project brief
Tanklager AG Cadenazzo has undergone a digital overhaul to modernize its storage infrastructure.
Digital Twin Integration in Oil & Gas Storage
The challenge
Tightening rules, reactive maintenance methods, and aged infrastructure provide growing issues for Europe’s tank storage sector. Due to age-related hazards, more than one-third of Tanklager AG Cadenazzo’s tanks need rigorous biannual testing. This is a problem that affects the entire continent and results in €4.2 billion in unscheduled outages every year. With antiquated sensors and calendar-based inspections missing over half of new problems, traditional maintenance models are failing and resulting in expensive shutdowns and false alarms. As competitors embrace AI-driven solutions, our legacy systems could face penalties and competitive disadvantages due to the 2025 SEVESO III modifications, which require automatic compliance and real-time monitoring.
project goals
Tanklager AG Cadenazzo has undergone a digital overhaul to modernize its storage infrastructure. Through 3D laser scanning and LiDAR, digital twins of all 32 tanks were created with 2mm accuracy, revealing hidden structural changes. A network of 240 IoT sensors now provides real-time data on erosion, vapor levels, and mechanical stress, feeding into a predictive AI engine that forecasts failures with 94% accuracy. These insights integrate directly into SAP, automating maintenance planning and eliminating paperwork errors. Phase 2 includes AR tools, blockchain audits, and drone inspections, aiming for full asset coverage by Q3 2024. The system operates with 99.998% uptime, refreshing data every 15 seconds under high-grade cybersecurity protocols.
the result
The project at Tanklager AG Cadenazzo generated important operational, financial, and regulatory wins.
✔ Repairs are now 30% faster, thanks to AI-driven early warnings that spot flaws days in advance, preventing costly failures like a €250,000 tank spill.
Real-time compliance records meant that all 32 tanks were instantly audit-ready, resulting in zero regulatory infractions.
✔ Annual operational savings of $2 million were obtained by reducing unplanned downtime and extending asset life, with money redirected to solar growth.
✔ A 12% reduction in methane venting brought it into compliance with EU emission standards and increased its attractiveness to environmentally aware customers.
The initiative received industrial accolades from Siemens and ENI, as well as the 2024 Swiss Energy Innovation Award. Blockchain-based carbon tracking will be added in phase three to expedite ESG reporting.
recent projects
The expansion added 12 double-walled tanks with robotic epoxy coating, AI-driven inventory management and solar-powered heating systems to cut bunker fuel
Responding to EU renewable energy demand, we’ve allocated 20,000m³ of dedicated biofuel storage (HVO, ethanol) with corrosion-resistant lining and vapor recovery tech.
Creating high-quality services you can trust, serving you better with reliable, innovative systems
