✓Real-time Connectors: OPC-UA, Modbus TCP, HART Protocol, Foundation Fieldbus, REST API
✓Trend Analysis: 90-day
✓Alerts: Email, SMS, WhatsApp, Siren/PA
✓Multi-site Aggregation
📈 Real-time Chart
metric:reactor_pressure
unit:bar
timeframe:real-time
chart type:line
min threshold:1
max threshold:15
target:8
update interval ms:2000
data source:OPC-UA
topic:reactor/vessel/pressure
📈 Real-time Chart
metric:reactor_temperature
unit:°C
timeframe:real-time
chart type:line
min threshold:20
max threshold:350
target:180
update interval ms:2000
data source:OPC-UA
topic:reactor/vessel/temperature
📊 KPI Card
metric:reactor_conversion_rate
label:Conversion Rate
format:percentage
target:92
critical low:80
description:Reactant-to-product conversion efficiency — target >90% for cost-effective operation
📊 KPI Card
metric:selectivity_pct
label:Selectivity
format:percentage
target:88
critical low:75
description:Percentage of desired product vs byproducts — key for yield optimization
📊 KPI Card
metric:sif_criticality
label:SIL Rating
format:badge
target:SIL 2
badges:{"SIL 1":"yellow","SIL 2":"green","SIL 3":"blue","SIL 4":"green"}
description:Safety Integrity Level of the reactor Safety Instrumented Function per IEC 61511
📉 Trend Analysis
metrics:["reactor_pressure","reactor_temperature","reactor_conversion_rate"]
periods:[7,30,90]
chart type:multi_line
show control limits:true
show cppk:true
export format:["pdf","csv","xlsx"]
📋 Data Table
title:Batch Reaction Records
columns:[{"key":"batch_id","label":"Batch ID","sortable":true},{"key":"recipe","label":"Recipe","sortable":true},{"key":"reactant_a_kg","label":"Reactant A (kg)","type":"number","sortable":true},{"key":"reactant_b_kg","label":"Reactant B (kg)","type":"number","sortable":true},{"key":"max_temp","label":"Max Temp (°C)","type":"number","sortable":true},{"key":"max_pressure","label":"Max Press (bar)","type":"number","sortable":true},{"key":"conversion","label":"Conversion %","type":"number","sortable":true},{"key":"product_yield_kg","label":"Yield (kg)","type":"number","sortable":true},{"key":"status","label":"Status","type":"badge","badges":{"complete":"green","in_progress":"blue","aborted":"red","hold":"yellow"}}]
sort by:batch_id
sort order:desc
filters:["recipe","status","date_range"]
pagination:25
📄 Compliance Report
standards:["OSHA PSM","EPA RMP","IEC 61511","ISO 45001"]
report types:["batch_record","safety_audit","pressure_vessel_inspection","incident_log"]
frequency:per_batch
auto generate:true
pdf template:chemical_reactor_batch
include signature block:true
retention days:3650
🔔 Alert Engine
rules:[{"name":"Overpressure Warning","metric":"reactor_pressure","condition":"above","threshold":14,"severity":"critical","message":"Reactor pressure above 14 bar — safety relief valve may activate","channels":["email","sms","whatsapp","siren"],"escalate_after_min":2},{"name":"Temperature Runaway","metric":"reactor_temperature","condition":"rate_of_change_above","threshold":5,"threshold_unit":"°C/min","severity":"critical","message":"Temperature rising >5°C/min — potential thermal runaway","channels":["email","sms","whatsapp","siren"],"escalate_after_min":1},{"name":"Conversion Drop","metric":"reactor_conversion_rate","condition":"below","threshold":80,"severity":"warning","message":"Conversion rate below 80% — check catalyst condition and feed quality","channels":["email","whatsapp"]}]
channels:{"email":{"enabled":true,"recipients":["plant_manager","process_engineer","safety_officer"]},"sms":{"enabled":true,"recipients":["plant_manager","safety_officer"]},"whatsapp":{"enabled":true,"group":"reactor_ops"}}
🏭 Site Aggregator
max sites:12
metrics:["reactor_conversion_rate","selectivity_pct","sif_criticality"]
comparison mode:side_by_side
ranking metric:reactor_conversion_rate
Compliance Standards
OSHA Process Safety Management (PSM) 29 CFR 1910.119EPA Risk Management Program (RMP)IEC 61511 (Safety Instrumented Systems)ISO 45001 (Occupational Health & Safety)DOT/UN Transport of Dangerous GoodsMAL Fire Services Act 341 (Section 27 — Chemical Storage)
Supported Data Connectors
OPC-UA
● Connected
Modbus TCP
● Connected
HART Protocol
● Connected
Foundation Fieldbus
● Connected
REST API
● Connected