Operational Digital Twins for Day-to-Day Infrastructure Management

The Challenge

Oil refineries operate complex networks of equipment where any malfunction can lead to significant safety, environmental, and financial risks. Key challenges include:

Real-Time Visibility: Traditional monitoring methods offer limited insight into real-time operational dynamics.
Predictive Maintenance: Reactive maintenance leads to costly downtime and potential hazards.
Data Silos: Information scattered across various systems hinders prompt decision-making.
Training & SOPs: Conventional 2D manuals can be outdated and less intuitive for modern operations

McKinsey & Co. Study on impact of unplanned outages in oil refineries.

How digital twins impact daily operations on-site?

Integrate 3D Spatial Computing: The digital twin provides a highly detailed 3D model of the refinery, integrating sensor data and IoT inputs. This spatial computing approach offers a holistic view of the plant, enabling operators to virtually “walk through” facilities and assess conditions in real time.

Enhance Monitoring and Intervention: Real-time data from sensors and control systems are fed into the digital twin, allowing for constant monitoring. Advanced analytics and AI detect anomalies and predict potential equipment failures, enabling proactive interventions.

Improve Decision-Making: By consolidating data into a single, interactive model, engineers and decision-makers access timely, accurate information. This integration helps prioritize maintenance, optimize operations, and manage resources more effectively.

Standardize Operating Procedures in 3D: The digital twin incorporates interactive, 3D standard operating procedures (SOPs). These visual guides simplify complex tasks, improve training for new staff, and ensure consistency across daily operations.

[data-wf-bgvideo-fallback-img] { display: none; } @media (prefers-reduced-motion: reduce) { [data-wf-bgvideo-fallback-img] { position: absolute; z-index: -100; display: inline-block; height: 100%; width: 100%; object-fit: cover; } }

Key Benefits Observed

Reduced Downtime: Proactive monitoring and predictive maintenance significantly decreased unplanned outages.

Enhanced Safety: Early detection of potential failures minimized risks and improved overall site safety.

Improved Operational Efficiency: With all critical information centralized, decision-makers could respond more swiftly to operational challenges.

Cost Savings: Optimized maintenance schedules and reduced downtime contributed to lower operational costs.

Better Training & Collaboration: The 3D SOPs improved staff training, fostering a better understanding of complex systems and smoother coordination among teams.

Project Implementation

How It Was Rolled Out

Phase 1: Assessment & Data Integration
The project began with a thorough assessment of the refinery’s physical infrastructure. Existing sensor networks and data systems were mapped to create a digital replica of critical equipment and process flows.
Phase 2: Developing the 3D Model
Using advanced spatial computing technologies, a detailed 3D model of the refinery was created. This model was continuously updated with real-time data.
Phase 3: Deploying Analytics & AI
Predictive analytics tools were integrated into the digital twin to monitor performance, forecast maintenance needs, and simulate operational scenarios.
Phase 4: Training & SOP Integration
Engineers and operators were trained on the system, utilizing interactive 3D SOPs. This step not only improved operational efficiency but also enhanced safety protocols.

The Future of Smart Industries with Fabrik

Fabrik’s approach to operational digital twins is revolutionizing critical infrastructure management, offering transformative solutions for daily operations, safety, and long-term resilience. By integrating real-time data, advanced analytics, and immersive 3D visualization, Fabrik empowers engineers and decision-makers to proactively monitor systems, reduce downtime, and optimize resource allocation.

Why Fabrik?

100% Made in India: Retaining intellectual property and development talent within the country, driving local innovation and expertise.
Industry Leader: Pioneering a new category of operational digital twins that streamline maintenance, improve safety, and enhance day-to-day efficiency in sectors like oil refining, utilities, and transportation.
Global Potential: Positioning India as a leader in digital twin innovation, with scalable solutions that can be applied to diverse industries and geographies.

By focusing on the intersection of data-driven intelligence and immersive 3D environments, Fabrik is poised to reshape how industries function, making them smarter, more efficient, and more resilient to future challenges.