Process Parameter and Control Data

Common Types

• Flow rates (liquid, gas, slurry)
• Tank and vessel levels
• Temperature and pressure readings from process stages
• Valve positions and actuator status
• Batch timing and sequencing data

Uncommon/Advanced Types

• Inline spectrometry for real time chemical composition
• Multi variable correlation (temperature, pressure, viscosity) for predictive yield
• High resolution time series capture of transient events (pressure spikes, flow surges)

Possible Insights

• Process optimization to maximize yield and reduce waste
• Early detection of process drift before out of spec production
• Reduced startup/shutdown transition losses in continuous plants

Safety and Compliance Data

Common Types

• Gas detection (O2, CO, CO2, H2S, VOCs)
• Alarm logs and emergency shutdown (ESD) events
• Emission level monitoring (stack emissions, particulates)

Uncommon/Advanced Types

• Continuous leak rate quantification (methane, volatile gases)
• Thermal imaging for flare stack efficiency
• Corrosion monitoring sensors in high-risk piping

Possible Insights

• Automated regulatory compliance reporting
• Quantifying fugitive emissions for ESG goals
• Predictive safety interventions before equipment failure or environmental breach

Equipment Health & Predictive Maintenance Data

Common Types

• Pump and compressor vibration analysis
• Motor current monitoring
• Bearing temperature readings

Uncommon/Advanced Types

• Acoustic monitoring of cavitation pumps
• Infrared monitoring for heat exchanger fouling
• Magnetic flux analysis for motor winding degradation

Possible Insights

• Extending equipment life with condition-based maintenance
• Reducing unplanned outages in critical process stages
• Detecting energy efficiency losses early (e.g., pump impeller wear)

Quality and Product Integrity Data

Common Types

• Batch records and lot tracking
• In-process lab test results
• Moisture content or density measurements

Uncommon/Advanced Types

• Inline particle size distribution monitoring
• Spectral fingerprinting for purity verification
• Process analytical technology (PAT) data streams in Pharma & food-grade chemical production

Possible Insights

• Real time release testing in pharmaceuticals
• Waste reduction by adjusting parameters mid batch
• Stronger product traceability for recalls or audits

Environmental and Utility Data

Common Types

• Water flow and level in cooling systems
• Energy consumption of major process units
• Steam system pressure and temperature

Uncommon/Advanced Types

• Real time CO2 intensity per production unit
• Waste heat tapping for recovery opportunities
• Water quality sensor arrays (pH, turbidity, conductivity) in effluent streams

Possible Insights

• Lowering cost per unit through utility optimization
• Identifying ESG improvement opportunities
• Avoiding fines with proactive environmental compliance

Logistics and Distribution Data

Common Types

• Pipeline flow and pressure telemetry
• Inventory levels in tank farms
• Shipping schedule and loading data

Uncommon/Advanced Types

• AI driven leak localization in pipelines
• Predictive tank inventory management using consumption forecasting
• Automated vessel/truck routing based on real-time demand

Possible Insights

• Reduced transport delays and demurrage costs
• Avoiding supply bottlenecks in downstream operations
• Lower distribution costs through optimized routing