Case Study Category: Manufacturing

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Process Furnace Optimization – Hybrid Modeling & AI Analytics Pilot – Sabic

Challenge Limited visibility into remaining furnace run length, causing unplanned decoking Reactive monitoring delayed anomaly detection and corrective action High operating cost and yield losses due to unstable furnace performance AIGC Solution Hybrid AI model combining first-principle simulations with data-driven analytics…

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Digitizing Corporate Data Center Project – Saudi Aramco

Challenge Limited real-time visibility into data hall operations and asset health Manual monitoring across multiple systems increased response time and risk Disconnected technologies for safety, access control, asset tracking, and maintenance AIGC Solution 3D Digital Twin for real-time simulation and monitoring…

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Data Center Digital Twin – Digitizing Corporate Data Center Project – Saudi Aramco

Challenge Limited unified visibility across data halls, racks, and server assets Siloed IT, facilities, and engineering data made capacity and thermal planning slow Reactive issue handling for power, cooling, and rack-level constraints Manual analysis for “what-if” scenarios increased operational risk AIGC…

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AI Based Video Surveillance – Digitizing Corporate Data Center Project – Saudi Aramco

Challenge Manual surveillance limited real-time awareness across large data center facilities Delayed detection of safety violations, fire, smoke, and abnormal human behavior Slower incident response due to fragmented monitoring systems AIGC Solution AI-powered video analytics integrated with VMS and edge computing…

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Al-Based Safety Monitoring Inside Substation Project – Aramco

Challenge Manual substation monitoring is labor-intensive and prone to human error, as it relies on periodic inspections rather than continuous observation. This often results in delayed detection of equipment faults, overheating, or abnormal load conditions, which can escalate into costly outages….

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Al-Based Smart Safety & Command Center Project – SASREF

Challenge High safety risk during turnaround and shutdown activities Manual monitoring across large, restricted industrial areas Limited real-time visibility into PPE compliance, unsafe behavior, and perimeter breaches Need for centralized control with fast incident response across the shutdown site AIGC Solution…

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Fuel Gas and Hydrogen Network Optimization Study Project – Petro Rabigh

Challenge Complex fuel gas and hydrogen network with multiple sources, consumers, and varying compositions High flaring and liquid fuel usage during imbalance and transient conditions Difficulty maintaining stable fuel quality and calorific value across units Limited visibility into pipeline bottlenecks, pressure…

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Energy Optimization & Green Energy Study – WOODPLC / Aramco Gas Increments Program

Challenge High energy consumption across gas processing units leading to increased OPEX CO₂ emissions driven by sub-optimal heat integration and utility system design Multiple design improvement options with no clear economic prioritization Inefficient pump sizing, exchanger design, and CHP configuration affecting…

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Energy Optimization & Green Energy Study for NGL Pumps – TIDAREC /Aramco Uthmaniyah Gas Plant

Challenge High operating cost from fixed-speed pump and driver configurations Uncertainty between electric motor (VFD) vs gas turbine–driven pumps Load variations at forecast rates causing efficiency losses Need to balance energy cost, reliability, and CO₂ emissions No clear, data-backed comparison across…

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External/Internal Boiler Stacks Aerial Inspection Using Drones Project – YNGL/Saudi Aramco

Challenge Boiler stacks were critical assets with no inspection done for 14+ years Internal inspection involved confined spaces, height risk, and long shutdown windows Manual methods required scaffolding and extended outages lasting months High safety exposure for inspection teams Limited visual…

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