Industrial Process Monitoring Software: From Data to Setpoint

Looking for industrial process monitoring software? Intellect is our flagship process monitoring and optimization software that gives you a live view of process behavior across differing materials, equipment states, operating modes, and production conditions.

Your plant produces a lot of data.

Sensors measure your process. Your distributed control system (DCS) or supervisory control and data acquisition (SCADA) system collects and uses those measurements. Your historian stores and serves the measurement history.

The challenge is turning that data into a clear answer:

What is my process doing and how is it all related?

That answer requires process context, multivariable analysis, production status, equipment state, and a clear way to see meaningful changes as they occur.

See the process as it is operating now

Intellect brings your process measurements and equipment-state information into one operating view.

It can monitor:

Process measurements
Equipment states
Material characteristics
Production rates
Product grades
Batches or campaigns
Operating modes
Recipes and compliance
Quality measurements

You get a live view of how your process and products are behaving under changing operating conditions.

You can see the process status, identify a developing change, and understand the measurements that explain it.

That is the purpose of industrial process monitoring software: to give you a current understanding of your process while it is running.

Monitor many variables without creating a wall of tags

Industrial operations generate large amounts of data.

Reviewing those measurements one at a time makes it difficult to recognize a change that appears across several.

Intellect evaluates your process measurements together.

It can summarize the behavior of many variables into a smaller number of meaningful process indicators, so you can see:

A change in process behavior
A shift in equipment performance
A difference between operating modes
A developing deviation
A relationship between material conditions and process response
A change that individual measurements do not make obvious by themselves

You get a connected view of your process instead of a long list of unrelated signals.

Monitor across differing operating conditions

A process can behave differently when the operating conditions change.

Relevant differences can include:

Material grade
Feed composition
Production rate
Equipment configuration
Recipe
Product
Batch stage
Gas-lift condition
Facility condition
Operating mode

Intellect evaluates process behavior in the context of those conditions.

This matters because a value that is normal for one product, asset, rate, or operating mode may be unusual for another.

Process monitoring must compare your process with the conditions that apply to your current production.

Intellect helps you see how your process behaves across those differences and identify when current behavior moves outside the expected range for that situation.

Detect process deviations early

A process deviation is a change in behavior that requires your attention.

The change may appear as:

A shift in several process measurements
A change in equipment response
An increase in cycle time
A change in production rate
A change in pressure or temperature behavior
A quality measurement moving away from its required value
A material change affecting the process
An operating condition moving outside its accepted range

Intellect monitors your process for these changes and presents each deviation with the operating context you need to investigate it.

You can see:

Which asset or unit is affected
When the change began
Which measurements moved
Which material or product was in process
Which operating mode was active
Whether similar behavior occurred before
Which conditions may explain the change

This gives the engineer a path from something changed to what changed and why it matters.

Find the conditions behind the change

A process monitor becomes useful when it helps you explain process behavior.

Intellect examines relationships between process measurements, material conditions, equipment state, and operating results.

That helps answer questions such as:

Did a material change affect the process?
Did equipment performance change?
Did the production rate move outside the usual range?
Did a recipe or operating mode change?
Did several measurements change together?
Has this asset shown similar behavior under these conditions?
Is the process moving toward a production, quality, or reliability problem?

You get more than a simple alarm or trend.

You can investigate the change using the measurements, conditions, and process history connected to the event.

Use your existing measurement path

Intellect works with information from:

DCS and SCADA
Data Historians
Laboratory systems
Quality systems
Manufacturing execution systems
Engineering applications
Material systems
Maintenance and equipment systems

Your systems continue to perform their existing roles.

You get a monitoring capability connected to the data your plant already produces.

Manufacturing process monitoring

You need to monitor manufacturing across products, grades, batches, equipment, and production conditions.

Intellect can monitor process behavior together with:

Material characteristics
Product and grade
Recipe
Equipment state
Production rate
Batch stage
Quality measurements
Inspection results

This supports:

Live process status
Deviation detection
Batch and campaign monitoring
Grade-change monitoring
Equipment-performance monitoring
Process investigation
Quality and production monitoring
Root-cause analysis

When your process changes, you can see the conditions present when the change occurred and investigate the measurements connected to it.

Oil and gas process monitoring

Your oil and gas production systems also change across differing operating conditions.

Relevant conditions can include:

Well, pad, platform, field and overall asset production
Pressures
Wellhead and downhole temperatures
Choke positions
Gas-lift allocations
Fluid properties
Equipment states
Separator conditions
Facility constraints
Commingled production

Intellect monitors production behavior across your assets and central processing facilities.

This supports:

Production surveillance
Facility monitoring
Well and stream monitoring
Virtual metering
Allocation support
Production optimization

A well test provides a measured snapshot while the well is on test. Process monitoring provides continuing visibility into changing production behavior between those measurements.

From process monitoring to a setpoint

Process monitoring is a foundational capability of Intellect.

It establishes your current process state and shows how that state changes across materials, equipment, products, rates, and operating modes.

That monitored process state can then support additional applications, including:

Current process or product estimates
Process and product diagnosis
Virtual sensors
Constrained optimization
Optimal setpoint calculation

When an optimization application calculates a setpoint, it uses your monitored process state, your operating objective, and the applicable constraints.

The monitoring capability comes first because you must understand your current process before determining a better operating setpoint.

Industrial process monitoring software from IntelliDynamics

Intellect, IntelliDynamics’ flagship process monitoring and optimization software, helps you see how your products and processes behave across differing operating conditions.

It connects to the process measurements and equipment-state information your operation already collects. It brings those measurements into context, detects meaningful changes, and helps you investigate what is affecting your performance.

You get a live operating view for manufacturing, chemicals, materials, oil and gas, and other industrial processes.

When your operating challenges require more, Intellect provides your monitored process state for estimation, diagnosis, prediction, optimization, and setpoint calculation.