Client Overview
A large chemical processing plant located in Maharashtra, India, operating 24/7 with hazardous and temperature-sensitive materials. The plant manages complex processes across pressure vessels, pipelines, and mixing chambers. Safety, precision, and real-time visibility were top priorities for this client.
Our Approach
Our strategy focused on:
- Replacing analog gauges with smart field instruments
- Enabling wireless data transmission from remote locations
- Integrating real-time dashboards and alerts
- Implementing predictive maintenance using sensor data
Challenge
The client relied on outdated analog gauges and manual logging for temperature, pressure, and flow measurements. This led to safety risks, slow response times, and inconsistent data during audits and maintenance.
Field Instrumentation
India
Key pain points included:
- No real-time monitoring or alerts
- Manual error in data logging
- High maintenance downtime due to lack of predictive insights
- Compliance challenges due to missing historical data
Solutions Delivered
Smart Sensor Deployment & Instrumentation
Replaced analog gauges with digital pressure, flow, and temperature sensors for accurate measurements.
IoT Integration for Real-Time Monitoring
Enabled continuous data flow and visibility using gateways and remote wireless sensor communication.
Automated Logging & Alert System
Digitized data logging with built-in threshold alerts to enhance safety and reduce response delays.
Predictive Maintenance Using Sensor Analytics
Implemented condition-based maintenance workflows triggered by anomalies in live sensor data.
Technologies Used
Business Impact / Results
Qematic’s smart field instrumentation deployment delivered:
What Our Clients Say
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Key Highlights (Summary Box)
| Metric | Before | After |
|---|---|---|
| Unplanned Downtime | High (weekly) | Rare (monthly) |
| Data Logging | Manual | Fully Automated |
| Safety Threshold Response Time | 30+ mins | <10 mins |
| Compliance Audit Readiness | Manual prep | Instant access |
