A large Petrochemical company with operations along the US Gulf Coast had been doing plant monitoring at the plant level with DCS. Although a lot of data was captured at DCS by historians and LIMS, this operator was lacking the tools to get insight from the massive amount of data and realize its value.

This presents a challenge in improving plant health and asset performance. The engineering team was leveraging an in-house developed tool using spreadsheets and downloading the data in batches. But these tools were static and had limited analytics capability and value add.

Visionaize experts moved various data from historian, LIMS, ERP etc. to the V-Suite platform in a contextualized way so that data analysis is efficient and everything is easily accessible when there is a need. Then experts created KPIs dashboards for overall plant, individual system and equipment and also created an intelligent 2D Digital Twin of each system.

The solutions also provided alerts of plant/asset health issues or operating parameters that are off-limits, allowing for performance improvements through diagnosis, root cause assessment, using data science, and actionable recommendations using GenAI.

• $8M-$9M benefits per year
• 1-1.5% gain in production and yield
• 5-10% reduction in energy consumption
• Decrease in carbon emissions and safety incidents
• Collaboration among different departments, and quick decision making and problem resolution