Autonomous Process Optimization
A physics-grounded AI agent platform that detects operational faults hours before traditional alarms and advises panel operators on lowest-energy steady states.
The Industrial Data Tomb
The Status Quo
- Data Underutilization: Plants gather tens of thousands of sensor readings, but 99% is buried in historians and only accessed retroactively after an incident.
- Cognitive Strain: Live operations are highly complex. While skilled panel operators can monitor their units, continuously synthesizing dozens of parallel data streams in real time strains human cognitive limits.
- Delayed Interventions: Traditional DCS systems trigger alarms only after operational limits are crossed, leaving operators minimal time to prevent critical escalation and costly shutdowns.
The AI Solution
- Continuous Synthesis: Machine learning monitors, cleans, and evaluates the entire sensor dataset concurrently in real time.
- Physics-Grounded Detection: Blends mathematical modeling of thermodynamics/hydraulics with AI to foresee failure states before alarms occur.
- Proactive Adjustments: Unlocks a critical warning window—detecting anomalies at a median of ~35 minutes from event initiation—allowing operators to adjust parameters and avoid equipment degradation or safety trips.
System Components
The core orchestration framework that coordinates all downstream segments. It handles data ingestion schedules, manages system permissions, triggers simulation runs, and feeds cleansed sensor logs into the diagnostics layer.
Reads user-defined Design Basis spreadsheets to construct a thermodynamic and hydraulic simulator of the process. It outputs synthetic training datasets containing hundreds of randomized fault transients, modeling true physical constraints.
A multi-layered diagnostic system. Maps arbitrary DCS tags to canonical roles. Resolves local client units to standard SI units. Evaluates process health (8 faults) alongside rotating equipment health (bearing temperature/vibration trends).
Translates algorithmic classifications into human-readable operations briefings. Generates PDF reports detailing fault timelines, Excel spreadsheets mapped back to client tag formats, and sends live advisory alerts to operators.
How Data Flows Through the Agent
End-to-End Integrity
- Zero Tag Leakage: Client tags (e.g. `LIC-xyz`) remain strictly standard internally but map automatically to physical inputs (`Vessel Level`).
- Secure Validation: The core maps incoming data against DCS configurations, prompting engineering validation *before* execution.
- Energy Advice: When steady state is identified, the optimization layer compares design boundaries to suggest the lowest power duty configuration.
Double-Blind Validation Protocol
Decoupled Data Generator
A separate simulation generates 30 days of physically sound process data with injected randomness, missing sensor gaps, and randomized tag naming.
The Blind Experiment
The AI Agent is fed the design basis and DCS data. It runs without any prior knowledge of faults, mapping tags dynamically and identifying anomalies blind.
Independent Scorer Algorithm
A third software compares the Agent's reports against the secure "ground truth" ledger, calculating exact diagnostic accuracy and temporal responsiveness.
Validated Performance Metrics
Target Fault Classifications
Feed Loss Process
Upstream feed failure leading to steady liquid inventory decline and pump cavitation risk.
DetailsTank Overfill Process
Inlet valve stuck open. Inventory rises toward emergency high-high trips or atmospheric release.
DetailsPad Valve Stuck Open Process
Nitrogen supply valve stuck in open position, continuously pressurizing vapor space.
DetailsPVRV Stuck Open Process
Vapor pressure safety valve venting gas continuously to atmosphere, causing utility loss.
DetailsPadding Gas Loss Process
Upstream N₂ supply failure while drawing liquid, creating structural vessel vacuum risk.
DetailsHeater De-energized Process
Electrical immersion heater failure. Fluid cools, risking line freezing orSpec failures.
DetailsLevel Transmitter (LIC) Process
Telemetry level signal freezes. Loop continues static output while inventory drifts blindly.
DetailsPressure Transmitter (PIC) Process
Pneumatic vapor pressure reading freezes. Automated system drifts unchecked.
DetailsPump Bearing Wear Equipment
Progressive bearing degradation across up to 4 pumps. Vibration/temperature trends.
DetailsTube-Side Fouling Process
Silt, scaling, or organic deposit accumulation inside the tubes, reducing cooling effectiveness.
DetailsFin (Air-Side) Fouling Process
Dust, debris, or insect accumulation blocking draft airflow through external fin banks.
DetailsTube Plugging Process
Hydraulic restriction / narrowing of tube bores, risking pump overpressure or feed limits.
DetailsFan Belt Slip Equipment
Slipping or worn drive belts leading to reduced fan shaft speed and loss of draft cooling.
DetailsMotor Overload Equipment
Mechanical binding or high blade pitch causing motor current and winding temp to spike.
DetailsCooling-Air Loss Equipment
Blocked cowl or hot air recirculation causing motor winding temp rise under normal current.
DetailsFan Imbalance Equipment
Blade erosion, dirt buildup, or ice causing high overall vibration at normal bearing temps.
DetailsFan Bearing Wear Equipment
Progressive mechanical wear showing as concurrent rises in both vibration and bearing temperature.
DetailsCommercialization Roadmap
Why Partner With Us
Air-Gapped Cybersecurity
Designed for on-premises edge server deployments. Zero proprietary plant telemetry leaves the client's internal network, bypassing standard cloud compliance hurdles.
Massive Operational ROI
Early detection of a level drop, heat exchanger fouling, or a bearing degradation will help your asset save time and money in unplanned shutdowns and/or emergency maintenance.
Scalable Physics-First Foundation
By defining physical and thermodynamic bounds dynamically through Design Basis templates, the platform scales efficiently without requiring costly customized rebuilds.
Supreme Cortex Technologies
Ready to lead the next generation of industrial intelligence. Partner with us as we expand our physics-first diagnostics platform across global refining and processing plants.