Illustrative scenario
A 1970s boiler brought onto the dashboard
Illustrative scenario — representative of common industrial IoT applications
Natural gasBuilding Materials & Heavy IndustryManufacturing — automotive, plastics & rubber
A fifty-year-old boiler, integrated through its 4-20 mA output. Nothing was ripped out.
A heavy manufacturing plant
How it went.
Every study on this site runs the same four beats, in the same order.
01
Alert
The boiler predates every network in the building. It has no tag, no protocol and no vendor still answering the phone. It does have a 4-20 mA output.
02
Cost
4-20 mA integration — Existing analog output read directly; no controls were touched.
03
Fix
4-20 mA transmitter on the existing boiler output · Industrial gateway with local buffering · Firing-rate and gas-flow trending
04
Restored
An asset on the same dashboard as everything else
In full.
Illustrative scenario — representative of common industrial IoT applications.
The problem
The boiler predates every network in the building. It has no tag, no protocol and no vendor still answering the phone. It does have a 4-20 mA output.
What would be installed
- 4-20 mA transmitter on the existing boiler output
- Industrial gateway with local buffering
- Firing-rate and gas-flow trending
What changes
Before — An asset invisible to every system in the plant After — An asset on the same dashboard as everything else
The number
4-20 mA integration — Existing analog output read directly; no controls were touched. Illustrative scenario, not a client result. Figure is representative, not measured. [TOM-REVIEW]
In one line
We respect existing investments. We integrate; we don’t rip things out.
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.
| Interval | Boiler 1 firing rate (%) |
|---|---|
| 00:00 | 35 |
| 00:30 | 37 |
| 01:00 | 35 |
| 01:30 | 32 |
| 02:00 | 33 |
| 02:30 | 32 |
| 03:00 | 33 |
| 03:30 | 32 |
| 04:00 | 35 |
| 04:30 | 35 |
| 05:00 | 34 |
| 05:30 | 32 |
| 06:00 | 60 |
| 06:30 | 58 |
| 07:00 | 60 |
| 07:30 | 60 |
| 08:00 | 56 |
| 08:30 | 57 |
| 09:00 | 59 |
| 09:30 | 58 |
| 10:00 | 57 |
| 10:30 | 55 |
| 11:00 | 60 |
| 11:30 | 57 |
| 12:00 | 57 |
| 12:30 | 56 |
| 13:00 | 57 |
| 13:30 | 61 |
| 14:00 | 60 |
| 14:30 | 59 |
| 15:00 | 57 |
| 15:30 | 56 |
| 16:00 | 60 |
| 16:30 | 56 |
| 17:00 | 59 |
| 17:30 | 59 |
| 18:00 | 33 |
| 18:30 | 36 |
| 19:00 | 35 |
| 19:30 | 37 |
| 20:00 | 32 |
| 20:30 | 33 |
| 21:00 | 33 |
| 21:30 | 33 |
| 22:00 | 32 |
| 22:30 | 32 |
| 23:00 | 32 |
| 23:30 | 32 |
| Before | An asset invisible to every system in the plant |
|---|---|
| After | An asset on the same dashboard as everything else |
Illustrative dataset — a representative operational profile, seeded and deterministic, not measured at any site.
What changed.
Before
An asset invisible to every system in the plant
After
An asset on the same dashboard as everything else
4-20 mA
integration
Existing analog output read directly; no controls were touched.
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 — representative of common industrial IoT applications
Natural gasPharmaceutical & ChemicalFood & Beverage Processing
Steam trap failure monitoring
A pharmaceutical manufacturing site
A failed-open steam trap vents energy continuously and silently.
Continuousmonitoring
Illustrative scenario — representative of common industrial IoT applications
Find out what’s hiding in your plant.
Half a day on your floor, no charge and no obligation. At the end of it we tell you what we saw, what we would meter first, and what the return looks like.
Your first opportunity assessment is free.
Book a free consultationAll case studies
or call 1-833-QUANTFY (1-833-782-6839)