Reliable Automation for
Reliable Automation for
Reliable Automation for
Power Plants
Power Plants
Power Plants
Predictive maintenance, equipment monitoring, and safety compliance systems that help power plants maintain peak availability and grid-ready reliability.
20%
Reduction in maintenance costs
24/7
Turbine and boiler health monitoring
ISO 45001
Occupational health & safety ready
Trusted by Leading Enterprises Globally
Trusted by Leading Enterprises Globally
Industry Hazards
Most Common Challenges in
Power Plants
Each one has a measurable impact in downtime, safety, energy costs, or compliance readiness. Without continuous monitoring, they persist across shifts.
Coal Conveyor Failures
Coal Conveyor Failures
Coal Conveyor Failures
Rotating Equipment Degradation
Rotating Equipment Degradation
Rotating Equipment Degradation
Fire & Electrical Hazards
Fire & Electrical Hazards
Fire & Electrical Hazards
Safety Gear Non-Compliance
Safety Gear Non-Compliance
Safety Gear Non-Compliance
Unplanned Equipment Failures
Unplanned Equipment Failures
Unplanned Equipment Failures
Limited Plant Visibility
Limited Plant Visibility
Limited Plant Visibility
Unauthorised Zone Access
Unauthorised Zone Access
Unauthorised Zone Access
Environmental Compliance Gaps
Environmental Compliance Gaps
Environmental Compliance Gaps
Our Solutions
Scalable Capabilities for
Every Challenge
Integrates with your existing DCS, SCADA, and protection relays over Modbus, DNP3, IEC 61850, and OPC-UA. No changes to your control infrastructure.
Safety Monitoring
AI-powered monitoring that detects PPE violations, harness non-compliance, and fire hazards across turbine halls, boiler areas, coal handling zones, and switchyards.
Security & Access Control
Automated perimeter surveillance, vehicle management, and identity verification protecting switchyards, turbine halls, control rooms, and coal storage areas.
Operations Intelligence
Real-time monitoring of coal movement, maintenance vehicle activity, worker productivity, and auxiliary energy consumption across the power generation facility.
01
Safety
Safety Helmet & Vest Detection
Monitors compliance for helmets and high-visibility vests across coal handling, boiler, and maintenance areas. Instant alerts when violations are detected anywhere in the plant.
02
Safety
Safety Harness Detection
Monitors harness compliance for workers on elevated structures, boiler inspection platforms, and rooftop areas of generating units. Alerts triggered before an incident, not after.
03
Safety
Fire & Smoke Detection
Detects fire and smoke in coal storage, cable galleries, and turbine auxiliary areas at the earliest visible stage — effective in environments where dust and heat impair traditional detectors.
04
Safety
Person Under Suspended Load
Detects workers positioned beneath overhead cranes or suspended loads during maintenance lifts in turbine halls and boiler areas. Real-time alerts prevent fatal crane incidents.
05
Safety
Crowd & Occupancy Monitoring
Tracks the number of personnel in boiler rooms, turbine halls, and electrical switchyards. Alerts when occupancy exceeds safe limits in high-risk generation zones.
06
Safety
Object Detection in Pathways
Identifies equipment, tools, or materials left in access routes and maintenance pathways around turbines and boilers — preventing collisions and tripping hazards during high-activity maintenance periods.
07
Safety
Safety Shoes Detection
Monitors footwear compliance in coal handling, boiler, and electrical areas where the risk of burns, electrical hazards, and falling objects is constant.
08
Safety
Vehicle Safety Monitoring
Checks vehicle headlights, wheel stoppers, and parking zone compliance on internal roads and coal yard areas — particularly relevant during night operations and high-traffic shift changes.
Safety Monitoring
AI-powered monitoring that detects PPE violations, harness non-compliance, and fire hazards across turbine halls, boiler areas, coal handling zones, and switchyards.
Security & Access Control
Automated perimeter surveillance, vehicle management, and identity verification protecting switchyards, turbine halls, control rooms, and coal storage areas.
Operations Intelligence
Real-time monitoring of coal movement, maintenance vehicle activity, worker productivity, and auxiliary energy consumption across the power generation facility.
01
Safety
Safety Helmet & Vest Detection
Monitors compliance for helmets and high-visibility vests across coal handling, boiler, and maintenance areas. Instant alerts when violations are detected anywhere in the plant.
02
Safety
Safety Harness Detection
Monitors harness compliance for workers on elevated structures, boiler inspection platforms, and rooftop areas of generating units. Alerts triggered before an incident, not after.
03
Safety
Fire & Smoke Detection
Detects fire and smoke in coal storage, cable galleries, and turbine auxiliary areas at the earliest visible stage — effective in environments where dust and heat impair traditional detectors.
04
Safety
Person Under Suspended Load
Detects workers positioned beneath overhead cranes or suspended loads during maintenance lifts in turbine halls and boiler areas. Real-time alerts prevent fatal crane incidents.
05
Safety
Crowd & Occupancy Monitoring
Tracks the number of personnel in boiler rooms, turbine halls, and electrical switchyards. Alerts when occupancy exceeds safe limits in high-risk generation zones.
06
Safety
Object Detection in Pathways
Identifies equipment, tools, or materials left in access routes and maintenance pathways around turbines and boilers — preventing collisions and tripping hazards during high-activity maintenance periods.
07
Safety
Safety Shoes Detection
Monitors footwear compliance in coal handling, boiler, and electrical areas where the risk of burns, electrical hazards, and falling objects is constant.
08
Safety
Vehicle Safety Monitoring
Checks vehicle headlights, wheel stoppers, and parking zone compliance on internal roads and coal yard areas — particularly relevant during night operations and high-traffic shift changes.
Safety Monitoring
AI-powered monitoring that detects PPE violations, harness non-compliance, and fire hazards across turbine halls, boiler areas, coal handling zones, and switchyards.
Security & Access Control
Automated perimeter surveillance, vehicle management, and identity verification protecting switchyards, turbine halls, control rooms, and coal storage areas.
Operations Intelligence
Real-time monitoring of coal movement, maintenance vehicle activity, worker productivity, and auxiliary energy consumption across the power generation facility.
01
Operations
Vehicle Turnaround Time Tracking
Tracks coal trucks and maintenance vehicles from plant entry to exit. Identifies delays at coal intake and ash dispatch points to improve fuel supply chain efficiency.
02
Operations
Worker Productivity Analysis
Monitors workstation occupancy and activity levels across control room and maintenance shifts. Tracks active periods versus idle time to improve shift planning and staffing decisions.
03
Operations
Tarpaulin Detection
Checks that coal and ash transport trucks have tarpaulin covers fitted before leaving the plant — preventing road contamination and meeting transport and environmental compliance requirements.
04
Operations
Coal & Ash Volume Tracking
Counts coal trucks at intake points and tracks ash removal volumes. Maintains automated fuel and waste logistics records without manual tallying.
05
Operations
Coal & Ash Volume Tracking
Counts coal trucks at intake points and tracks ash removal volumes. Maintains automated fuel and waste logistics records without manual tallying.
06
Operations
Energy Consumption Monitoring
Tracks auxiliary power consumption across pumps, fans, and plant systems. Identifies inefficient auxiliary loads and provides data for ISO 50001 energy management and grid compliance reporting.
Our Capabilities
Our Capabilities
Complete Operational Technology Stack for
Power Plants
Industrial Automation
PLC and SCADA integration with existing plant systems
MES and ERP connectivity (SAP, Oracle, Microsoft Dynamics)
Industrial IoT sensor networks for temperature, vibration, pressure, and load
Communication protocols - OPC-UA, MQTT, PROFINET, EtherNet/IP, Modbus TCP/IP
Edge computing and industrial gateway devices
Centralised dashboards with real-time plant status
Production data analytics and OEE tracking
Industrial Automation
PLC and SCADA integration with existing plant systems
MES and ERP connectivity (SAP, Oracle, Microsoft Dynamics)
Industrial IoT sensor networks for temperature, vibration, pressure, and load
Communication protocols - OPC-UA, MQTT, PROFINET, EtherNet/IP, Modbus TCP/IP
Edge computing and industrial gateway devices
Centralised dashboards with real-time plant status
Production data analytics and OEE tracking
Industrial Automation
PLC and SCADA integration with existing plant systems
MES and ERP connectivity (SAP, Oracle, Microsoft Dynamics)
Industrial IoT sensor networks for temperature, vibration, pressure, and load
Communication protocols - OPC-UA, MQTT, PROFINET, EtherNet/IP, Modbus TCP/IP
Edge computing and industrial gateway devices
Centralised dashboards with real-time plant status
Production data analytics and OEE tracking
AI-Powered Monitoring
PPE and safety gear detection (helmet, vest, shoes, gloves, harness)
Fire and smoke detection
Intrusion and restricted area monitoring
Vehicle tracking, speed monitoring, and ANPR
Crowd and occupancy management
Worker productivity analysis
Production counting and quality inspection
SAP integration and custom API connectivity
Real-time alerts via Email, WhatsApp, SMS, hooters
AI-Powered Monitoring
PPE and safety gear detection (helmet, vest, shoes, gloves, harness)
Fire and smoke detection
Intrusion and restricted area monitoring
Vehicle tracking, speed monitoring, and ANPR
Crowd and occupancy management
Worker productivity analysis
Production counting and quality inspection
SAP integration and custom API connectivity
Real-time alerts via Email, WhatsApp, SMS, hooters
AI-Powered Monitoring
PPE and safety gear detection (helmet, vest, shoes, gloves, harness)
Fire and smoke detection
Intrusion and restricted area monitoring
Vehicle tracking, speed monitoring, and ANPR
Crowd and occupancy management
Worker productivity analysis
Production counting and quality inspection
SAP integration and custom API connectivity
Real-time alerts via Email, WhatsApp, SMS, hooters
Compliance & Readiness
ISO 9001 - Quality Management Systems
ISO 45001 - Occupational Health and Safety
ISO 14001 - Environmental Management
IEC 62443 - Industrial Cybersecurity
ISA-95 - Enterprise-Control System Integration
ISA-88 - Batch Process Automation
Audit-ready documentation and automated reporting
Pre-certification readiness assessments
Compliance & Readiness
ISO 9001 - Quality Management Systems
ISO 45001 - Occupational Health and Safety
ISO 14001 - Environmental Management
IEC 62443 - Industrial Cybersecurity
ISA-95 - Enterprise-Control System Integration
ISA-88 - Batch Process Automation
Audit-ready documentation and automated reporting
Pre-certification readiness assessments
Compliance & Readiness
ISO 9001 - Quality Management Systems
ISO 45001 - Occupational Health and Safety
ISO 14001 - Environmental Management
IEC 62443 - Industrial Cybersecurity
ISA-95 - Enterprise-Control System Integration
ISA-88 - Batch Process Automation
Audit-ready documentation and automated reporting
Pre-certification readiness assessments
Compliance & Standards
Built to Meet the Standards
Your Industry Requires
Every system KGT deploys for steel and metal operations is designed to meet or exceed the compliance standards that govern your industry.
If your plant has gaps in any of the areas listed below, whether in safety documentation, environmental monitoring, traceability, or cybersecurity - our team will assess what is missing and build the infrastructure needed to support certification.
ISO 9001
- Quality Management Systems
ISO 45001
- Occupational Health and Safety Management
ISO 14001
- Environmental Management Systems
IEC 62443
- Industrial Automation and Control Systems Security
ISA-95
- Enterprise-Control System Integration
ISA-88
- Batch Control Standards
ISO 9001
- Quality Management Systems
ISO 45001
- Occupational Health and Safety Management
ISO 14001
- Environmental Management Systems
IEC 62443
- Automation and Control Systems Security
ISA-95
- Enterprise-Control System Integration
ISA-88
- Batch Control Standards
Deployed in Live Operations
•
Tata Steel
$86K+ Lost in 1 Month. Zero Since Vizibelt.
Connect to Content
Add layers or components to swipe between.
Vizibelt is an Ai-powered monitoring system designed for conveyor operations - detecting foreign objects in real time and preventing belt failures before they disrupt production.
Detected Foreign Object Incidents
1+
1+
Reduction in Downtime
1%
1%
Increase in Productivity
1%
1%
Industrial AI System
Computer Vision
IIoT
Modbus Protocol
PLC
Deployed in Live Operations
•
Tata Steel
$86K+ Lost in 1 Month. Zero Since Vizibelt.
We built Vizibelt
An AI-powered monitoring system that detects foreign objects in real time and stops the belt before damage occurs.
Detected Foreign Object Incidents
1+
1+
Reduction in Downtime
1%
1%
Increase in Productivity
1%
1%
Industrial AI System
Computer Vision
IIoT
Modbus Protocol
PLC
Ready to discuss your
plant operations?
Ready to discuss your
plant operations?
Ready to discuss your
plant operations?
Deployed in Live Operations
•
Tata Steel
$86K+ Lost in 1 Month. Zero Since Vizibelt.
Connect to Content
Add layers or components to swipe between.
We built Vizibelt
An AI-powered monitoring system that detects foreign objects in real time and stops the belt before damage occurs.
Detected Foreign Object Incidents
0+
0+
Reduction in Downtime
0%
0%
Increase in Productivity
0%
0%
Industrial AI System
Computer Vision
IIoT
Modbus Protocol
PLC