Unlocking operational excellence: Integrating AVEVA™ PI System™ with AVEVA™ Process Simulation

Posted: June 23, 2025

Real-time data-driven decision-making

As industries continue their digital transformation journeys, the need for real-time data-driven decision-making is more critical than ever. Two powerful tools from AVEVA—AVEVA PI System and AVEVA Process Simulation—are shaping the way engineers and operators optimize process design, monitor operations, and accelerate innovation. When integrated, these platforms unlock a new level of operational intelligence, bridging the gap between historical data and predictive modeling.

What is AVEVA PI System?

AVEVA PI System is an industry-leading data infrastructure that captures, stores, and analyzes real-time and historical operational data from sensors, control systems, and other sources. It is widely used across industries such as energy, chemicals, consumer products, and manufacturing to enable monitoring, visualization, and analytics.

What Is AVEVA Process Simulation?

AVEVA Process Simulation is a next-generation platform for process design and optimization. It provides a flexible environment for simulating chemical and energy processes with advanced modeling capabilities. Operating within a digital twin environment, it enables engineers to test scenarios, optimize plant operations, and drive innovation.

Benefits of integrating AVEVA PI System & AVEVA Process Simulation

By integrating AVEVA PI System with AVEVA Process Simulation, companies can create a closed-loop system that connects real-world performance data with virtual simulations. This integration allows for:

• Model calibration using real-time data
  Use live or historical AVEVA PI data to validate and refine process models, improving simulation accuracy.
• Data-driven what-if analysis
  Run simulations using actual plant data to test operational changes without disrupting production.
• Real-time performance benchmarking
  Compare simulated optimal performance with actual plant behavior to uncover inefficiencies.
• Predictive analytics and scenario planning
  Combine PI data trends with simulation models to predict process deviations and prepare mitigation plans.

How does the integration work?

The integration involves data exchange between AVEVA PI System and AVEVA Process Simulation, typically through the following steps:

1. Data extraction from AVEVA PI System
   Using AVEVA PI System’s tools like AVEVA™ PI DataLink™, AVEVA™ PI Integrator for Business Analytics, or PI Web API, relevant historical or real-time process data is extracted.
2. Data mapping and input into AVEVA Process Simulation
   This data is then mapped to corresponding process variables in AVEVA Process Simulation. Engineers can use scripts or integration middleware to automate this mapping.
3. Model execution and analysis
   Simulations are run using the real-world data inputs. The results can be visualized in dashboards or exported for deeper analysis.
4. Feedback loop to operations
   Insights gained from the simulations—such as optimized setpoints or operating conditions—can be sent to operators or control systems to improve process performance.

Use cases: AVEVA PI System + AVEVA Process Simulation in action

• Energy optimization in chemical plants
  Simulations powered by AVEVA PI System data can identify energy-saving opportunities by analyzing heat integration and utility usage patterns.
• Process troubleshooting
  When a process deviates from normal behavior, historical AVEVA PI System data can be replayed in simulations to diagnose root causes and test corrective actions.
• Training and scenario planning
  Engineers and operators can use integrated simulations to rehearse emergency responses or evaluate the impact of feedstock changes.

Looking ahead: Toward autonomous operations

The integration of AVEVA PI System and AVEVA Process Simulation is a step toward autonomous operations, where AI-driven models continuously learn from real-time data to self-optimize processes. By combining the strengths of AVEVA PI System and AVEVA Process Simulation, you can create a powerful toolkit for driving operational excellence. Unifying real-time data and simulation, the two solutions together unlock new capacities for synergy and empower organizations to make better decisions—reducing downtime, improving yields, and enabling more sustainable operations.

Want to see AVEVA PI System and AVEVA Process Simulation in action? Join our upcoming webinar to learn how to improve operational decisions using real-time data.