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Data Configurations

Data Configurations

Data Configurations is the data integration and ETL layer within the DataHubX Suite. It connects information from DCS, PLC, plant historians such as PI, PHD, and IP.21, MES, ERP, LIMS, spreadsheets, and other industrial databases. The solution cleans, aggregates, transforms, and standardizes data while enabling validated engineering calculations and KPIs. It converts fragmented source data into a consistent, calculation-ready format for reliable monitoring, reporting, analytics, and optimization.

Salient Features

Multi-Source Data Connectivity

Connect plant and enterprise information from historians, control systems, laboratory platforms, business applications, and spreadsheets.

Standardized ETL Pipelines

Configure repeatable pipelines to extract, transform, and load industrial data across different systems and operating environments.

Data Cleaning

Identify and address incomplete, duplicated, inconsistent, or poor-quality information before it reaches downstream applications.

Data Aggregation

Convert high-frequency operational data into relevant intervals, summaries, and calculations for different business requirements.

Data Transformation

Convert source information into consistent structures and formats that can be reliably used across multiple applications.

Naming and Unit Standardization

Establish consistent tag names, equipment references, engineering units, and data formats across sources and sites.

Engineering Calculations

Configure and deploy calculations ranging from simple formulas to complex process-engineering KPIs.

Calculation Validation

Validate calculation logic and outputs before using them for monitoring, reporting, analytics, or optimization.

Customizable Limits, Priorities, etc.

a. Engineers can manipulate configured KPI limits based on plant priorities.

Sensitivity Analysis

Optimax provides feature to run multiple cases simultaneously with different limit ranges to enhance the actionable insights.

Role-Based Access and Security

Provides access control to ensure only authorized personnel can view or edit monitoring configurations.

Result Analysis Tool

Offers diagnostic tools to help engineers quickly investigate and resolve performance issues with different configurations
Client-Benefits
Client Benefits

Eliminate Data Silos

Bring operational, laboratory, maintenance, and business information together through one connected data layer.

Reduce Manual Data Preparation

Automate repetitive cleaning, consolidation, transformation, and calculation activities previously managed through spreadsheets.

Improve Data Quality

Provide engineers and applications with cleaner, more consistent, and dependable plant information.

Accelerate Analytics Deployment

Make validated, calculation-ready data available to monitoring, modeling, reporting, and optimization solutions.

Standardize KPIs Across Plants

Use consistent engineering calculations, units, and KPI definitions for reliable performance comparisons.

Improve Confidence in AI Outputs

Strengthen AI reliability by ensuring source data is properly cleaned, standardized, and validated.

Simplify Multi-Site Reporting

Use common data structures and calculations to support consistent reporting across multiple plants.

Dashboard & Snapshots
Landing page of OptimaX:
Configure all tags related to specific Equipment:
Solution configuration [Defining the Objective: Maximize Production, Minimize Utility]:
Solution configuration [Defining cases of interest – Multiple cases can also be added]:
General Configuration:
Result Tag Configuration: Identify the potential actionable insights.
Sensitivity Analysis: Supporting engineers to evaluate appropriate configurations
Result Analysis:
Case Studies

 

Development of Soft Sensor to predict the C5 contents in Debutaniser column Overhead:

Background

In modern petrochemical operations, maintaining product specifications within tight limits is critical for both quality assurance and process efficiency. One of the key challenges faced by a leading chemical plant was the need for real-time prediction and monitoring of C5 content in the overhead stream of the debutanizer column — a crucial step to ensure product specification compliance and optimize operations.

Challenge

Traditional laboratory testing methods for measuring C5 content introduced significant time delays, making real-time adjustments difficult. The plant required a fast, accurate, and reliable solution to continuously monitor C5 levels, allowing operators to take timely corrective actions and avoid off-spec products.

Solution with AnalyticX

Using AnalyticX, the engineering team was able to develop a soft sensor — a machine learning-based predictive model — specifically designed to estimate the C5 content in the debutanizer overhead stream in real time.

Key steps included:

  • Seamless ingestion of historical operational data into AnalyticX without any coding requirements.
  • Applying statistical analysis to identify key process variables influencing C5 concentrations.
  • Rapid development and training of a machine learning model tailored to predict C5 content with high accuracy.
  • Deployment of the predictive model into live operations for real-time product spec monitoring.

Results

  • Enhanced Product Monitoring:
    Operators now have a real-time view of the predicted C5 content, significantly reducing reliance on delayed lab measurements.
  • Improved Process Control:
    By closely tracking C5 levels, the plant was able to make timely adjustments to operational parameters, ensuring consistent product quality.
  • Reduced Off-Spec Production:
    Real-time insights helped minimize off-spec batches, leading to material savings and reduced reprocessing costs.

 

 

 

Key Takeaways

  • AnalyticX enabled the rapid development of a soft sensor customized for critical KPI monitoring.
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