Featured Case Study
Digital Twins for Oil & Gas
-
Partner
- Sector Energy, Refining & Exploration
Oil & Gas
ROI & Business Impact
Improvement in overall refinery efficiency
15-25%
Reduction in total operational costs
20-30%
Reduction in asset maintenance costs
25-35%
Reduction in turnaround time
20-30%
Investment & Costs
- Pilot$50,000 – $75,000
- Single PlantTBD
- Multiple PlantsTBD
- Multi-RefineriesTBD
Investment Recovery
- Typical payback period: 12-18 months
- Ongoing operational savings compound annually
- 5-year NPV: 200-400% of initial investment
Challenges
Oil and Gas Industry Operations
Equipment Failure and Downtime
Aging drilling and refinery equipment causing unexpected shutdowns and production losses across upstream and downstream operations
Safety Incidents and Compliance
High-risk environments requiring continuous safety monitoring and stringent regulatory compliance across all operational areas
Environmental and Carbon Impact
Increasing pressure to reduce carbon footprint and environmental impact while maintaining operational efficiency and profitability
Asset Integrity and Maintenance
Complex maintenance requirements for critical infrastructure across remote locations with limited access and harsh conditions
- The average oil & gas facility experiences 150 hours of unplanned downtime annually.
- Each hour of production downtime costs oil companies up to $500,000.
Oil & Gas operational costs can be reduced with IoT & digital twins
Why Digital Twins
Substations
Operations
Integrate data from multiple sources - SCADA, DCS, safety systems, production data and environmental monitors - into a single, interactive 3D platform.
Decisions
Real-time simulations allow teams to test scenarios, predict equipment failures, and respond proactively to safety and production challenges.
Costs
Reduce reliance on reactive maintenance and enable predictive strategies that extend asset life and optimize operational costs.
Scalability
User-friendly interfaces reduce training time and scale seamlessly with evolving oil & gas needs and digital transformation initiatives.
Solution
For Oil & Gas Industry
Combining 3D, IoT, and AI on a patented no-code web application for creating digital twins that serve as cognitive assistants
- SCADA/DCS
- AI/LLM Data
- OPS/SOP/Manuals
- Video Feed
- Historical Data
- IoT/Sensors/GPS
- Assets/ERP/Safety
- SCADA/DCS
- AI/LLM Data
- OPS/SOP/Manuals
- Video Feed
- Historical Data
- IoT/Sensors/GPS
- Assets/ERP/Safety
Immersive 3D Command Control
Monitor entire oil & gas operations in an interactive 3D environment, updated with AI-driven real-time data for proactive decision-making.
AI-Driven Predictive Maintenance
Identify and prevent issues before they arise with AI that continuously learns and predicts potential risks for drilling equipment, pipelines, and critical infrastructure.
Dynamic Performance Optimization
Leverage advanced analytics and dashboards to reduce downtime, optimize resource allocation, and achieve peak operational performance
Scenario Simulation
Harness AI-powered digital twins to simulate emergency scenarios, safety protocols, and production optimization with unmatched accuracy.
Sustainability Intelligence
Optimize energy consumption, reduce emissions, and meet ESG goals with AIenhanced sustainability insights and automated compliance reporting
High Performance Without Infrastructure
Web-based platform delivers seamless performance without GPU servers, saving costs while maintaining scalability across all devices
Our USP
Mass Accessible Digital Twins
| Traditional Solutions | Our Breakthrough | |
|---|---|---|
|
Accessibility barrier
|
Siloed Solutions
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Browser Application
|
|
Creation complexity
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Requires 3D Designers/ Developers
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No-code platform
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|
Hardware requirements
|
GPU Servers ($250k-$750k)
|
No GPUs or heavy servers needed
|
|
Deployment time
|
6 to 9 Months
|
6 to 9 Weeks
|
|
Device limitations
|
PC/Desktop or specific hardware
|
Access on any device
|
|
Technical dependencies
|
Constant IT support required
|
Self-service platform
|
|
Annual pricing per twin
|
$100k-$1M
|
$25k-$80k
|
Features (1/4)
Benefits of Digital Twins for Oil & Gas
Refinery Process Optimisation
- Asset uptime
- Failure rates
- Maintenance costs
- MTBF
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Description
Monitor and simulate refinery processes to optimize production yields, energy consumption, and product quality.
-
Business Impact
Improved equipment reliability, reduced downtime, and optimized maintenance planning.
-
Key Elements
IoT sensor data, equipment control feeds, historical performance data.
Predictive Maintenance & Uptime
- Predicted vs Actual Failures
- MTTR
- Maintenance Cost Savings
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Description
Develop AI-driven predictive models to anticipate valve, production, and critical equipment failures, enabling proactive maintenance
-
Business Impact
Reduction in unplanned downtime and maintenance costs while increasing asset life.
-
Key Elements
Historical failure logs, maintenance records, operational data from DCS/SCADA and IoT systems.
Real Time Operations Dashboard
- Operational MTTR
- Asset Utilisation
- Refinery Throughput
- Operational Efficiency
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Description
Provide a unified dashboard integrating data from SCADA, DCS, and safety systems for realtime operational decision-making.
-
Business Impact
Improved operational transparency and faster response times to operational issues.
-
Key Elements
Data feeds from existing systems, KPIs for operational performance.
Features (2/4)
Benefits of Digital Twins for Oil & Gas
Automated Incident Response
- Incident detection time
- Resolution success rate
- Number of incidents
-
Description
AI-powered detection of operational incidents (e.g., leaks, equipment failures, safety violations) and automated alerts for resolution.
-
Business Impact
Reduced incident response time and improved MTTT
-
Key Elements
Sensor feeds, IOT Data, Historical incident reports
Supply Chain and Logistics Management
- Supply Efficiency
- Logistics cost optimisation
- Vendor Performance
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Description
Real-time optimization of supply chain operations including inventory management, transportation, and logistics coordination.
-
Business Impact
Improved Minimized supply disruptions and optimized logistics costs
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Key Elements
Supply chain data, transportation schedules, inventory levels
Facility Operations Analytics
- Facility utilization
- Delivery Performance
- Cost optimization
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Description
Analyze facility usage patterns and operational efficiency to optimize layouts and plan infrastructure improvements.
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Business Impact
Improved facility utilization and enhanced operational efficiency.
-
Key Elements
Operational data, facility usage patterns, infrastructure layouts.
Features (3/4)
Benefits of Digital Twins for Oil & Gas
Asset Health Monitoring
- Compliance efficiency
- Maintenance reduction
- Response time reduction
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Description
Real-time monitoring of critical oil & gas assets, such as drilling rigs, compressors, pumps and pipeline infrastructure, using IoT sensors and SCADA systems.
-
Business Impact
Improved safety performance, reduced incidents and enhanced emergency response capabilities.
-
Key Elements
Reduced Gas detection data, safety system status, emergency response procedures.
Integrated Command and Control Center
- Response times
- Incident MTTR
- User satisfactions KPIs
- NPS and other stats
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Description
Provide a unified dashboard integrating data from Maximo, BMS, and other systems for realtime decision-making.
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Business Impact
Improved facility operational transparency and faster response times to issues.
-
Key Elements
Data feeds from existing systems, KPIs for operational performance.
Emergency Scenario Simulation
- Evacuation Time
- Scenario accuracy
- Compliance Levels
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Description
Use simulations to plan evacuation and disaster response scenarios.
-
Business Impact
Enhanced premise safety and compliance with regulatory standards.
-
Key Elements
Oil flow data, building layouts, emergency response protocols.
Features (4/4)
Benefits of Digital Twins for Oil & Gas
Drilling Operations optimisation
- Drilling efficiency
- Equipment utilisation
- Cost per well
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Description
Use AI to optimize drilling parameters and equipment performance based on real-time drilling data and geological conditions.
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Business Impact
Improved drilling efficiency and reduced operational costs.
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Key Elements
Drilling parameters, geological data, equipment performance metrics.
Refinery Security and Access Control
- Security Compliance
- Access efficiency
- Threat detection rate
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Description
Real-time monitoring and optimization of refinery security systems including access control and security protocols.
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Business Impact
Enhanced refinery security and improved compliance with security regulations
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Key Elements
Security system data, access logs, compliance metrics.
Monitoring Assets Beyond Premises
- Pipeline utilization
- True alerts accuracy
- Delivery based efficiency
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Description
Analyze and Monitor pipelines and cargo outside the refinery premise wholistically.
-
Business Impact
Improved visibility, lesser false alarms and enhanced long-term planning.
-
Key Elements
Theft detection, leakage patterns, pipeline transport accuracy.
Business Model
Oil & Gas Digital Twin
| Feature | Basic | Plus | Pro |
|---|---|---|---|
|
Application Complexity
|
Low
|
Medium
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High
|
|
Level of Detail
|
LOD2
|
LOD3
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LOD4
|
|
Workflows
|
4
|
10
|
no limit
|
|
Viewer Access
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1 User
|
5 Users
|
10 Users
|
|
Editor Access
|
1 User
|
2 User
|
3 Users
|
|
Heatmap view
|
Yes
|
Yes
|
Yes
|
|
Real time IOT integration
|
Yes
|
Yes
|
Yes
|
|
RBAC
|
-
|
Yes
|
Yes
|
|
Alerts & Notifications
|
-
|
Yes
|
Yes
|
|
X-Ray View
|
-
|
Yes
|
Yes
|
|
Simulated Data Integration
|
-
|
-
|
Yes
|
|
Custom Branding
|
-
|
-
|
Yes
|
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AI/LLM Integration
|
-
|
-
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Yes
|
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3rd Party API Integration
|
-
|
-
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Yes
|
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One-Time Cost for Process Twin Sandbox
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-
|
-
|
-
|
|
Sandbox Development Duration
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3-4 Weeks
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4-6 Weeks
|
6-9 Weeks
|
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Process Twin Platform Price (per month)
|
$750
|
$1500
|
$3000
|
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Additional Viewer License (per month)
|
$100
|
||
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Additional Editor License (per month)
|
$500
|
Implementation Approach
Pilot / POC
Discovery, Design, Integration (Weeks 1-3)
- Current state assessment, use case prioritization and ROI analysis
- Feasibility report and digital twin implementation plan
- Digital twin architecture design
- Data pipeline establishment and system integration
- Initial 3D model creation and validation
Development, Deployment (Weeks 3-6)
- Phased rollout starting with priority use cases
- User training and change management
- Performance monitoring and optimization
- 3D digital twin application publishing for multiple platforms
- Role-based access and control for digital twin usage
Training, Handover, Roadmap (Weeks 7-9)
- Knowledge transfer and documentation
- Additional use case implementation
- Advanced analytics and AI model deployment
- Continuous improvement and feature enhancement
- Expansion to additional terminals/facilities
Media Mentions
Substations
Tracxn
Top 10 Digital Twin Startups in India
Forbes
Forbes Asia 30 Under 30
Shark Tank
Featured in S02E28 – “Game Changers”
USPTO
US Patent Granted till 2035
GATES
Best Innovation Award (2024)
TechCrunch
Featured in TC NoCode/IoT Startups
Technology Architecture
Digital Twin Platform
Explore How a Digital Twin Can Boost Your Operations
