Plant-aware predictive maintenance

Know what's failing, why, and how long you have.

VROC reads your P&IDs and functional descriptions to learn how your plant is connected and controlled. Then it watches live data and explains every alert with the evidence behind it.

P-201Raw water pump, dutyWarning
Running left of its best efficiency point. Vibration will reach the FDS alarm limit in 18 to 26 days.
BEP ratio
0.71
Vibration
5.8 mm/s
Alarm limit
7.1 mm/s
Likely causes, ranked by evidence
  1. Discharge valve XV-204 throttled since 3 Oct FDS 4.2.3: duty point 420 m³/h at 38 m
  2. Suction strainer loading: suction pressure down 0.3 bar

Example alert, for illustration

What it does

Five answers for every critical asset

Each one is built from your plant's own documents and data, and each one shows its working.

Anomaly detection

Catch the change before the alarm

Behaviour models for each asset are trained on a period you confirm as healthy, and they understand operating modes. A pump on standby isn't a pump that has failed.

Every alert names the measurements that drove it.
Root cause analysis

Walk upstream, not just through dashboards

Using the plant model from your P&IDs, VROC traces upstream from the symptom and ranks causes by sensor evidence and timing. It writes a summary that cites the FDS clause or reading behind each step.

Grounded in evidence. No unsupported guesses.
Time to failure

Days until the limit

VROC projects how long a degrading signal has before it reaches the alarm limit in your functional description.

Works from day one, with no trained model.
Remaining useful life

Life left, as a range

A health-index trend, or a Weibull life model where failure history exists.

Always shown as a range, never a single date.
Setpoint optimisation

Better setpoints, approved by people

Advisory recommendations from a process model, kept inside FDS limits and the data the model has seen.

Operators approve. It never writes to control.
How it works

From drawings to work orders

Most predictive maintenance tools start with tags and guess the rest. VROC starts with how your plant is designed.

  1. Upload

    P&IDs and FDS

    DEXPI or vector PDF drawings and your functional description. VROC extracts equipment, connections, control loops and alarm limits.

  2. Review

    Your plant model

    Engineers check the proposed asset graph and tag map before anything goes live.

  3. Connect

    Live and historical data

    An edge gateway streams from OPC UA or DNP3 over an outbound-only connection. Historian CSVs backfill the past.

  4. Watch

    Models for each asset

    Features for each equipment type, such as pump head and BEP ratio, exchanger UA and compressor efficiency, are scored every ten minutes.

  5. Act

    Alerts into your CMMS

    Triage, then raise a work order in Maximo, SAP PM or MaintainX. Completed work comes back to sharpen the models.

At the edge

A gateway that runs signed apps

Each VROC gateway runs apps from the VROC library, such as pump station monitoring, lighting schedules, generator supervision and camera-based inspection. Operators get local screens on site and the same screens remotely, all through the gateway's outbound connection.

TIER 0Read only: monitor and report
TIER 1Low-risk commands, such as lighting schedules
TIER 2Equipment control, approved separately for each site
TIER 3Process control, with its own engineering sign-off

Analytics are advisory

Models, analytics and AI features can't issue commands. Control happens only through an approved app, within its tier.

Outbound only

Gateways dial out. No inbound ports open at your site, and the OPC UA bridge is read-only.

Signed apps, enforced permissions

A gateway runs only signed apps. Each app can read and command only what its approved permissions allow, and the gateway enforces this. No app performs a safety function.

Your data, kept apart

Each site has its own time-series database. Every table has row-level security, and access is set for each organisation and site. Sign-in supports passkeys.

Where it runs

Built for plants with pumps, not just plants with dashboards

Water and wastewater

Pump stations · SBR plants · blowers

Off-BEP running, blocked strainers, cycle drift and stormwater duty.

Power generation

Gas engines · alternators · cooling

Engine state and operating modes, with alerts that know when a set is meant to be idle.

Manufacturing

Fans · compressors · exchangers · vision

Efficiency and fouling trends, plus camera-based defect inspection at the line.

Councils and campuses

Sports and decorative lighting

Schedules, calendars and remote screens for distributed assets.

Integrations

Fits the systems you already run

Plant data

OPC UADNP3Historian CSVDALI-2

Engineering documents

DEXPI P&IDVector PDF P&IDFunctional descriptions

Maintenance and messages

IBM MaximoSAP PMMaintainXMicrosoft TeamsEmail

See it on one of your own assets

Send us a P&ID and a few weeks of historian data. We'll show you what VROC finds.

Book a demohello@vroc.ai