Industry
Power · Petrochemical
Integrated safety and operational efficiency at scale
Monitor the vast equipment of petrochemical and power plants on one platform and detect anomalies early to improve both safety and uptime.
A process plant is a different order of magnitude — in tag count and in safety requirements. The essence of a plant data platform is twofold: throughput that absorbs tens of thousands of tags with headroom, and early detection that flags precursors before alarms ever fire.
A Challenges
Real-time monitoring burden of tens of thousands of tags
Reactive limits of rule-based alarms
Tracking safety-regulation compliance
Control views scattered across areas and utilities
B How PlantPulse helps
Large-scale real-time processing
Handle large plants comfortably with 40,000 msg/sec ingestion and 512,000 events/sec CEP.
Early anomaly detection
Catch precursors before incidents with stream-analytics advanced alarms and AI forecasting.
Automatic diagnostic engine
A diagnostic engine from 10 years on the floor detects equipment fault cases automatically.
Unified web monitoring
Bring per-area and utility views onto one web SCADA canvas, posted full-screen in control rooms and on floor TVs.
Predictive maintenance
Set maintenance priorities with MTBF/MTTR, reliability metrics, and an equipment health index.
Energy & emissions management
Continuously watch utility peaks and energy intensity, and automate CO₂ accounting and reporting.
40K
messages ingested/sec
512K
CEP events/sec
24/7
always-on anomaly pipeline
30–50%
less unplanned downtime (estimate)
C Where it applies
Refined bare threshold alarms into band and CEP composite conditions, cutting alarm floods and focusing on real precursors.
Less alarm noise · shorter response lead time
Learned baselines on rotating-machinery vibration and temperature series, turning degradation rules never caught into early warnings.
Early-warning system established
Continuously watched HVAC, compressed-air, and power peaks with pre-threshold alarms.
Lower risk of exceeding contracted power
C Outcomes
- 30–50% less unplanned downtime (estimate)
- Safety and uptime together
- Unified visibility
D Related products
D FAQ
Do we have to replace our DCS or SCADA?
No. Control stays with your DCS and SCADA; PlantPulse collects in parallel over standards like OPC-UA and adds a visibility, analytics, and prediction layer on top.
Can it run in a closed network?
Yes. Collection, storage, analytics, and AI complete fully on-premises, with offline installation for internet-blocked environments.
Does performance hold at tens of thousands of tags?
The platform is designed around 40,000 msg/sec ingestion and 512,000 events/sec stream processing, and scales horizontally with site size.
See it live on real operating screens
A 15-minute demo walks you from ingest to AI. Check the fit for your plant with an expert, right away.