Why Rejig Digital ?
Deep domain expertise + digital transformation: Industrial IoT execution knowledge fused with large-scale production AI to modernize operations and unlock real-world efficiency.
Outcome-first playbooks: Challenging safety and compliance constraints, operator-in-the-loop.
Fast value: Post GO-LIVE 8–12 week waves targeting margin enhancement, reliability improvement, and effective cost KPIs.
AI INITIATIVES ACROESS THE REFINERY CHAIN
The Outcome Horizon
USE CASE 1
TAR Scope, cost optimization & cycle enhancement
Shorten shutdowns, freeze scope, evaluate craft productivity — and safely extend run length between TARs with predictive analysis & AI based risk models.
Executive Summary
Turnarounds lock significant value. Our Digital Twin of permits, critical tasks, material management and SIMOPS—paired with proposed duration and scope aligned with RBI references & catalyst life—predicts growth work, resolves conflicts and re-sequences safely.
Between TARs, predictors for fouling, corrosion and catalyst life justify cycle extension windows aligned with market and maintenance opportunities.
Business Challenge & Contex
Late scope growth and low workpack readiness extend critical path and cost.
SIMOPS conflicts and constrained resources (cranes / NDE / vendors) cause ripple delays.
Degradation uncertainty forces conservative cadence; missed market windows.
Ambiguous TAR interval defining parameters.
The Outcome Horizon
& SIMOPS activities
(permits / scaff / crane)
Data Integration
Primavera/MSP (baseline, updates), CMMS WOs/BOM, vendor calendars, permit/isolation systems.
Tags/historian for critical assets; LIMS for QA gates post‑TAR; warehouse for kitting & staging.
SSO/RBAC; approvals and audit trail; constraint map (HARD vs SOFT).
USE CASE 2
(UpStream → MidStream → DoWnStream)
Orchestrate tanks, blends, units and logistics with a live Value Chain Digital Twin and constraint‑aware optimizers.
Executive Summary
A unified Digital Twin mirrors terminal‑tank‑unit‑pipeline networks and aligns blending, tank cycles, unit severity and dispatch. AI advisors recommend clean cutovers, blending targets and slotting plans within hard safety/quality constraints, closing the loop from plan to execution.
Business Challenge & Contex
Disjointed data across terminals, pipelines, tanks and units causes decisions lags.
Interfaces and estimated time of transit uncertainty drive contamination, downgrades and demurrage.
Product specifications and assays risk reputation; static plans diverge from reality.
Data Integration
SCADA/terminal systems, movement ledger, strapping tables, custody tickets / prover.
LIMS/analyzers (bias logs, drift), ERP/TMS, pricing feeds, LP exports (planning).
APC/MPC envelopes; interlocks; setpoint APIs; SSO/RBAC and audit trail.
USE CASE 3
Lean cost management
Reduce energy, hydrogen, steam, chemicals and giveaway with a Utilities & Economics Digital Twin and AI optimizers.
Executive Summary
Variable costs dominate day‑to‑day margin. A digital twin of steam/power/H₂ and quality ensures optimized values, routing and schedules minimize $/bbl without sacrificing throughput or specs—while remaining within hard safety envelopes.
Business Challenge & Context
Dynamic operation ignores network interactions and intraday changes.
Analyzer bias and assay drift drive costly giveaway and additives overspend.
Inability to leverage economic inflection points by calendar-based cleaning and dosing.
Poor visibility on tracking of variable cost aligned with business plan.
Business Solution
Utilities & energy control room with optimum operations to minimize loss accounting.
Standard furnace/heater efficiency program; Exchanger fouling management playbooks.
Overall heat integration and effective energy solutions
Quality governance to align specs, analyzer health and economics.
AI Solution
The Outcome Horizon
Energy intensity (Fouling, firing management and Heat integration)
Common utilities synergy & optimization
Chemicals cost optimization aligned with required process utilization
AI enabled Blending management
Data Integration
REJIG DIGITAL
Where Integrity MeetS Intelligence
Experience the next evolution in Asset Integrity and Industrial IoT excellence — an integrated suite of AI-powered solutions designed to enhance reliability, safety, and lifecycle performance across complex industrial operations.
Thermal Vision Hotspot • AI Enabled CP Management • Underground Power Cable Health — engineered AI that prevents failures and reduces O&M.
At‑a‑Glance Value
USE CASE 4
Automated Thermal Anomaly detection Intelligence for Smarter Operations
Executive Summary
Continuous thermal analytics for high/low temperature surfaces and assets (cryogenic, cold boxes, heaters, boilers, Reactors & Regenerators, expanders, Kiln, Electrical Distribution and Transmission Facilities…etc)
Core Capabilities (Thermal)
Dashboard & ChartS (Thermal)
Indicative Metrics
Data & IntegrationS (Thermal)
USE CASE 5
AI Enabled Smart CP Management
Executive Summary
Smart nodes perform On/Off PSP and current density reads, transmit securely, and use AI to detect CP loss, stray DC and AC interference. GIS corridor view prioritizes patrols; regulator‑ready audit packs compress compliance effort
Business Challenge & Context
Core Capabilities (TLP CP)
Dashboard & Charts (TLP CP)
Data & Integrations (TLP CP)
Field I/O: TLP terminals, rectifier outputs, bonds/coupons; soil resistivity, coating age.
Edge & Cloud: MQTT/HTTPS with buffering, OTA config; GIS/SCADA/PI historian; CMMS (SAP PM/Maximo); RBAC & signatures.
USE CASE 6
Underground Power Cable Health Monitoring
Executive Summary
Hybrid discrete + distributed sensing with AI to detect hotspots, insulation degradation and third‑party interference. Delivers early warnings and ±10–30 m localization for targeted interventions and reduced SAIDI/SAIFI impact
Core Capabilities (Power Cables)
Discrete sensors at joints/terminations: RTDs/Thermocouples for thermal; HFCT/UHF for PD; switchgear UHF/acoustic.
Distributed fiber: DTS/DTSS for temperature/strain; DAS for digging/vibration; FOCS for load correlation.
AI analytics: PRPD & PD clustering; hotspot progression vs load; DAS signature classifier for digging vs traffic.
Dashboard & Charts (Power Cables)
PRPD pattern panel + PD event timeline with severity clusters; fault zone highlight on map (±10–30 m).
Thermal hotspot slope chart vs load current; dynamic rating tile (allowable load vs ambient).
DAS corridor map with excavation alerts and geofenced permits; risk ladder by feeder.
Data & Integrations (Power Cable)
Sensors: RTD/Thermocouple, HFCT/UHF PD, fiber-optic DTS/DTSS/DAS, FOCS current.
Systems: DMS/OMS, SCADA/PI historian, GIS route overlays, CMMS auto-tickets, SSO/RBAC; evidence locker.
UNIFIED DATA, INTEGRATIONS & GOVERNANCE
Single data spine powering AI initiatives, adhering to safety first, state of art automation and auditable decisions”.
Integration & Control
Setpoint APIs to APC/MPC envelopes; interlocks/trip limits enforced (HARD vs SOFT).
operator-in-the-loop with explanations; autio-manual handoff; approval workflows.
Evidence locker for audits (decisions, constraint,versions,data lineage).
Program Rollout
REJIG DIGITAL
Build • Digitize • Optimize • Realize
Rejig Digital integrates Industrial IoT excellence with AI-first operations, driving the next industrial revolution in Oil & Gas. We help enterprises maximize margins, reduce operational risk, and accelerate sustainability through data-driven transformation.
Platform, Governance & Safety
Our platform ensures reliability, transparency, and compliance across every stage of digital operations.
What You Get?
REJIG DIGITAL — Delivering AI Outcome
Domain engineering + AI + governance. Every alert with context. Every action auditable. Every dollar of value tracked.