Digitizing Existing Industrial Plants
Non-Invasive upgrade in minutes at a fraction of the cost
Many industrial plants were built 30 or more years ago, and they still rely heavily on mechanical, analog, and pneumatic systems, which lack digital capabilities, limiting data visibility and preventing the adoption of advanced fault detection, predictive maintenance, and AI-driven analytics. Consequently, operations remain labor-intensive and face ongoing challenges in safety, reliability, and efficiency. Upgrading these plants with digital technologies is prohibitively expensive, requiring extensive engineering, regulatory approval, and operational disruption—making such investments difficult to justify for most operators.
Introducing the Wireless Gauge Reader
- Non-Invasive Digital Overlay to read existing pressure, temperature, flow, level and other gauges/indicators
- Ten minute installation – optical clamp-on to existing gauges, no breaking seals, no leak checks
- Already proven in-use at Fortune 500 companies
- Minimal engineering design and review required, cybersecurity approved
- Non-invasive – no disruption to plant operations, no downtime required
- No need to run wires – wireless and battery operated (3 year battery life)
- Costs 90% less than installing traditional pressure or temperature transmitters
- Improves safety, reliability, efficiency
- Condition Based Maintenance/CMMS
- Troubleshooting, fault detection analytics
- Operator efficiency
- Thermal/process performance
- Worker Safety
Additional Non-Invasive Digital Overlay Solutions
Wireless Valve Cycle Isolation Monitor
- Non-invasive valve cycle isolation monitor using clamp-on high temperature thermocouple
- Early detection of leaks – optimize thermal efficiency
- Wireless communication
- Battery and line power operated capability
Wireless Vibration Sensor
- MEMS sensors for tri-axial vibration measurement
- Max, RMS, and FFT values
- Secure wireless communication, battery operated (3 year life)
- Manufactured by Honeywell – strategic partner of Cypress Envirosystems, 100% compatible with Cypress
Drone Video Digitization
- Uses machine vision to digitize videos and images captured by drones.
- Converts images to digital values to enable trending, alarming, and advanced analytics
Industrial Customers
- Proctor and Gamble
- Eli Lilly
- NASA Jet Propulsion Laboratory
- Caterpillar
- Applied Materials
- IBM
- Constellation Energy
- Microchip
- Kodak
- Honeywell
- Merck
- Western Digital
- Duke Energy
Plant-Wide Benefits
Departments:
- Operations
- Maintenance
- Engineering
- Safety
- Monitoring & Diagnostics Center
Benefits:
- Improve operator efficiency
- Equipment fault detection/reduce unplanned downtime
- Reduce maintenance cost – enable condition-based maintenance
- Extend Equipment Qualification life
- Optimizing thermal/process performance
- Improve worker safety – hazardous locations
- Troubleshooting via crash cart, emergent needs
Learn more about proven applications deployed at industrial plants with documented benefits and fast ROI
Case Studies and Industry Papers
- Gases and Instrumentation – Gas Cylinder Monitoring
- Genentech – Article: Steam Traps and Freezer Monitoring Case Study
- Genentech – Slides: Steam Traps and Freezer Monitoring Case Study
- Proctor and Gamble – Fire Riser Monitoring
- Entergy Vermont Yankee – Control Magazine
- Cypress Envirosystems – compilation of industrial use case applications
