A typical 660 MW thermal power plant generates more than 12,000 alarms per day. The shift engineer can pay attention to maybe 30 of them. The other 11,970 are noise — nuisance trips, threshold flutter, repeat alerts that everyone has learned to ignore. iFactory's Live AI Insights Feed inverts the problem. Every model on the plant — boiler shell anomaly detection, BFP cavitation, ash deposition, mill roller vibration, economizer fouling, ToD scheduling — converges into one ranked feed. Each insight carries a severity band (Critical / High / Medium / Low), a remaining-useful-life forecast, a confidence score, and a one-click action chip. The feed runs on the on-site GB300 + H200 stack — no cloud round-trips, no per-alert billing, no vendor data lake. ower and a network drop are the only things you provide. One-time CapEx — no recurring license. You own the models, the feed, the data. To scope your asset list, get a turnkey quote.
Upcoming iFactory AI Live Webinar:
Live AI Insights Feed for Thermal & Combined-Cycle Power Plants
One ranked feed. Every model on the plant. Boiler shell anomalies, BFP cavitation, ash deposition, mill roller vibration, economizer fouling, ToD scheduling — all prioritized into Critical / High / Medium / Low with RUL forecasts and one-click action chips. Shipped to your plant, deployed by our engineers, owned by you. No cloud. No per-alert billing.
12,000 Alarms a Day. The Operator Reads 30.
The DCS doesn't have an attention problem — your operators do. Threshold-based alarms fire on every load swing, every fan trip, every momentary sensor flutter. By the third shift, "alarm" has become "background noise." iFactory's Live Insights Feed is the layer that decides which 30 actually matter today. Schedule a 30-minute walkthrough to see your alarm flood ranked.
Four Bands. Plain Language. No Ambiguity.
Every insight carries one of four severity bands. The bands are calibrated to operator action — what should the shift engineer actually do in the next 60 minutes vs. the next 60 days. This isn't a gradient. It's four discrete decisions.
Equipment is at risk of unplanned trip within hours. Operator is paged. Plant copilot drafts the immediate action checklist. Auto-escalation to control room supervisor if not acknowledged in 15 min.
Degradation trend confirmed. RUL forecast under 14 days. Schedule intervention into the next planned outage window. CMMS work order auto-generated, parts requirement attached.
Anomaly pattern emerging but not yet at action threshold. Daily watch list. Reliability engineer reviews trend in morning meeting. Sensor fingerprint refined as data builds.
Subtle deviation worth tracking. No action required. Builds the asset history that informs future degradation models. Reviewed weekly by reliability team.
What the Operator Actually Sees on the Dashboard
This is the live feed view from a real-world deployment — anonymized, but every alert type is one our models surface daily. The feed re-ranks every 30 seconds as conditions change. Click any insight for full sensor traces, suspected failure mode, and one-click action.
Acoustic + vibration ensemble detects cavitation precursor. NPSH margin trending down with discharge pressure dip. Confidence 91%.
Thermal imaging + tube-wall temp model flags localized hot spot. Pattern matches early-stage scale buildup precursor. Confidence 84%.
Bearing fault frequency rising over 36-hour window. Pattern matches outer-race spalling. Mill discharge temp normal. Confidence 78%.
Differential pressure across economizer rising 0.4 kPa/day faster than 12-month seasonal baseline. Soot blower frequency may need adjustment.
Day-ahead market signal + load forecast models suggest pulling 80 MW from 02:00–05:00 block to 18:00–21:00. Estimated revenue gain ₹4.2 lakh.
Five insights from the same hour. Different severities. Different models. Different actions. Without the feed, these would be scattered across the DCS, the CMMS, the historian, and four engineer email threads. Book a working session to see the feed run on your unit.
One Click. From Feed to Closed Loop.
Every insight ships with the actions an operator actually takes. No tab-switching, no copying lot codes, no calling control room supervisors. The chip closes the loop into your CMMS, scheduler, or DCS.
Generates a CMMS work order with asset, suspected fault mode, parts list, and recommended technician. Pushes to SAP PM, Maximo, Infor EAM, or any modern CMMS.
Operator confirms the alert is seen. Stops re-paging. Logs ID + timestamp + operator name into the audit trail. Does not close the alert — that requires action.
Pages the next tier — control room supervisor, reliability lead, or plant manager — with full context and the action chip menu. Used when the alert exceeds shift authority.
Hides the alert for a configurable window (1h / 8h / 24h). Available only on Medium / Low. Critical alerts cannot be snoozed. Auto-restored if the underlying trend worsens.
For ToD / load-shape recommendations — pushes the suggested schedule into the day-ahead optimizer with operator note. Scheduler still owns the final approval.
Opens the full multi-sensor time-series view that the model used to generate the insight. Shows the exact frequency band, temp gradient, or pressure deviation that triggered it.
Every Model on the Plant Pipes Into One Ranked View
The Live Insights Feed is not a model — it's the destination layer. Every anomaly, vibration, thermal, acoustic, heat-rate, and ToD model running on your GB300 + H200 stack feeds insights through a unified ranking pipeline.
Severity scoring · RUL forecast · asset criticality · operator history · de-duplication · noise filtering
CRITICAL · HIGH · MEDIUM · LOW — one ranked view, action chips on every card
All this runs on the on-site GB300 + H200 stack — the LLM that powers the plant copilot lives on the same node, so an operator can ask "why is BFP-2B critical?" and get an explanation drawn from the actual sensor traces. Talk to support for sizing on your model count.
Six Reasons Plant Operators Pick Us Over DCS Alarm Lists
Most "AI for power plants" pitches end at "we'll detect anomalies." iFactory ships the operator-facing layer too — the feed, the action chips, the CMMS hand-off, the LLM explanation — all on your on-site hardware. Schedule a working session to see it on your unit.
The feed is designed by control-room engineers, not data scientists. Plain-language insights, action chips, snooze rules. Shift engineers actually use it — that's the whole point.
Anomaly, vibration, thermal, acoustic, heat-rate, RUL, ToD — every model on the plant converges into one ranked view. No tab-switching, no five-dashboard tax.
Click any insight and ask "why is this Critical?" The LLM running on the same on-site GB300 explains the underlying signal in plain English — pulled from the actual trace, not generic text.
Every byte of plant data, every insight, every operator action stays inside your fence. No cloud sync. No API calls to vendor LLMs. NERC CIP / ISO 27019 / IEC 62443 audit-ready.
Existing DCS alarms, existing CMMS, existing dashboards keep working exactly as before. The Live Feed lives alongside, not on top of. No rip-and-replace, no parallel SCADA.
One-time CapEx. No per-asset billing. No per-alert billing. You own the GB300, the H200, the models, the feed, the data. Talk to support for terms.
All You Provide. Seriously.
Most "AI dashboard" deployments stall because the customer is expected to wire the historian, define severity rules, and integrate the CMMS. iFactory inverts that. Talk to deployment support for a remote walkthrough.
- Power — 3-phase circuit at the plant DC for the GB300 + H200 rack
- Network drop — single Gigabit uplink with path to historian + DCS read-only zone
- GB300 + H200 plant node build, ship, install
- Historian integration (PI / Wonderware / Ignition)
- DCS read-only OPC UA bridge
- All AI models pre-trained on your asset list
- Severity bands calibrated to operator action
- CMMS work-order connector (SAP PM / Maximo / Infor)
- Plant copilot LLM tuned to your assets & SOPs
- Operator + reliability engineer training
From Purchase Order to First Live Insight
A typical Live Insights Feed deployment is in production within 6–12 weeks of PO — anywhere in the US, EU, India, LATAM, or APAC. Hardware ships pre-configured, our engineers handle integration on site.
Remote walkthrough. Asset list. Historian audit. Severity-band calibration meeting with reliability + operations. Fixed BOM in 5 business days.
GB300 + H200 racked. Models pre-trained on your historian backfill. Severity rules pre-loaded. Plant copilot tuned. Crate ships.
Engineers fly in. Historian connections, DCS OPC UA bridge, CMMS connector. Feed goes live in shadow mode for reliability team.
Feed goes to control room. Action chips wired to CMMS. Severity calibration tuned with operator feedback. Training delivered. Platform handed over.
Buy It Once. Own It Forever.
No SaaS subscriptions. No per-asset billing. No per-alert billing. Year-one support is included; everything after that is optional and at your discretion.
GB300 + H200, models, deployment, training, year-one support — single PO. Sits on your balance sheet as a depreciable asset, not a cloud line item.
You own the boxes, the trained model weights, the LLM, the feed UI, every byte of plant data. Full audit rights. No vendor lock on data export.
After year one, renew remote support & model retraining annually, run it in-house with our handover docs, or mix. The feed keeps running either way.
What Plant & Reliability Buyers Ask
No. The Live Insights Feed lives alongside the DCS, not on top of it. Existing alarms keep firing exactly as before. The feed is the analytics layer that filters noise and surfaces true degradation. Talk to support for the integration architecture.
Three guardrails. First, dynamic baselines learn each asset's normal — not generic thresholds. Second, the ranking engine de-duplicates and suppresses repeat alerts on the same root cause. Third, severity bands are calibrated to operator action, not algorithm confidence — so Medium and Low don't compete for attention.
Common. We connect natively to PI System, Wonderware/AVEVA, Ignition, FactoryTalk, and generic OPC UA HA historians — back to versions from the early 2010s. Multi-year backfill is included so models train on your real history. Send your historian details for a written architecture in 5 business days.
Fixed price per unit, scoped to asset count, model coverage, and historian backfill scope. No per-alert billing. No recurring fees. Includes hardware, software, deployment, training, year-one support. Get a quote — written proposal back in 5 business days.
Join the Webinar. Or Get a Quote on Your Unit.
Watch the Live AI Insights Feed run on a live thermal unit on May 13. Or send your asset list, historian inventory, and CMMS details — we come back with a fixed-price BOM in 5 business days. Hardware, software, on-site deployment, multi-year backfill, training, and year-one support all included. No recurring fees. You own the platform outright the day it goes live.
