FA-03Intermediate
Separation & Desalting Optimization
Tunes separator and desalter operation to meet the export specification with less chemical, less heat and fewer off-spec events.
Facilities, Rotating Equipment & IntegrityAIDomain
FA-08FrontierWave 3DomainAIIT
Surface Facilities Digital Twin
In one sentence
A live process model of the plant that stays calibrated against the real one, used to test a change before making it.
The problem
Process changes on a producing facility are evaluated by experience and a spreadsheet, because the design simulation was built for the original case and was never maintained. Operators are therefore conservative in exactly the situations where capacity is worth the most.
How it works
A first-principles process model is built from the P&IDs and equipment datasheets and then continuously reconciled against live measurements, with the reconciliation residual reported as a trust indicator. The twin is used for what-if evaluation, operator training and soft sensing, and its predictions are always shown alongside the current reconciliation quality.
Data required
- P&IDs, equipment datasheets and the original process design basis
- Live DCS data with reliable instrument tags and ranges
- Laboratory analyses for composition reconciliation
- Equipment performance test data where it exists
What you get
- Calibrated process model with live reconciliation and a trust indicator
- What-if evaluation of operating and debottlenecking changes
- Soft sensors for quantities that are not directly measured
What it cannot do
A digital twin is a maintenance commitment, not a delivery. Every plant modification must be reflected in the model or it silently diverges from reality, and a twin that has quietly diverged is more dangerous than no twin. We scope this only where the operator funds an owner for the model, and we say no to it otherwise.
Every capability page states a real limitation. If a vendor cannot tell you where their product stops, you are not being told the truth about where it starts.
Related capabilities
- FA-07Foundational
Field Energy Management
Shows where the field’s fuel and power actually go, per barrel, and which equipment is drifting away from its best efficiency.
Facilities, Rotating Equipment & IntegrityAIIoT - OP-07Foundational
Integrated Operations Center
One room, and one screen layout, where production, drilling, maintenance and HSE see the same numbers at the same time.
Operations DigitalizationIT - OP-06Intermediate
Training Simulator & Competency
Lets operators practise upsets and start-ups against a model of their own plant, and records what they can demonstrably do.
Operations DigitalizationDomainIT - OP-08Frontier
Real-Time Decision Support Layer
Brings the recommendations from every capability into one prioritised queue, so the team works the highest-value item rather than the loudest alarm.
Operations DigitalizationAIIT