Case Study: Emerson Electric achieves predictive monitoring and millions in savings with Microsoft Power BI

IoT solution proves data is power in the energy industry

Emerson Electric, a global energy and manufacturing company, struggled with inefficient, manual equipment monitoring that left refineries vulnerable to missed warning signals, unplanned downtime, and high labor costs. To address this, Emerson deployed its Plantweb IoT ecosystem built on Azure and integrated Microsoft Power BI for real-time analytics and visualization, replacing periodic manual inspections with continuous sensing and alerts.

Using Plantweb sensors that send data to Azure and Microsoft Power BI dashboards, Emerson enabled predictive monitoring and automated alerts for heat exchangers and other equipment. The pilot reduced installation and commissioning time from six weeks to one, cut staff monitoring time, improved plant reliability, and is projected to save the customer millions of dollars annually while scaling condition monitoring across pumps and cooling towers. Microsoft Power BI’s analytics were central to these measurable operational gains.

Emerson Electric

Mike Boudreaux

Director of Connected Services