Large petrochemical units provide core power for crude oil processing, ethylene cracking and catalytic reforming. Continuous heat, pressure, flammable/explosive conditions, corrosion and heavy loads cause wear, corrosion, excessive vibration and oil deterioration. This integrated, accurate and intelligent online system uses explosion-proof sensing, big-data analytics and dedicated algorithms for real-time monitoring of all parameters, early warnings and deterioration prediction. It transforms O&M to support long-term safe, efficient operation and the refining industry's move toward precise, intelligent and safe maintenance.