Process Units
8
All online
Throughput
94.2%
Target: 95%
Active Alarms
3
1 high priority
AI Savings
$42K
This month
🔧 Process Flow Diagram — Plant Alpha
8 process units
🧠 AI Optimization Suggestions
3 recommendations
Recommendation #1 — Energy Optimization
Reduce heat exchanger HX-02 outlet temperature by 3.2 C.
Current setpoint 185 C exceeds optimal by 3.2 C based on feed composition analysis.
Projected savings: $8,400/mo in fuel gas consumption.
Confidence: 94.7%
Recommendation #2 — Throughput Increase
Increase reactor R-01 feed rate from 450 bbl/hr to
468 bbl/hr. Catalyst activity supports higher throughput
with current feed quality. Additional revenue: $18,200/mo.
Confidence: 89.3%
Recommendation #3 — Predictive Maintenance
Compressor C-01 vibration trending upward — +12% over 14 days.
Schedule inspection within 72 hours to prevent unplanned shutdown.
Estimated downtime cost avoided: $125,000.
Confidence: 91.8%
🔔 Alarm Management
| Time | Tag | Unit | Description | Priority | Value | Status |
|---|---|---|---|---|---|---|
| 14:23:07 | TI-R01-04 | Reactor R-01 | Temp high alarm | HIGH | 412 C | ACTIVE |
| 14:18:33 | PI-C01-02 | Compressor C-01 | Discharge pressure high | MEDIUM | 42.8 bar | ACTIVE |
| 14:12:55 | LI-T03-01 | Tank T-03 | Level high warning | MEDIUM | 87% | ACTIVE |
| 13:45:20 | FI-P02-01 | Pump P-02 | Flow rate low | LOW | 180 m3/h | ACK |
| 12:30:10 | VI-C01-03 | Compressor C-01 | Vibration advisory | LOW | 4.2 mm/s | ACK |
| 11:55:44 | TI-HX02-01 | HX-02 | Outlet temp deviation | LOW | 188 C | CLEARED |
🏗 Digital Twin — Plant Alpha
🏭
3D Digital Twin Visualization
Real-time plant model synchronized via api.weylandai.com
8 process units · 142 instruments · 36 control loops
8 process units · 142 instruments · 36 control loops
Instruments
142
Control Loops
36
Last Sync
2s
Model Version
v3.4
📊 Operational KPIs — Plant Alpha
| Unit | Type | Throughput | Efficiency | Uptime | Status |
|---|---|---|---|---|---|
| Feed Drum D-01 | Vessel | 500 bbl/hr | 98% | 99.9% | NORMAL |
| Furnace F-01 | Heater | 450 bbl/hr | 92% | 98.5% | NORMAL |
| Reactor R-01 | Reactor | 450 bbl/hr | 88% | 97.2% | HIGH TEMP |
| Column C-01 | Distillation | 420 bbl/hr | 95% | 99.1% | NORMAL |
| HX-01 | Heat Exchanger | — | 94% | 99.8% | NORMAL |
| HX-02 | Heat Exchanger | — | 87% | 99.5% | FOULING |
| Compressor C-01 | Compressor | 12,000 Nm3/hr | 85% | 96.8% | VIBRATION |
| Tank T-03 | Storage | — | — | 100% | HIGH LEVEL |