Skip to content

Industrial IoT & Digital Twins

Thermal twin of a 50 MW AI factory and its liquid-cooled GPU racks

360 racks at 40–100 kW each on direct-to-chip cooling, perimeter air and dry coolers. The twin tracks every loop against healthy physics and prices the energy a fault is costing.

Client
Production twin on a private client platform
Industry
Data centres
Disclosure
Anonymised under NDA
Facility modelled end to end
50 MWFacility modelled end to end
Racks at 40–100 kW each
360Racks at 40–100 kW each
Simulated PUE against a 1.12–1.25 target
1.18Simulated PUE against a 1.12–1.25 target

The challenge

At 80–100 kW a rack, a partly blocked cold plate or a tired pump becomes a throttled GPU within minutes, long before a monthly PUE report would show it.

Stack

  • Direct-to-chip cooling
  • CRAH units
  • Dry coolers
  • Physics model
  • Isometric twin

What we did

  1. 01Coolant distribution, rack manifolds and dry coolers modelled loop by loop
  2. 02Rack heat derived from flow and temperature rise, not nameplate
  3. 03Fault detection on pumps, cold plates, heat exchangers and fans
  4. 04Energy booked against a healthy baseline at the same IT load
Generic reference architecture
blockageGPU RACKSdirect-to-chipCDUpumps · plate hxDRY COOLERec fansHEALTH ENGINEflow · rise · approachLIVE TWINper-part statusENERGYppue · kw lost

A generic representation of the pattern, not the client’s topology.

Live demo

See this class of system as a live twin: AI pod · liquid-cooled GPU racks

Launch the twin

How you would buy this

Digital Twin Pilot

A physics-informed live twin of one plant system, connected to your BMS or gateway data, with fault detection and energy accounting.

Compare all engagements →

Fixed fee · 4–8 weeks

Digital Twin Pilot

From

$40,000

fixed fee

A physics-informed live twin of one plant system, connected to your BMS or gateway data, with fault detection and energy accounting.

  • Data audit and point mapping (BACnet, Modbus, MQTT)
  • Physics model of the asset, calibrated on your data
  • Live isometric twin with health and fault views
  • Energy-loss report against a healthy baseline
Ask about this engagement

More industrial iot & digital twins work

Industrial IoT & Digital TwinsNDA · Commercial buildings

A live digital twin of a 2,400 TR central chiller plant

Production twin on a private client platform

Three 800 TR water-cooled centrifugal chillers on primary-secondary pumping, modelled from first principles and bound to live plant telemetry so faults show up as physics, not as alarms after the fact.

kW/TR plant efficiency tracked live
0.58kW/TR plant efficiency tracked live
Chiller COP on the dashboard
6.06Chiller COP on the dashboard
Cooling-tower approach watched per cell
2.8 °CCooling-tower approach watched per cell
Industrial IoT & Digital TwinsNDA · Commercial real estate

Every VRF unit in a 10-floor office tower on one live model

Production twin on a private client platform

359 indoor fan-coil units and 20 rooftop outdoor units, read through their gateways and drawn floor by floor so facilities staff can see comfort, faults and efficiency at once.

Indoor units on one live view
359Indoor units on one live view
Outdoor condensing units modelled
20Outdoor condensing units modelled
Floors zoned independently
10Floors zoned independently
Industrial IoT & Digital TwinsNDA · Energy & utilities

SCADA and smart-meter telemetry at 99.999% reliability

Commercial energy and facility operator

Remote meters were dropping packets and accumulator rollovers were corrupting consumption figures. We hardened the edge and made the arithmetic deterministic.

Telemetry reliability
99.999%Telemetry reliability
Forensic query response
<50 msForensic query response
Rollover calculation errors
0Rollover calculation errors

Start with a scoping call.

Thirty minutes with the founder. Bring your architecture diagram, your cloud bill or your plant drawings, and leave with what is realistic — including when the answer is that you do not need us yet.

Mutual NDA before any detail is shared. First response within 24 hours.