DX-PLANT®

We enhance the profitability of our clients with industrial plants through DX-PLANT®, a system that leverages Industrial IoT (IIoT) and AI-driven big data analysis to provide comprehensive solutions.

DX-PLANT® consists of four service groups: "Information Integration Support Service," "Operation Support Service," "Maintenance Support Service," and "Business Support Service." It creates a virtual plant in the cloud using big data, including operational data, inspection records, and maintenance histories of actual plants. This enables clients to monitor the status of their plants in real-time from anywhere at any time, improving operational efficiency and enhancing maintenance processes.

Information Integration Support Service (Engineering)

Through our Information Management System, we support clients' information analysis and decision-making by aggregating data from engineering documents during EPC (Engineering, Procurement, Construction) phase and operational maintenance data post-EPC. Traditionally, essential data for plant operation and maintenance has been stored in multiple, disparate systems. By consolidating this siloed data into a unified system, the system facilitate easier access and sharing of information, streamlining work processes. Additionally, contextualization allows for data interpretation and correlation across systems, enabling insights from multiple data sources. Furthermore, integration with 3D models and/or point cloud models provides visual comprehension of equipment status and information.

Operation Support Service

By aggregating plant data and providing various dashboards and applications such as ADVIDA®, PMOS®, and RL-Tracker® to gain insights and support plant operations, we optimize plant management and improve operational efficiency.

ADVIDA® detects early signs of anomalies in plant operation using anomaly detection models built from historical data. It can identify abnormal areas across all plant equipment, enabling early detection and response to issues. Additionally, it allows for efficient identification of problem occurrences, speeding up and enhancing root cause analysis.

PMOS® automates plant performance evaluation by comparing process simulation outputs based on real-time operational data with design conditions, thereby supporting decision-making.

RL-Tracker® is an application used to predict Tube Metal Temperature (TMT), a key indicator for decoking in ethylene cracking furnaces. It leverages historical operational data (DCS data, TMT measurements) to build a predictive model that estimates TMT values from real-time DCS data. By using RL-Tracker®, clients can optimize operational conditions for ethylene cracking furnace operation planning.

Furthermore, in a case study involving the use of DX-PLANT® for a large compressor, one of the critical equipment in an ethylene plant, DX-PLANT® established a mechanism that uses simulators to apply real-time process data for performance calculations. This allows for more accurate compressor performance calculations compared to those based solely on DCS data and design conditions. Through this initiative, we aim to alleviate the bottlenecks in plant load-up.

DX-PLANT® (digital twin) confirms 4% room for improvement in Cracked Gas Compressor power

Maintenance Support Service

By monitoring static and rotating equipment in real-time and predicting abnormal conditions, we transition from conventional time-based maintenance (TBM) preventive maintenance to condition-based maintenance (CBM) predictive maintenance. This shift enhances plant reliability and reduces maintenance costs.

DX-PLANT® offers AOCM® (Advanced Online Corrosion Monitoring) for the urea process. AOCM® monitors pipe corrosion, detects abnormal corrosion in critical equipment early, and prompts early intervention. Traditionally, for thickness measurements, scaffolding would be set up and insulation removed during maintenance. With AOCM®, these costs and time requirements are significantly reduced.

Additionally, we provide a "Rotating Equipment Maintenance Support Service," which uses digital twin to monitor the performance of rotating equipment in real-time and detect abnormalities.

Business Support Service

By integrating plant management information with plant operation data, the Business Support Service optimizes plant management. DX-PLANT® provides automatic and immediate feedback to support management decision-making. For instance, by linking DX-PLANT® with APM and ERP systems, it assists in the planning and management of human resources, materials, and finances. Additionally, for clients managing multiple plants, DX-PLANT® offers a Spare Parts Management System to oversee the inventory of spare parts across all facilities.

When implementing DX-PLANT®, we first review the current situation with our clients, identify challenges, and clarify the solutions to be delivered before developing the most suitable applications. If specialized technology is required to solve a problem, we collaborate with partners and licensors to create the necessary applications. DX-PLANT® aims to be a platform for co-creation, generating new value with our clients and partners.

At TOYO, by integrating DX-PLANT® with our Technical Advisory Services for Plant Operation and Maintenance, we enable real-time monitoring of the operational status of plants remotely and enhancing the sophistication of our services. Additionally, we have established a monitoring room within the office that utilizes DX-PLANT®, where our experts monitor the status of each plant and provide tailored advice and recommendations to the clients.