Energy
Clarity that strengthens reliability, safety, and production performance in upstream, midstream, refining, and LNG engineering and operations teams.
Big Picture
Insight that Powers Reliability
Energy and hydrocarbon facilities operate under extreme conditions where even small design or control changes can create large operational consequences. Onyx 360 gives engineering and operations teams a clear, model-driven view of how processes, equipment, and automation will behave before changes reach the field. From upstream production to refining and LNG, our Connected Performance Solutions help you reduce risk, accelerate startup, and improve reliability across the entire asset lifecycle.
Case Study
Connected Performance for Energy Systems
Accelerating Startup in Oil & Gas
Challenge
A new offshore production facility faced tight startup deadlines, complex system interactions, and major operational risks including hydrate formation, compressor sequencing, and expander/JT valve behavior. Multiple high-risk scenarios needed to be understood and prepared for, yet the facility required training and competency assessment long before first oil. Limited weather windows for commissioning increased pressure to “get it right the first time.”
Solution
Conducted a structured study to determine how dynamic simulation could reduce project risk. We developed a Multi-Purpose Dynamic Simulation integrated with a copy of the FATed Distributed Control System (DCS). The system enabled:
- Engineering verification of control logic and key process behaviors
- Virtual loop checks for commissioning support
- Abnormal situation management training
- Development and refinement of operating procedures
- Pre-startup training 18 months ahead of first oil
The solution also revealed over 300 design issues early, including missing startup overrides, duty/standby functionality gaps, and restart failures after process trips.
Results
- 3X return on investment before startup
- 300+ issues identified and corrected early
- Major reductions in commissioning time and risk
- Early training improved operator readiness and procedural consistency
- System later extended for Integrated Operations & Production Assurance
3X
Return on Investment before startup
18
months
early operator training
300
issues resolved
pre-startup
High-fidelity MPDS + DeltaV ICSS
Procedure development +
abnormal situation training
3D Simulation for Energy Facilities
Faster, safer startups and ramp-up Identify issues early and rehearse critical scenarios off-line.
Increased Operational Availability at Refinery
Challenge
A major refinery struggled with dangerous, infrequent operations such as startup, shutdown, and fuel transitions (gas–diesel swing). Relying on their few lead operators because many operators had little or no direct experience with high-risk procedures, and experienced staff were retiring. The site averaged 3–4 operational incidents per year, often related to inconsistent execution and lack of training opportunities.
Solution
Developed an Operator Training System that allowed refinery operators to repeatedly practice critical operations before performing them in the field. The model supported:
- Startup and shutdown sequence training
- Park/unpark operations
- Gas–diesel swing transitions
- Decision-making exercises for rare and abnormal conditions
Operators regularly trained immediately before performing the same operations in the live unit, improving confidence and procedural discipline.
Results
- ZERO unplanned downtime events attributed to operator error the year after implementation
- Reduced planned downtime from improved operational decision-making
- Major reductions in commissioning time and risk
- Safer execution of rarely performed high-risk transitions
- Simulator expanded to additional refinery units
- Minimal maintenance required to remain aligned with the automation lifecycle
Training for rare, hazardous refinery operations
Eliminated unplanned downtime events
Reduced planned downtime
Improved operator confidence and consistency
Easily expandable, low-maintenance digital twin
3D Simulation for Energy Facilities
Faster, safer startups and ramp-up Identify issues early and rehearse critical scenarios off-line.
Benefits
What Energy Teams Gain
Faster, safer startups and ramp-up
Identify issues early and rehearse critical scenarios off-line.
Higher process safety and reliability
See how disturbances propagate and prevent abnormal conditions.
Greater operational availability
Predict and prevent failures, transitions, and equipment challenges.
Improved operator readiness
Prepare teams for rare, hazardous, or complex procedures.
Reduced commissioning and project risk
Test logic, sequences, alarms, and controls long before cutover.
Stronger cross-team alignment
Give EPCs, automation engineers, and operators a unified, realistic view of system behavior.
Use Cases
Where Connected Performance Delivers Impact
- Load change and transient response modeling
- Turbine, boiler, or reactor performance evaluation
- Control logic optimization and testing
- Operating procedure validation
- Emergency response and safety training
- Equipment upgrades and plant modifications
- Fuel, water, and energy efficiency studies
- Digital twins for continuous monitoring