Client profile

A large steel alloy manufacturing plant located in Bhubaneswar, Odisha, India, operates across a vast industrial campus spanning more than 100 acres. The facility includes multiple furnaces and chemical processing infrastructure used to produce high volumes of ferroalloys for both domestic and international markets.

Due to the scale of operations and the use of high-temperature processes and pressurized pipelines, maintaining strict safety standards is critical. Continuous monitoring of plant infrastructure and early detection of operational anomalies play a key role in protecting both personnel and equipment.

Project background

One of the operational challenges at the facility was monitoring unexpected steam release from pipelines. Previously, detecting such incidents relied heavily on manual observation and reporting from staff working in the production areas.

This approach created delays in communication and increased the risk of hazardous situations for workers. The client required a system capable of identifying abnormal steam emissions in real time and immediately alerting the control room, enabling faster response and improved safety across the plant.

Solution

TRASSIR designed a centralized monitoring solution using advanced video analytics capable of detecting smoke-like visual patterns such as steam leaks.

The project included:

- TRASSIR NeuroStation 8800R/128 INT server
- TRASSIR AnyIP INT licenses for camera integration
- TRASSIR Neuro Fire and Smoke Detector analytics modules
- TRASSIR ACS license to integrate a third-party access control terminal and hooter alarm system

The solution analyzes video streams in real time and detects visual indicators of steam or smoke within defined zones of the plant. When an anomaly is detected, the system immediately generates alerts for operators and triggers the hooter alarm in the control room through the ACS integration.

The project was implemented in collaboration with a local system integration partner, with TRASSIR pre-sales and technical specialists supporting system configuration and third-party integration.

Results and impact

The deployment transformed how the plant monitors critical pipeline areas and responds to potential hazards. Automated video analytics now continuously monitor designated zones, allowing operators to detect steam releases much faster than with manual reporting methods.

The plant now benefits from:

- Real-time detection of steam emissions in production areas
- Immediate alerts to the control room and hooter alarm activation
- Reduced dependence on manual monitoring and reporting
- Faster incident response and improved workforce safety
- A scalable platform for additional safety analytics

Following the successful implementation, the facility is now planning the next phase of the project, which will include AI-based hard-hat detection to further enhance workforce safety compliance.