Case Study: Digital Transformation of Environmental Monitoring in a Petrochemical R&D Facility

Industry: Petrochemical Research & Development

Challenge:

A leading petrochemical R&D facility in India faced increasing challenges in ensuring workplace safety and regulatory compliance. The site experienced safety hazards from industrial gas emissions, air quality deterioration, and ventilation inefficiencies that risked both personnel health and operational reliability.The customer required a scalable, real-time monitoring solution capable of integrating with their existing sensors while providing actionable insights through analytics and reporting.

Solution:

Ai-DEA Labs implemented a comprehensive Environment Monitoring System (EMS) supported by its suite of connected devices — Smart Environment Monitors (SEM), Indoor Air Quality (IAQ) Monitors, and the Echo Logger.

Solution was  deployed in a Private Cloud with restricted role-based access.Being a brownfield deployment, the solution was carefully engineered to leverage the customer’s existing fixed sensors while integrating seamlessly with Ai-DEA Labs’ hardware and cloud-based EMS platform.

The solution delivered:

• Real-time monitoring of industrial gases and ambient air quality parameters

• Instant alerts via email for any deviations

• Cloud dashboards accessible via desktop and mobile devices

• Historical trend data and automated report generation

  
  

Implementation:

The project involved nearly 10 person-days of detailed site study, followed by the deployment of 17 monitoring devices across critical zones.End-to-end implementation, testing, and validation was completed within one month, including user training and integration with the facility’s IT systems.

Results:

• Full visibility of real-time environmental data and device status

• One year of historical data enabling trend analysis and predictive insights

• Improved regulatory compliance and proactive safety management

• Optimized ventilation control and reduced energy usage

  
  

Key Takeaway:

Through this brownfield digital transformation, Ai-DEA Labs enabled the customer to move from reactive safety management to proactive environmental intelligence, setting a benchmark for sustainable industrial operations.