Limitations of current monitoring systems
Reactive monitoring systems
Reactive monitoring systems leave operators no time to prevent damage or downtime, forcing a constant state of damage control.
Sensor drift
Slow degradation of sensors causes drifts that doesn’t trigger alarms, but silently erodes a plant's performance and reliability.
Siloed data
Siloed systems often traps critical data; maintenance logs, process trends, and operator notes are scattered and prevents a complete picture of operations.
Introducing the solution
Build the model
Create a digital reference, using engineering data, process design documents, and operational experience. The goal is to create a high-quality dynamic simulation that reflects the intended plant behavior.
From offline to live
The simulator is deployed into the digital twin and connected to real-time field data. Live plant signals are mapped to the model’s boundaries and ensures all connections are technically sound. This ultimately verifies that the simulator now responds to actual operating conditions, not just design assumptions.
Model tuning
Through thorough analysis, closing the gap between the model and the real plant. This process improves the model's quality, making it accurate enough to serve as a live benchmark.
Calibrating monitoring logic
As the live model runs, residual data is collected over a baseline period. This allows the system to learn what normal deviations look like and then automatically calibrate its thresholds.
