Maintenance Intelligence for
Hydrocarbon Processing Plants.
KeplrAI predicts asset failures, guides maintenance teams, and coordinates parts readiness before downtime happens.
The plants that process hydrocarbons are drowning in sensor data.
Every critical asset streams pressure, temperature, vibration, and flow data into historians nobody can fully leverage. Plants still run maintenance on calendars and tribal knowledge. The result: over $1M per day in unplanned downtime, parts that arrive weeks after failures are predicted, and institutional knowledge that walks out the door when a senior reliability engineer retires.
We believe every asset should have its own brain. Not a plant-wide black-box model. Asset-level reasoning: the compressor learns what a healthy compressor looks like. The exchanger learns its own fouling signature. Every wrench turn makes the model sharper, and that intelligence compounds across the fleet.
From raw signal to sharper model, start to finish.
One continuous loop per asset. Field data flows back into the model. Every repair makes the next prediction sharper.
Connect
Plug into the plant's existing DCS, SCADA, PLCs, and historians (PI, Aspen IP.21, Honeywell PHD). Read-only integration. No rip-and-replace.
Connect
Plug into the plant's existing DCS, SCADA, PLCs, and historians (PI, Aspen IP.21, Honeywell PHD). Read-only integration. No rip-and-replace.
Model per asset
Every critical asset gets a physics-informed model trained on its specific operating conditions and failure modes. Not generic anomaly detection. Bearing wear, fouling signatures, valve degradation — each detected with engineering-grade reasoning.
Predict
Assets flag degradation early with time-to-failure estimates, confidence intervals, and supporting evidence. Your reliability team gets a prioritized view, not a stream of alerts.
Coordinate parts
Predictions auto-check inventory and trigger procurement workflows in your existing procurement system. Long-lead items surfaced weeks before failure.
- 1.Isolate K-101 · LOTO
- 2.Drain lube oil reservoir
- 3.Replace mech seal SKU-44918
- 4.Recommission · verify vib < 2.8 mm/s
Schedule and execute
Work orders flow to your existing CMMS at the optimal window. Technicians get asset history, predicted failure mode, and repair procedure on their mobile device.
Learn
Technicians log what they actually found. Field data flows back into the asset's model. Every repair makes the next prediction sharper. The asset library compounds across every plant we deploy.
Built for the plants that process hydrocarbons.
Active across downstream and midstream. Same asset DNA, same sales motion, adjacent customer base.
Refineries
Unplanned downtime runs $1M+ per day. Fleet-wide asset intelligence flips that economics.
Petrochemical
Continuous processes where a single unplanned stop cascades through downstream units.
Gas Processing & Fractionators
Uptime is throughput. Early degradation flags protect contracted volumes.
LNG
Downtime economics at $3–5M per day per train. Every prediction pays for itself.