Machine-learning models trained on a plant’s own sensor history flag deviations in vibration, temperature or pressure long before a failure — the technical foundation of predictive maintenance.
…more about Anomaly →Documentation that reflects the plant as it actually is — including every repair, replaced part and modification since commissioning. In PlantPilot the twin stays as-built automatically, because changes are recorded where the work happens.
…more about As-Built →An existing, historically grown plant — as opposed to a greenfield new-build. Brownfield digitization is PlantPilot’s core use case: AI document classification makes the retrofit of a digital twin affordable.
…more about Brownfield →Computerized Maintenance Management System — software for work orders, maintenance schedules and asset history. PlantPilot complements a CMMS with document intelligence, a spare-part marketplace and energy AI, connected via API.
…more about CMMS →PlantPilot’s first layer: one as-built twin in which OEM, EPC, engineering partners and operator work together with role-based access — from the P&ID to the re-engineering request and the purchase order. Unlike a vendor’s digital twin, it is shared across companies and transactional.
…more about the Twin →Continuous measurement of equipment health indicators such as vibration, temperature and pressure. Provides the data stream that anomaly detection and predictive maintenance are built on.
…more about Condition →The EU Corporate Sustainability Reporting Directive and its reporting standards — requiring audited emission data from 2025 onwards. PlantPilot generates the energy & emission part from live consumption data.
…more about CSRD →PlantPilot’s second layer: all sensor and actuator data of a plant — historian, SCADA, condition monitoring, OEM telemetry — collected read-only from every party and mapped to the components of the twin. The foundation for pattern recognition, predictive maintenance and predictive operations.
…more about the Data Hub →Distributed Control System — the system that actually runs a process plant. PlantPilot never writes to the DCS: energy recommendations are advisory-only, executed by operators.
…more about DCS →A living digital representation of a plant: documents, asset structure, spare parts and live sensor data in one navigable model — kept as-built after every repair. In PlantPilot the twin is collaborative: every partner in the chain works in the same one.
…more about Digital →The AI discipline of recognizing document types, extracting tag numbers and linking files to assets automatically. Compresses brownfield onboarding from years of manual data entry into weeks.
…more about Document →Any medium that delivers energy into the process: electricity, natural gas, steam, compressed air, hydrogen. Per-carrier accounting is the basis of credible Scope 1/2 reporting and energy optimization.
…more about Energy →Engineering, Procurement, Construction — the companies that build a plant around the OEM’s core units, from global contractors to local engineering offices. With PlantPilot they work in the OEM’s twin, hand over an operation blueprint and stay in the value chain as service contractors.
…more about EPCs →Environmental, Social, Governance — the framework investors and regulators use to assess non-financial performance. In PlantPilot the E is a by-product of TCO optimization: CO₂ is treated as a cost next to energy and material, and reports come from the same metered data.
…more about ESG →A pre-negotiated supply agreement with a vendor. PlantPilot applies frame contracts automatically during quote comparison — a key driver of the −30% spare-part savings.
…more about Frame →The best production run in a plant’s history — maximum output, minimum specific consumption, quality in spec. Comparing current operation against golden batches is the cheapest optimization program available.
…more about Golden →A plant built from scratch on a new site. Greenfield projects can be documented digitally from day one — hydrogen plants are the current showcase.
…more about Greenfield →Hazard and Operability Study — the systematic safety review of a process plant, conducted on the P&ID. Living documentation keeps HAZOP results connected to the components they describe.
…more about HAZOP →The time-series database that records process data (temperatures, flows, pressures, states) for years. Most plants store this data and never analyze it — energy AI changes that.
…more about Historian →The international standard family for asset management: value from assets over their whole lifecycle, based on reliable asset information — exactly what a current digital twin provides.
…more about ISO →The identification system that gives every component in a plant a unique code. Tag extraction from drawings is how AI classification links documents to assets.
…more about KKS →Maintenance, Repair and Operations — the global spend category PlantPilot addresses; over $600bn per year in the process industries.
…more about MRO →Mean Time Between Failures and Mean Time To Repair — the two classic reliability KPIs. Predictive maintenance raises MTBF; a digital twin with linked parts and docs cuts MTTR.
…more about MTBF →Systematically identifying parts and components that are no longer manufactured or supported — and securing re-engineering or alternatives before they stop the plant.
…more about Obsolescence →Overall Equipment Effectiveness — availability × performance × quality. The standard metric for how much of a plant’s theoretical capacity is actually used.
…more about OEE →Original Equipment Manufacturer — the company that built a machine, core unit or component, often the brand on the whole plant while an EPC builds the rest. In PlantPilot the OEM opens the twin on its installed base, receives re-engineering requests digitally and turns one-time hardware into after-sales business.
…more about OEMs →The open, platform-independent standard for industrial data exchange. PlantPilot uses OPC UA for read-only ingestion of historian and SCADA data — without touching the OT network.
…more about OPC →What an EPC hands over with PlantPilot instead of a digital binder: the as-built twin, the connected data hub and the plant’s proven operating model — so the operator knows from day one how the plant runs cheapest and most reliably.
…more about the Blueprint →A time window in which a plant ran at maximum output with minimum specific energy and wear. PlantPilot finds these patterns and helps operators reproduce them.
…more about Optimal →Piping & Instrumentation Diagram — the operational map of a process plant. In PlantPilot every component on the P&ID is clickable and linked to parts, docs and history.
…more about P&ID →The emissions attributable to one unit of product — increasingly demanded by industrial customers. Derived from per-carrier energy accounting allocated to production orders.
…more about Product →Maintenance triggered by predicted failure windows (from anomaly detection on vibration, temperature, pressure) instead of fixed intervals or run-to-failure.
…more about Predictive →The step beyond predictive maintenance: pattern recognition on the data hub learns the states in which a plant runs best, detects drift and recommends how to steer back — advisory-only, with operators in control. Predicts problems in the process, not only in the equipment.
…more about Predictive Ops →Maintenance on fixed intervals or operating hours, regardless of actual condition. Safer than run-to-failure, but over-maintains healthy equipment — predictive maintenance closes that gap.
…more about Preventive →PlantPilot’s live aggregate of turnaround preparation: parts ordered and delivered, documentation complete, crews mobilized — one number per work package, system and TAR.
…more about Readiness →Renewable Fuel of Non-Biological Origin — the EU category for green hydrogen and derivatives. Certification requires metered proof of renewable power input per kg of product.
…more about RFNBO →Request for Quotation — in PlantPilot generated directly from the drawing: parts, drawing excerpt and quantities go to matched vendors; quotes come back comparable.
…more about RFQ →Operating equipment until it breaks. Feels cheap, but the costs hide in expedited freight, collateral damage and unplanned downtime — the baseline predictive maintenance is measured against.
…more about Run-to-Failure →Supervisory Control and Data Acquisition — the layer that monitors and controls distributed plant equipment. A key read-only data source for energy AI and predictive maintenance.
…more about SCADA →The GHG Protocol’s emission categories: direct emissions (1), purchased energy (2) and value chain (3). Plant operation platforms generate Scope 1/2 from metered consumption automatically.
…more about Scope →Total Cost of Ownership — the full cost of running a plant: energy, material, wear, maintenance, downtime and CO₂ per unit produced. PlantPilot’s third layer computes the operating strategy with the lowest TCO for a given production target — the honest metric for operating points and investments.
…more about TCO →The licensor or OEM whose process or core unit defines a plant — the turbine, the cold box, the electrolyzer, the gas system — and whose name is on it, even though EPCs build most of it. PlantPilot’s natural platform owner.
…more about Technology Providers →A planned full shutdown for inspection and overhaul, typically every 4–6 years, mobilizing 500–2,000 external workers on site for several weeks.
…more about Turnaround →The unit of turnaround planning: a scoped set of jobs on one system with its parts, documents, permits and crew. The readiness score aggregates across all work packages.
…more about Work →Get a demo and an individual version of PlantPilot for your plant or your installed base — one twin, one data hub, one TCO optimum.
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