The platform

Nexus rtOpX — early event detection, root cause, and the response that follows.

Three diagnostic layers run continuously against live process data. Together they produce something a conventional alarm cannot: a developing problem, named, explained, and paired with the action your own procedures call for.

Process plant pipework and a distillation column, overlaid with the rtOpX wordmark

Scope

What the platform is built to solve

Issue

Abnormal events and upsets reduce operating performance, affect environmental safety, or produce off-spec product.

rtOpX response

A multi-variable approach that detects events early and identifies the corresponding root cause.

Issue

Non-performing or poorly performing I/O affects throughput and efficiency, and propagates into unit problems.

rtOpX response

Continuously diagnose every sensor and controller in real time to authenticate data for all downstream information systems.

Issue

Poorly operating process equipment affects reliability and overall availability while consuming resources.

rtOpX response

Deploy Knowledge Models that give operations and maintenance real-time diagnostics on process equipment.

Issue

Loss of operations knowledge affects total plant operation and performance.

rtOpX response

A framework that captures the collective knowledge of the organization and deploys it across shifts, assets, and facilities.

The suite

Instrument, equipment, and knowledge — diagnosed together

Each layer is useful alone. Run together, they are what turns a detected deviation into an explained one — because each one depends on the layer beneath it.

KMKnowledge ModelsYour operating IP, applied to the condition that was just diagnosed.EKMEquipment Knowledge ModelsFouling, cavitation, plugging and efficiency loss, surfaced while there is still time to act.SCDSensor & Controller DiagnosticsEvery measurement authenticated before anything downstream is built on it.LIVE PROCESS DATA · DCS, FIELD DEVICES, CONDITION MONITORINGEACH LAYER TRUSTS THE ONE BELOW

“Knowledge retention can only be solved through the digitization of knowledge.”

Industry CEO

“70% of operating issues are human-performance related; 30% are mechanical.”

Solomon Associates

“5–20% of sensors are not performing as per design.”

Nexus clients
01

SCD

rtSCDx

Sensor & Controller Diagnostics

Continuously authenticates every measurement feeding your control system, alarms, and historian. Bad data is caught before it drives a bad decision.

5–20%

of sensors are not performing as designed — Nexus clients

Still available — now delivered through VALID8A.AI

Sensor diagnostics

BlippedDeadHi / Lo safetyOperational hi / loSaturated hi / lo (OP)OscillationRate of changeSpikedStandard deviation (high)

Controller diagnostics

Sticking valveBad zeroPV above / below set pointRapid set point changeSet point variationCustom model hi / lo
02

EKM

rtEPMx

Equipment Knowledge Models

First-principles and empirical models run continuously against live process data, surfacing degradation — fouling, cavitation, plugging, efficiency loss — while there is still time to act.

70 / 30

of operating issues are human-performance related, 30% mechanical — Solomon Associates

Rotating & fired

PumpsFurnacesFin-fansControl valves

Heat & mass transfer

ExchangersReboilersCrystallizersDryersMaterial balances
03

KM

rtKMx

Knowledge Models

Your operating intellectual property — captured once, deployed everywhere. HazOp findings, PSM and HSE procedures, best practices, and the judgment of your most experienced operators.

Man-years

of operational experience captured and made repeatable — Nexus rtOpX

Sources captured

Operator knowledgeEngineering knowledgeBest practicesHazOp & operating proceduresHSE proceduresAdvanced applications (MVC, etc.)

Next

See it run on a real column

Eight developing conditions found simultaneously on one distillation column, the workflow that turns a HazOp study into a console message, and what the operator actually reads.

How it works

Architecture

Alongside your control system, not in front of it

rtOpX deploys on-premises, reading from the systems already installed and publishing to the people who need the answer.

Reads from

  • DCS

    Honeywell, DeltaV, and other control systems

  • Asset management

    AMS and smart field device data

  • Field instrumentation

    Analog, HART, and FOUNDATION fieldbus

  • Condition monitoring

    Vibration and equipment condition sensors

Real time

Nexus rtOpX

Decision support engine

  • Sensor & controller diagnostics
  • Equipment knowledge models
  • Operating knowledge models

Publishes to

  • Console operators

    Process automation LAN

  • Plant engineering

    Plantwide LAN

  • Corporate

    Corporate WAN

  • Business systems

    SAP, Maximo, ERP / MES / EAM

rtOpX augments the control system rather than replacing it. Nothing is ripped out; the existing DCS, asset management, and condition monitoring investments keep working and start being read together.

Where it fits

The diagnostic layer your automation stack is missing

Most plants already own optimization, control, and tuning applications. What they lack is a layer that continuously asks whether those applications are being fed good data and running against healthy equipment.

Tier

Vendor portfolio

Nexus analytics

Business systems
ERP / MES / EAM / PAM
Multi-unit operations diagnostics
Unit
Unit optimization / process models
Unit operations diagnostics
Application
Advanced process control · Equipment models · Neural nets
Equipment diagnostics
Loop
PID monitoring / tuning
Sensor & controller diagnostics

Engagement

How we work with you

Nexus stays involved from the first feasibility study through long-term support. The models only stay accurate if someone keeps maintaining them.

  • 01Feasibility studies
  • 02Project implementation
  • 03Training
  • 04Integration of third party applications
  • 05Maintenance packages with various levels of technical support and system updates

One of these three layers is still being delivered.

Sensor & Controller Diagnostics has been updated and is available today through VALID8A.AI as real-time process sensor data validation.

Continue to VALID8A.AISee measured results