Key Takeaways from Downstream USA 2025
In this blog
More than 3,000 OT leaders convened in Houston, TX, for Downstream USA 2025. The flagship event, held June 25-26, celebrated its 13th year and showcased technologies and strategies for modernizing operations. Yet it was a focus on people that took center stage.
Here are our experts' top takeaways from this year's event:
1. People and processes drive real adoption
Technology and data alone can't transform operations. Neither can top-down mandates. For downstream organizations, change must come from the bottom up. Frontline workers need to see how solutions make their jobs safer, and then easier, before adoption can take root. Empathy, trust and psychological safety are crucial to implementing the latest solutions. As one of our experts put it, "If the frontline isn't using a solution or believing in it, you have nothing."
We also heard concerns about an aging workforce and the loss of institutional knowledge as experienced workers retire. Yet there was optimism about younger generations entering the field. Gen Z's hyper-focused mentality could strengthen operations provided organizations invest in upskilling and knowledge capture to bridge generational divides.
2. New technologies show promise
Solutions like industrial AI, digital twins and quantum sensors all drew attention on the exhibition floor. In particular, industrial agents that integrate serial workflows into cohesive, reliable processes stood out. With a specific focus on industrial knowledge, these agents are less susceptible to hallucinations than traditional generative AI tools.
Another highlight was an inspection device that can scan through insulation and cladding using quantum sensors. We also enjoyed seeing a solution that digitizes the permit-to-work process, plus one that makes it easier to create 3D assets inside digital twins.
While promising, adopting these solutions may be tricky given the industry's tendency toward risk aversion. As one presenter cautioned, "Technology can make stupid happen at the speed of light."
3. Scaling beyond pilots remains a challenge
Many leaders shared frustrations about pilot programs that never reach full deployment. While next-gen solutions often show promise in controlled pilots, scaling them across sites requires more than technical validation; they must demonstrate measurable improvements in safety, productivity or cost reduction.
As one of our experts explains, "pilot purgatory" is all too common. To avoid the forever proof-of-concept phase, plant managers should prioritize validating solutions under real-world conditions.
4. Data governance is the backbone of digital transformation
Downstream plants generate vast amounts of operational data, but much of it remains siloed and underused. Downstream USA 2025 challenged attendees to think of their organizations as data companies that happen to produce hydrocarbons. This mindset shift is critical to modernization, positioning data as a strategic asset rather than a byproduct.
Speakers stressed that robust data frameworks are essential for capturing institutional knowledge, supporting predictive analytics, and powering technologies like digital twins and AI. Without a strong data foundation, even the most advanced tools will fall short.
5. Intelligent edge puts data to work
Edge computing took to the main stage with a presentation from WWT Technical Solutions Architect Earl J. Dodd about the "intelligent edge." Rather than simply collecting data at the edge and sending it to the cloud, intelligent edge solutions process data locally to generate immediate, actionable insights.
For example, combining computer vision with behavioral analytics can reveal why workers congregate in certain areas, identifying safety risks or process bottlenecks. By analyzing this metadata at the edge, operators can make quick decisions while still sending aggregated insights to central systems for broader optimization.
Dodd also introduced the Transformative Autonomic Resilient Operations Technology (TAROT) framework, designed to help operators manage this data paradigm shift.
Looking ahead
Downstream USA 2025 made it abundantly clear that modernization is a holistic effort that requires:
- Testing technologies alongside existing workflows.
- Building data governance frameworks that unlock operational insights.
- Investing in people, processes and cultural change for solutions to scale and take hold.
- Deploying intelligent edge solutions to drive decisions closer to operations.
While the industry is naturally risk-averse, Downstream USA 2025 showed that with the right approach — one grounded in empathy, safety and frontline trust — modern advances in technology can make work safer, operations more efficient, and the future more resilient.