At a Glance Multi Plant Operational Telemetry & Anomaly Detection
A global specialty chemicals manufacturer operating 14 continuous processing plants with over 80,000 IoT sensors tracking temperature, flow rate, pressure, and chemical acidity.
Run on Yantra · Plant Operations & Safety
The challenge
Plant operators monitored 25 separate SCADA and historian screens per control room, creating cognitive overload during critical process shifts.
Subtle process drift, such as minor heat exchanger fouling, went unnoticed across shifts until reactors exceeded critical thermal trip thresholds.
Unplanned reactor emergency shutdowns cost over $450,000 per incident in discarded raw materials and line decontamination downtime.
How Yantra solves it
Unified Multi Plant Sensor Stream Ingestion
Yantra aggregates real time telemetry from OPC UA, MQTT, and legacy SCADA systems across all 14 manufacturing facilities.
Single Pane Operational Cockpit
Renders an intuitive high level plant overview displaying live process health status, vessel conditions, and throughput rates.
Automated Statistical Anomaly Detection
Detects subtle multivariate sensor drift (e.g., pressure drop across catalyst beds) 18 hours before operating limits are breached.
Color Coded Risk Heatmaps
Visually highlights degrading plant zones on interactive 2D and 3D plant floor layouts, guiding operator attention immediately.
Predictive Maintenance Ticket Dispatch
Generates automated maintenance work requests with exact sensor telemetry attached when process deviations occur.
The outcome
- unplanned reactor process shutdowns reduced
- 0%unplanned reactor process shutdowns reduced
- control room operator alarm fatigue reduced
- 0%control room operator alarm fatigue reduced
Unplanned reactor process shutdowns reduced by 72%, saving $3.2M annually.
Control room operator alarm fatigue reduced by 60% through single pane visual telemetry.
Early detection of process drift improved from 15 minutes to 18 hours prior to threshold breaches.
Representative scenario: a modelled industry situation showing how this accelerator applies. Figures are projections, not a named client result.
Capabilities used
Every accelerator is assembled from the same capability layer, so a workflow you adopt here shares its foundation with the rest of the portfolio.
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