DutchBoy PLANT · Refining & Gas Plants
Before it stops — ahead of the trip. See degradation and its cause first
DutchBoy PLANT reads thousands of tags stored in your DCS and historian against normal baselines for each operating mode. It finds where degradation begins and which tags are driving it before limits are reached, and draws on past maintenance and action records to suggest a response. Your existing control and information systems stay as they are.
Applicable Processes
Data Analyzed
Wave
DCS/SCADA continuous tags
Table
Lab results · maintenance history
Pulse
Batch process recipes
What existing systems tell you — what happened. What's still up to people — why, and what's next.
Degradation is slow; alarms wait for the limit
Fouling, wear and catalyst decline develop over weeks, but alarms sound only when a limit is reached.
Too many alarms
False alarms flood in whenever the operating mode changes, making real signals hard to pick out.
Plenty of data, little analysis
Tags pile up in the historian, but people still decide which ones to look at first.
Maintenance know-how lives with people
The same trips and failures recur, while past fixes stay buried in the records.
The data you already have, read as one — anomalies, root causes and actions, delivered.
Input · existing systems and data
DUTCHBOY ANALYSIS
Collect & clean
Align scattered data on one timeline
Detect anomalies
Score deviations from the normal baseline
Find root causes
Where, what and why it differed
Connect to action
Next steps backed by past cases and evidence
Sensor, waveform, measurement and image data are all converted to time-series and analyzed by one engine — no need to build a new model for each data type.
Output
- Anomaly scores against normal baselines for each operating mode
- Degradation trends and warnings before limits are reached
- Likely causal tags and how the issue propagates through the process
- Comparison across parallel equipment and trains
- Past trip and maintenance cases and the actions taken
- Shift handover and equipment health reports
Your existing systems, unchanged — just the 'why' and 'what next' added on top.
DCS alarms
Limitation
Fixed limits, false alarms when operating modes change, late warning of slow degradation
What DutchBoy Adds
Anomaly scores against mode-specific baselines and trends before limits are reached
Process historian
Limitation
Stores data and shows trends, but people choose which tags to view
What DutchBoy Adds
Shows 'where it started' with a ranking of contributing tags and the process flow
Vibration monitoring
Limitation
Sees only the vibration of a single rotating machine
What DutchBoy Adds
Separates causes by looking at vibration together with flow, temperature and pressure
CMMS · EAM
Limitation
Maintenance records pile up as text and are hard to reuse
What DutchBoy Adds
Searches past cases and actions by symptom pattern, and verifies a return to normal after maintenance
LIMS
Limitation
Lab results arrive late and are viewed apart from operating conditions
What DutchBoy Adds
Aligns lab results with operating tags in time and analyzes them together
One approach, different problems — solved in every process.
Heat exchanger and compressor degradation
- 1Anomaly score starts rising
- 2Compare parallel equipment · contributing tags
- 3Past maintenance cases and timing
- 4Confirm a return to normal after the fix
Rolling and casting equipment anomalies
- 1Abnormal motor, roll or hydraulic signals
- 2Link quality defects on one timeline
- 3Past replacements and actions
- 4Confirm a return to normal after the fix
Efficiency loss at pumping stations and treatment plants
- 1Detect rising power draw relative to flow
- 2Compare equipment of the same type
- 3Past wear and clogging cases
- 4Weekly report · maintenance plan
Only the modules you need, added on top of what you have — Core to start, automated reporting and conversational AI as Add-ons. Every module running on the plant data Weave designs.
Your existing systems — unchanged
Weave
Data designCollects and cleans tags, defines unit-equipment-tag relationships, and time-aligns lab results
Sense
Detection & RCAMode-specific anomaly detection, degradation trends, contributing tags, parallel equipment comparison
Recall
Recall & responsePast trip and maintenance cases and recommended actions, post-maintenance verification
Watch
Integration & alarmsBrings DCS alarms, LIMS, CMMS and vibration monitoring results together, with rule-based alarms
Visualize
Evidence & reportingShift handover and weekly equipment health reports
Agent
Query & reasoning'Why did compressor 2 vibration go up?' → answers with evidence
Why an LLM alone isn't enough — Time series from just 150 sensors add up to millions of numbers (about 5.4 million in our technology video example), far more than an LLM can read directly. DutchBoy's manufacturing-specific tools condense them into a few lines of key evidence — severity, pattern, scope of impact and past cases — and hand them to the Agent.
Could this fit your process?
From feasibility to expected impact, the AIBIZ team will walk you through it directly.