Industry & infrastructure
Predictive plant maintenance
Understand changing plant conditions before the next shift depends on them.
Plan your monitoring →
The application in practice
Keeping a metal-finishing plant ready for production
A closer look at the challenge, the monitoring approach and the outcome described in Monnit’s application guide.
The challenge
At Magnetic Inspection Laboratory, a holiday cold-weather incident exposed a gap in plant visibility. Blocked make-up air equipment contributed to negative building pressure and a frozen sprinkler pipe. Maintenance staff needed a clearer picture of conditions while the plant was unattended.
The monitoring setup
The installation combined differential air pressure, temperature, steam pressure, voltage and sump-float monitoring. Thermocouples helped staff compare tank heating times, while a dry-contact sensor reported wastewater-pit level changes through the existing float.
The reported outcome
Monnit describes a maintenance team using those readings to assess readiness and investigate changes before the next production shift. The example connects environmental monitoring with process measurements rather than treating each machine in isolation.
Case-study information and photography: Monnit. Reported results relate to the installation described; your project’s design and results will depend on its requirements.
A practical starting point
Measure. Understand. Act.
Where to start
Begin with a critical utility: a boiler room, process tank or sump. Record normal warm-up, running and shutdown conditions before adding more assets.
A change worth investigating
Pressure or temperature changes unexpectedly while the plant should be ready for production.
Example scenario. Set limits and timing for your own site.Turn the alert into action
Check the asset against its normal operating pattern, inspect the cause and arrange maintenance with the responsible engineer.
Build your system
Measurements to consider
Use these as a shortlist. The right model depends on the range, environment, installation and accuracy you need.
Temperature
Follow heating, cooling and storage conditions over time. Match the probe range and calibration to your application.
Explore sensors →Differential Air Pressure
Compare pressure across suitable air-system measurement points to help investigate performance changes.
Explore sensors →Pressure Meter
Track process pressure using suitable fittings, range and media compatibility.
Explore sensors →Dry Contact
Bring a compatible existing switch or contact signal into your monitoring system.
Explore sensors →Plan for the real environment
Before you start
What matters for this application
Choose probes, fittings and enclosures for the actual pressure, chemistry and temperature. Condition monitoring does not replace protective interlocks.
How do the sensors connect?
ALTA sensors need a compatible gateway, internet connection and monitoring software. Suitable Wi-Fi models connect through a compatible Wi-Fi network. Confirm radio frequency, coverage and power arrangements at the actual installation points before choosing equipment.
Explore gateways →How quickly will an alert arrive?
Timing depends on sensor settings, reporting intervals, connectivity and notification rules. Email, SMS and voice options vary by service and plan. Test a controlled event, check that the nominated person receives it and confirm what happens if a device stops reporting.
Understand software and alerts →What should we prepare for a pilot?
Bring a site plan, the equipment or spaces to monitor, expected conditions, required accuracy and the names of the people who respond. Agree a trial period and a review date. Compare sensor readings with an appropriate reference and document any gaps in coverage or response.
Keep exploring
Related applications
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Watch the environment around the systems your business relies on.
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Put equipment run patterns and changing conditions into the same conversation.
Industry & infrastructurePest-control heat treatments
Give treatment technicians a clearer view of temperatures across a space.
Let's make it useful
A monitoring plan for your world.
Tell us what you want to protect, where it is and what you need to know. We'll help you choose a practical starting point.