Machinery & Plant

Large equipment and process,
controlled together in real time

Challenges on
plant sites

Recurring problems where large equipment runs non-stop.

Several energy sources run at once

Compressed air, electricity, process heating and cooling and HVAC all run at one site, and it never becomes clear where the energy goes or how much.

Equipment is tightly coupled

An anomaly in one machine carries straight through to the efficiency of the whole process.

Non-stop running with precise conditions

The plant cannot pause, and process conditions must still hold, leaving no obvious moment to intervene.

Aging, cost and rules arrive at once

Aging equipment, rising energy cost and carbon compliance run in parallel, so equipment and energy have to be seen as one system.

How the problems are solved

What Refinery actually does
on a plant site.

Demand-based compressed air control and monitoring

Problem
Shared utilities that keep running when demand drops
Approach
Real demand is read and discharge pressure and unit staging are matched to what is needed.
Outcome
Lower energy use and longer equipment life

Live power analysis by asset

Problem
Energy use grouped in clusters and impossible to separate
Approach
An AI agent watches consumption by asset in real time to catch use that departs from the usual pattern, and proposes both the cause and the next action.
Outcome
Energy-intensive assets identified and operations improved

Enthalpy-based HVAC VFD control

Problem
HVAC running fixed, regardless of outdoor conditions
Approach
Line temperature and humidity are converted to enthalpy, and the HVAC VFD is controlled to hold the target.
Outcome
Steadier process environment and lower heating and cooling energy

Energy intensity tied to output

Problem
No baseline for comparing efficiency against production
Approach
Production records and energy by asset are connected through an ontology into one structure, and intensity by process is derived automatically.
Outcome
Process efficiency made visible and cost structure improved

DC-microgrid-based equipment control

Problem
Equipment operation left unsteady, tied to a single grid feed
Approach
On-site generation and the grid are read together to distribute power across equipment.
Outcome
Lower fuel cost and steadier energy operations

Unified carbon emission monitoring

Problem
Emissions never broken out by process
Approach
Emissions are derived per process from energy data and hot spots are marked.
Outcome
Carbon compliance and energy performance management

How it fits together

How field data gains meaning and turns into a decision.

Site
  • Air compressors
  • HVAC
  • cooling equipment
  • large machinery sensors
Connect
  • Plant EMS
  • SCADA
  • PLC
  • ERP
  • Modbus
  • BACnet
Refinery
  • Ontology
  • AI agent
  • rules and automation
Use
  • Utility dashboard
  • energy intensity reports
  • emission management

Where a plant EMS or SCADA already exists, a layer sits on top of it and integrates bidirectionally rather than replacing it. Where none exists, collection is built from the ground up.

Systems we connect to

The systems and protocols commonly used on machinery and plant sites.

Plant EMSSCADAPLCERPModbusBACnetTCP⁠/⁠IPOPC UA

Systems not listed here can still be connected over standard protocols and APIs. Get in touch and we will walk through it.

What you gain

Benefits across operations, engineering and management.

Demand-based compressed air control

Shared utilities run only as much as actual demand requires.

Savings from HVAC VFD control

Load follows enthalpy, cutting heating and cooling energy.

Condition-based maintenance

Condition data sets the moment to intervene.

Efficiency analysis tied to output

Output and energy are joined to compare efficiency by process.

Lower fuel cost

A DC microgrid distributes power and steadies operations at the same time.

Carbon compliance

Emissions are derived per process so hot spots come first.

The Refinery team will work with you to find
the answer that fits your plant operation.

Request a demo