Biogas
Operations
Twenty-four biogas plants at palm oil mills. Operators log data once, SCADA readings arrive every 15 minutes, and management gets live dashboards, fleet analytics and a monthly report that writes itself.
- 24
- biogas plants
- 15 min
- SCADA sample
- 6h→10m
- monthly report
- 5
- analytic views
Are we on budget, and why not?
Generation, downtime and feedstock from every plant, turned into the questions management asks each month.
A written summary of the month
- Problem
- Managers read five dashboards to learn one thing: what went wrong this month.
- What I built
- Five sentences written from the data every month, one each for generation, revenue, availability, maintenance and feedstock, each naming its comparison and worst plant.
- Method
- Rule-based narrative over KPIs, with month-on-month and year-on-year deltas
Generation against budget
- Problem
- Budget misses surfaced at the quarterly review, too late to recover.
- What I built
- Every plant's actual against budget with the variance on each bar, a rolling 12-month view and a year-end forecast.
- Method
- Variance to budget per plant, rolling 12 months, year-end forecast at current pace
Why we lost hours
- Problem
- Downtime was a long list of incidents with no visible pattern.
- What I built
- Lost hours by cause and plant in one grid, and a Pareto that shows the few causes behind most of the lost hours.
- Method
- Root cause by plant heatmap, Pareto with an 80% line
How well each plant converts feedstock
- Problem
- Plants were ranked on output alone, which hides how well each one turns feedstock into gas.
- What I built
- A leaderboard of biogas per m³ of POME, COD removal and energy per tonne of fruit, each banded against target.
- Method
- Benchmarking against HQ targets with traffic-light bands
Feedstock trends
- Problem
- A falling conversion ratio went unnoticed until output dropped.
- What I built
- Feed supply, feed strength against removal, and conversion per plant over twelve months, so a drift is visible before output falls.
- Method
- 12-month supply, feed quality against removal, per-plant conversion lines
Where the data comes from
The analytics work because every reading, outage and job is captured in one place.