Illustrative scenario
Steam trap failure monitoring
Illustrative scenario — representative of common industrial IoT applications
Natural gasPharmaceutical & ChemicalFood & Beverage Processing
A failed-open steam trap vents energy continuously and silently.
A pharmaceutical manufacturing site
How it went.
Every study on this site runs the same four beats, in the same order.
01
Alert
Steam traps fail open and stay that way until the next survey. The loss is invisible, continuous and paid for on the gas bill.
02
Cost
Continuous monitoring — Replaces an annual ultrasonic survey with an always-on temperature signature.
03
Fix
Surface temperature probes upstream and downstream of each trap · Signature-based fail-open detection · Trap-by-trap status view in the dashboard
04
Restored
A trap-by-trap status board that updates every minute
In full.
Illustrative scenario — representative of common industrial IoT applications.
The problem
Steam traps fail open and stay that way until the next survey. The loss is invisible, continuous and paid for on the gas bill.
What would be installed
- Surface temperature probes upstream and downstream of each trap
- Signature-based fail-open detection
- Trap-by-trap status view in the dashboard
What changes
Before — An annual survey and eleven months of hope After — A trap-by-trap status board that updates every minute
The number
Continuous monitoring — Replaces an annual ultrasonic survey with an always-on temperature signature. Illustrative scenario, not a client result. Figure is representative, not measured. [TOM-REVIEW]
In one line
Baseload creep is invisible on a monthly bill. It is obvious on a 60-second trace.
What the data looked like.
Hover or arrow-key across the trace to read any interval. The flagged point is the one that started the conversation.
Illustrative dataset — a representative operational profile, seeded and deterministic, not measured at any site.
What changed.
Before
An annual survey and eleven months of hope
After
A trap-by-trap status board that updates every minute
Continuous
monitoring
Replaces an annual ultrasonic survey with an always-on temperature signature.
Source: Illustrative scenario, not a client result. Figure is representative, not measured. [TOM-REVIEW]
Where to go next.
The sector, the sibling studies, and the calculator that runs this same arithmetic on your own numbers.
Compressed airNatural gasMetal Fabrication & FinishingBuilding Materials & Heavy Industry
A furnace over-cycling, seen on the air and gas traces together
A heat-treating operation
Short-cycling that neither the gas bill nor the air system showed alone.
2 utilitieson one chart
Illustrative scenario
Natural gasBuilding Materials & Heavy IndustryManufacturing — automotive, plastics & rubber
A 1970s boiler brought onto the dashboard
A heavy manufacturing plant
A fifty-year-old boiler, integrated through its 4-20 mA output. Nothing was ripped out.
4-20 mAintegration
Illustrative scenario
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