maintenance

A system of increasing reliability for a reactor effluent air cooler (REAC), comprising:

• a process facility computer communicatively coupled to at least one REAC including an air condenser with a plurality of field devices coupled thereto in an industrial facility configured to run an industrial process, said process facility computer including a processor connected to a memory device storing a REAC predictive maintenance model comprising a digital twin of said REAC and a REAC adaptive model, wherein said process facility computer is programmed to implement said predictive maintenance model causing said process facility computer to:
• retrieve history data including at least one historical REAC value from at least one of said memory device and a cloud computing-based data historian;
• receive real time data from said plurality of field devices including at least one real-time REAC value, said digital twin calculating a current reliability value for said REAC using said history data including said historical REAC value and said real time REAC value;
• compare said current reliability value to a predetermined reliability value;
• and
• generate an alert indicating that said REAC needs current maintenance whenever said current reliability value is less than said predetermined reliability value.

A computer program product, comprising:

• a tangible data storage medium that includes program instructions executable by a processor to enable said processor to execute a method of increasing reliability for a reactor effluent air cooler (REAC);
• a process facility computer communicatively coupled to at least one REAC including an air condenser with a plurality of field devices coupled thereto in an industrial facility configured to run an industrial process, said process facility computer including said processor and said non-transitory data storage medium, said computer program product comprising:
• code for retrieving history data including at least one historical REAC value from at least one of a memory device and a cloud computing based data historian;
• code for receiving real time data from said plurality of field devices including at least one real-time REAC value, a digital twin calculating a current reliability value for said REAC using said history data including said historical REAC value and said real-time REAC value;
• code for comparing said current reliability value to a predetermined reliability value;
• and
• code for generating an alert indicating that said REAC needs current maintenance whenever said current reliability value is less than said predetermined reliability value.