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Industrial IoT & Digital Twins

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

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.

Client
Production twin on a private client platform
Industry
Commercial buildings
Disclosure
Anonymised under NDA
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

The challenge

A BMS reports hundreds of points but no judgement: a fouled condenser and a hot afternoon look the same until the energy bill arrives.

Stack

  • BACnet/IP
  • Modbus TCP
  • ClickHouse
  • Physics model
  • Isometric twin

What we did

  1. 01Point mapping from the BMS and chiller gateways over BACnet and Modbus
  2. 02Physics model of each chiller, tower and pump loop
  3. 03Health engine grading every reading against a healthy plant at the same load
  4. 04Isometric live twin with fault, comfort and energy views
Generic reference architecture
foulingCHILLERS3 × 800 trCOOLING TOWERSapproach · fansPUMP LOOPSprimary · secondaryGATEWAYbacnet · modbusPHYSICS MODELhealthy plant at loadLIVE TWINhealth per partENERGYkw/tr · kw lost

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

Live demo

See this class of system as a live twin: 500 kW water-cooled screw chiller

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.

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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

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Telemetry reliability
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Forensic query response
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Rollover calculation errors
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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.